Sa plastics '013 12 for web

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BY THE WAY ...

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

www.saplastics.co.za

GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@leafpublishing.co.za Printed by: Tandym Print, Maitland, Cape Town SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry. The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either. Copyright: All rights reserved. ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902

It depends which way you’re looking in Mozambique: if you look out to sea you’ll get spectacular vistas of Indian ocean vistas off Bilene, but look sideways over the fence at your lodge and you get a highly undesirable view of discarded PET bottles and other packaging. The Mozambique people just don’t seem to notice.

Industry needs to make its activities more visible WOOLWORTHS packaging manager Kiril Dimitrov congratulated AnnabĂŠ Pretorius and the SAPRO team on their achievements in the SAPRO best recycled product programme, and added: “Please make sure that the plastic industry and recyclers also promote their activities to the public and the consumer. A different strategy is needed for that, as so far polymer groups appear to be mainly focusing on business-to-business marketing and communication. Lack of visibility of plastics recycling activities give a viable step to be the visible collection of plastic bottles (milk and beverage)!â€?

Bizarre electrical increase CONVERTORS in the Eastern Cape were shocked to receive exhorbitant electricity accounts recently, in some cases of double the usual amounts. And if that wasn’t bad enough, the reaction from the local municipality was even more shocking: a municipal spokesman said larger companies could afford to absorb bigger increases, and they had thus decided to levy a higher increase rate on these enterprises and a lesser rate on smaller businesses. When last did you hear such boloney? The bigger companies employ more people, pay more tax and

management in the Eastern Cape is ludicrous

GPS essential in Durban CBD MUNICIPAL staff in Durban must be very switched on, with GPS navigation systems and so on: what else can you conclude from the rampant renaming of streets in the beautiful city’s CBD? My street guide isn’t that old, but virtually no street in the area compares with even the 2009 edition. Obviously people want to acknowledge ancestors and heroes, and to some extent the names of colonial era bigwigs may not be appropriate, but the wholesale renaming is excessive. But then Stalwart Dlamini Boulevard may mean nothing to many others either. And the renaming of streets is hardly going to achieve economic transformation.

Lights out in Jozi, nothing new

Plastics Institute of Southern Africa

Association of Rotational Moulders of South Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

"# $ % & & ' * ' * yesterday: it’s been going on for ages. Motorists in the city appear to remain calm at these delays, which possibly explains why they drive like maniacs the rest of the time. But seriously, irrelevant street renaming ; * ' & METHING HAVE SO do absolutely nothing for economic ‌ IF YOU : if you growth, in our view. Please let’s focus TO SAY bright side m to ok at the do Lo is w on workable solutions in 2014. gem of at ve some ha to us ease write impart, pl ica.com fr ia s@ saplastic

VOLUME 11 NR 6

DECEMBER 2013 / JANUARY 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 Trioplastics commission PET, PVC sheet lines

6

Enviroserv starts Cape tyre recycling line

8

ADDIS turns 100!

36

UV Tooling celebrates 25 years

22

Alpine grows

23

New grade of PhoenixPET soon

44

12

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

UĂŠ i>ĂŒÂˆÂ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠÂ™ĂŠÂŽ7 UĂŠ œœÂ?ˆ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠĂ“{‡™äĂŠÂŽ7 UĂŠ*ՓÊV>ÂŤ>VÂˆĂŒĂžĂŠĂˆäĂŠÂ?ÂˆĂŒĂ€iĂƒĂ‰Â“ÂˆÂ˜]ĂŠĂŽ°nĂŠL>Ă€

46

K2013 Many visitors from the East, and unusual sources

SAPRO: Recyclate value via additives

78

Plastics|SA spearheads ‘recognition of prior learning’ initiative

80

SAVA visits Germany for recycling tour

82

WORLD Lanxess on track with EPDM project in China

88

58

s 3IMULTANEOUS READOUT OF TEMPERATURE set-point and actual value 96

84

ON THE COVER ! Plexiglas will remain free from yellowing for up to 30 years; for coloured products (like the Evonik Plexiglas XT pictured on the cover), colour fastness will remain for up to 10 years. The material can be processed in all conventional thermoplastic processes and is 100% recyclable. Evonik Acrylics Africa (EEA) began producing extruded PlexiglasÂŽ sheets in Elandsfontein, Johannesburg, in August. With an initial 20 employees and a new extrusion facility, some several thousand per year for the African market.

www.evonik.com

UĂŠ ÂœÂ˜ĂŒĂ€ÂœÂ?Â?iÀÊ,/ĂˆÂŁĂŠ*

UĂŠĂŠ"Ă•ĂŒÂ?iĂŒĂŠĂŒi“iĂ€>ĂŒĂ•Ă€iĂŠ “>Ă?ĂŠÂŁxäc

UĂŠĂŠ i>ĂŒÂˆÂ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠ >ĂŒĂŠ{ää6ĂŠĂˆĂŠÂŽ7 UĂŠĂŠ œœÂ?ˆ˜}ĂŠV>ÂŤ>VÂˆĂŒĂžĂŠ Ă“nÂŽ7ĂŠJĂŠÂŁ{äc

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70

SPORTS Winning cinnovation for performance yachts

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

56

ASSOCIATION NEWS

Type 90 Smart

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

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

THIS ISSUE

Industry ends year

Martin Wells

, Publisher

on golden note! Positive news for plastics materials and the industry overall ITH 13 of the 19 gold, silver and bronze awards available in six categories (in the four main packaging groups, glass, metal, paper & board and plastics), plastics entries took well over half the awards at the IPSA Gold Pack Awards in October – and capped that with the IPSA Gold Pack Trophy for 2013 too.

W

COMMENT

That was one of the most obvious positives for the industry over the past year, and there were certainly numerous positive developments during the period – a time when trading conditions have been tough in virtually all sectors. Here we = & & >JQY

1 Top showing by packaging convertors Z [ & \ Gold Pack performance by the plastics packaging sector overall. The Astrapak group, which is in the process of a major rationalisation process, surprised by its outstanding success in the Gold Pack programme, where it took four gold awards, [ & well structured can produce the goods. The Astra companies JJ Precision, Marcom and Plastop KZN all got gold, and JJ was also a co-winner of the overall Gold Pack trophy. There were top performances as well from the Polyoak and Nampak groups as well as other independent & _ & particularly the high quality of print and labels, has helped this sector gain market share. In the process, several [ [

` about the Gold Pack successes on pages 12-19. Agreed, plastics do offer more creative and variation opportunities than rival materials at present, but you still have to make it happen. The result was testament to the exceptionally high standards prevailing in the local plastics packaging manufacturing sector. Statistics show that packaging now accounts for a higher

4 DECEMBER 2013 / JANUARY 2014

percentage of total tonnage converted in South Africa, up to 55% from an estimated 50% over the past few years. That result is partly due to the fact that the technical moulding sector has not progressed as rapidly, but you can’t take the shine off the very impressive performance by the packaging manufacturers.

2 Aspirant designers Next on our short list of highlights for the year are the design competitions presented by the professional associations. `|Z } & ` | & Z & ~ _€ } _ ` € ~‚ Z } & Z & ~ Z ` } ` Organisation) and others presented competitions which attracted enthusiastic responses from students around the country. Plastics|SA and POLYCO sponsored or cosponsored a number of these competitions, which helped generate interest from the students. The fact that students today are far more adept at using electronic design systems (and electronic communication media in general), which make the process of design far more ‘Many of the dynamic, is a big advantage. convertors have Most of the older guys in the also got smarter industry struggle to a greater and managed to or lesser extent with electronic create a situation systems, so it’s a big positive where they’ve got to have interest coming from younger individuals. the buy-in of their Earlier in the year, skills staff, and are now development specialists Chris looking forward to Vorwerk and Fiona Farquharbrighter things’ son conducted an industry research programme (com | `Z _

†Z ~ which they found that, surprisingly, more young people were being employed in the industry than expected as well as that [ [ `‡# [

The winning entry in the ARMSA Student Design Competition in August, ‘Strider’ by Daniel Carstens and Dillon Farrell of the University of Johannesburg, is a solar-powered catamaran with suspended net " # $ & ' " ' *# $ +/ novel solutions, in this and other design competitions, creating enthusiasm for the future of our industry

The research survey did not achieve an overwhelming response from the industry, but it stands to reason that companies who responded would generally speaking be the more effectively managed operations. This is a very encouraging development. One could conversely say that, if an industry is not attracting young people, it would slowly be regressing. `‡# and investing in young people, that these ‘successful’ companies may also be on a path which is going to take them further ahead of companies who do not pay attention to these _ '

[ * & & all to achieve, is worth aiming towards.

to these companies, we won’t identify them here, but most who are in production will know who the leaders are. Possibly more relevant is the fact that that group of businesses is in turn led by a similar number of individuals – let’s call it a few hundred guys (and yes, it is mainly male) – who make the machines turn. And the main characteristic of these gentlemen is the ability to map out a strategy and implement it: this requires tact, foresight, good sense, the ability to motivate and incentivize people and a lot more. A good sense of humour and at least a little bit of luck helps a lot too. Another hallmark of many of these individuals is the fact that they simply don’t believe that they are responsible for what’s been achieved. Well, you can remain anonymous guys, but we salute you!

3 Plastics|SA, SAPRO environment programmes ˆZ Z ` [ * environment projects that could be loosely described as ‘image building’ for the industry. Besides various clean-up # Z Z [ than is expected of them ‌ and still faced on-going criticism for, particularly, plastics litter. It might seem a thankless task, but Steyn and Co are always upbeat and always ready to undertake projects ‌ any project for that matter, so long as it’s positive for the industry. Š Z ` [ * wonders in building up the plastics recycling sector. Their two main successes have been in the area of developing new applications for recycled material (in which area they have managed to get the buy-in of brand owners such as Unilever and Woolworths) as well as the increased sale of recycled material into the neighbouring states. The latter has proved a big boost for several of the recycling operations, and likewise provided an advantage for convertors in Namibia, Botswana, Zambia, Zimbabwe, Mozambique and other countries in our region. Well done!

4 The top groups, and top individuals Our observation is that, although there are an estimated 1800 companies, and possibly more, involved in the plastics, composites and rubber moulding sectors in Southern Africa, a relatively small percentage of these are actively driving the industry. Our estimates suggest that approximately 100 companies are responsible for the bulk of progress made. In fairness

5 Our products are good! Convertors in southern Africa have in recent years been largely out-competed by Chinese manufacturers, who have * & & & * imports are possible. With price being one of the top criteria for consumers, our manufacturers have struggled to compete ‌ but that is not in the area of quality. If anything, the quality of SA-made products has erred on the ‘too high’ side. Here’s an example: I’m now on to my fourth pool umbrella (a necessary accessory for the ‘eco’ pool installed in my yard in 2012). They were all unbelievably cheap, but the other less welcome feature has been that they haven’t actually worked. Just look at the thing the wrong way and something breaks! Whereas my vintage SA-made umbrella is still steady and strong. At the same time, manufacturers have had to operate in an environment where excessive labour legislation and the aggres [ & & [ & But many of the convertors have also got smarter – wiser after the setbacks of 2011 – and managed to create a situation where they’ve got the buy-in of their staff, particularly top production and sales personnel, and are now looking forward to brighter things. The fact that the rand has weakened in value against major international currencies means that imports will be more costly, and exports more feasible, so our belief is that it’s time for ‘Made in SA’ to become a lot more popular and that, bit by bit, we can grow the industry and support our many customers in the huge range of industries we supply in building a better future for all! Seasons’ greetings to all our readers!

DECEMBER 2013 / JANUARY 2014 5

INDUSTRY NEWS

Trioplastics commissions An enduring story – lessons in manufacturing in South Africa TRIOPLASTICS made one of the biggest investments in the industry in Southern Africa this year with the commissioning of its new PET and PVC sheet extrusion lines at its Krugersdorp plant in November.

$ Q \ Q \ 1150mm wide and from 0,1-0,8mm thickness at rates up to 800 kg an hour in clear, ] > [

The multi-million rand investment sees Trio migrating from the supply market (it has up till now mainly imported sheet for resale) to full-on converting. A ribbon-cutting ceremony was held at the plant in Chamdor on 31 October to mark the start-up of the lines: the PET system can

_ Q ‹

& & the PVC line operates by the calendaring

* Œ€ the country of this type. Calendared PVC material offers a number

& [ high gauge consistency (tolerances on Y‘ whereas conventional PVC extrusion is estimated to have a tolerance of 10%); high gloss and quality; ; ' in the material results in less degradation & ; ' thermoforming process. The high level of gauge control means the sheet is well suited for lamination

& & credit cards.

$ Q $ ^#_ ` { ^ ] }``] ~ > $ * Q $ Q \ € > Q $ € Q $ Q $  €Â

Venica Rossouw of Trioplastics, the >

? Q [ Extrupet

Bob Boden’s out to trap leopards ‌ BOB Boden has been putting his retirement

* &

preservation and conservation. & € " * Coextruded Film Technologies – and after

close to half a century in the industry – Bob retired in 2010. Disillusioned with the human race and feeling the need to repay nature for many hours in the bush recharging his “ in protecting and preserving [ [ Panthera pardus

When a sub-adult leopard was found dead on the side

& `

$ “ research how the animal had arrived there. The autopsy stated that the sub-adult had not been involved in a road

accident and that there had been no sign of captivity. Well-known for its ability to survive and go undetected in relatively built up indicated that there was possibly a leopard presence in the area between Lanseria

“

claimed sightings. At this point Bob launched the initiative ;”

& ' _ [ aimed to identify the presence and sustainability of the population through [ the end goal being the creation of a natural leopard sanctuary. \ \

Bob on the job – Bob Boden mounting one of the motion-activated cameras in the Magaliesberg. The cameras take photos of passing wildlife, often at night when nocturnal creatures such as leopard are active. To date Bob has captured images of = " 6 DECEMBER 2013 / JANUARY 2014

PET, PVC sheet lines $ * Trio CEO ‚ ] ? had operated as an accountant for 20 years prior to starting a contract packaging business in 2003. That led to his association with \ „ and the & & _

 >JJ— _ ' & ; ˜ Z [ '

competitive sheet supply market. The sales personnel Mike Wright and „ \ joined in 2009 >JQJ [ ™ š said Moonsammy. Z _ ' the supplier of choice to a steadily increasing number of sheet ;‹› '

>JJœ & &

achieved with the recent plant start-up. The company has achieved double-digit sales increases over the

& [ & [ The trio in Trio – $ & * $ * &Q ˆ ' * ? ] ‰ Š ‹ ‚ ] ? Š\ ‹ \ „ Š ‹

$ $ Q \ € calendaring process, which means the material is milled and kneaded and then fed through a series of rollers before introduction to the extruder

In late 2011 Trioplastics moved from premises in Roodepoort to € Â? _ premises in Jacobs Street were ironically occupied previously by  & & The Chamdor site offers considerably more space as well as greater the potential to expand further. The commissioning of the two sheet lines in November mark the & & & ‹› |

_ \ [ & [ &

_

* increasingly at exports into other countries in Southern Africa. ™– [

š |

# # #[

‚\ Q ] „ † Q ‡ „ \ $

on camera # # #[

# soon cooled – after a year of work there was no proof of a resident or transient population. * [ sightings were dated two years back. Having initially planned the geographic spread of the initiative to cover the area from Lanseria to “

Z*

Bob moved the research to Broederstroom and centred on the Glen Afric Lodge with incredible support given by the lodge owners. Glen Afric has a large cave on their property which had in the past seen leopard presence. Camera traps were set up both at the cave and on game paths in the southern Witwatersberg Mountains. To date the work [ & *

* * * and porcupine. Whilst the camera surveillance will continue

• & & – the scope of the project will increase to cover the area of Hekpoort and then into the Magaliesberg. Bob explained that the cameras used [ & * = [ coloured daylight pictures and black-and-white night photos. “The setting up of the cameras has been a learning curve! Initially the cameras were producing thousands of pictures of grass and bushes waving in the wind!� All the photos are real time with transmission to both cell phone and email. Bob said that while acceptance by

for the initiative is growing slowly and the aims for creation of a natural sanctuary continue. Bob can be reached on bodenrg@ telkomsa.net or 082 801 9332. DECEMBER 2013 / JANUARY 2014 7

INDUSTRY NEWS U-turn – The plant was originally designed for in-line processing, but the size of the hall available dictated that a U-shaped layout be used, which Peter Waldburger believes is effective

Enviroserv starts Cape tyre recycling line Accepts used tyres and recovers valuable materials ENVIROSERV, one of South Africa’s biggest waste management groups, is setting up a tyre recycling plant in Cape Town, one of its most ambitious projects yet. Enviroserv has up until now focused

began looking for alternative solutions, ; ' [ & [ ž category tyres clearly fall. Even with the REDISA tyre recycling plan currently being implemented, large quantities of discarded tyre casings have been left abandoned around the country. With one of Enviroserv’s

main strengths being its logistics and transport abilities, the group is able to accept used tyres from existing customers and then recover the valuable materials. _ investment, caters for this need. The commissioning of the line is being managed by Enviroserv consultant Peter Waldburger, ; ' & Â&#x; & [ [ as many as eight major recycling projects around the country. A complete tyre reprocessing line from South Korea has been installed at the Enviroserv premises in Bellville. The site was previously occupied by Albert Moore

Bulk rubber crumb at the Enviroserv plant in Bellville

Industries, a plastic recycling business. Enviroserv was leasing the property for use as its Cape depot, but purchased the site earlier this year. A multi-stage process is involved: the &

&&‚ following which the casings go through a

Mid-stage – Metal and other tyre reinforcement material needs to be removed from shredded material during the process

Crumbs – Processed rubber crumb material is used in surfacing of roads or paths as well as a variety of other applications

Aerontec, MMS Technology plays vital role in award-winning international project BRITISH architects Hugh Broughton Architects Ltd design of the Halley VI Antarctic Research Station has been crowned as the British Construction Industry’s International Project of the Year ž [ design translated into reality were South African composite companies, Aerontec and

MMS Technology. Aerontec supplied all the vacuum bagging and vacuum-resin-infusion materials and consumables for Halley VI. MMS Technology manufactured the GRP panels. According to the architects, MMS Technology was awarded the contract partly because it was one of the

The British Antarctic Survey’s Halley VI research station is the sixth facility to occupy the site on the † = " ^Œ km from the edge of the South Atlantic. Halley VI is made up of four-legged modules linked by enclosed walkways and designed to house up to 52 people

8 DECEMBER 2013 / JANUARY 2014

few manufacturers capable of creating both steel frame and GRP cladding as a complete package, and partly because of the technology it used to make the GRP. Cracking a cladding conundrum In designing the new Halley Research Station for environmental science organisation the British Antarctic Survey

JUST BRIEFLY Johannesburg ‘inland port’ status challenged

reduced to 50-70mm particles. Thereafter the material passes through two mills where the particles are further reduced in size, following which the batches go through a granulator during which the particles are reduced to rubber crumb with a particle size as little as ÂĄ ž & ¢ *¢ path surfacing applications.

` [ & particles takes place at several points along ‚ \ Further processing can yield rubber crumb powders which can be used for surfacing of sports tracks, playgrounds and buildings as ; › '

THE city of Johannesburg’s status as ;

South African Revenue Service. Up till now, containerized cargo could move direct to City Deep in Johannesburg (as an inland port) upon arrival in the country under cover of a manifest, but it’s been proposed that a new declara ž & [

ž manifests. A debate on this took place during public hearings in Parliament on the draft Customs Control and Customs Duty bills in October. Freight forwards and importers suggested the change could cause chaos at the Durban port. SARS said it was necessary for importers or their agents to clear goods on arrival in the country, and that this would help prevent the arrival of illegal or risky goods.

Shipments of sand

www.enviroserv.co.za The granulator stage is ' [ reduction of the tyre shreds. Waldburger Š ‹ ' ' in the blade design, using experience from earlier recycling applications. Here we see him with Heinz Preusker, who was also at Hoechst SA group in ^‘’` }`

(BAS), architect Hugh Broughton pioneered the use of glass-reinforced plastic (GRP) on the building, which opened in January 2013. | ž blue for the science and sleeping quarters, and a vivid red for the largest, central module, which forms the base’s social hub. The advantages of GRP are obvious. It forms large panels and is light, making it easy to handle and install. It is used in cryogenic applications, so can withstand low temperatures. But this project pushed GRP technology to its limits. MMS used a vacuum method of infusing the resin, allowing the design team to develop large panels and create a semi-monocoque \

Early test castings were encouraging, but there were problems caused by the  & To meet these the design team added a ; ' _ has the effect of giving off water vapour in a [ & Broughton is delighted with the result. Valuable knowledge has been accumulated on using materials in extreme conditions. “ & •` ' properties that a new station he has designed for the Spanish in the Antarctic will be entirely of GRP construction, with no supporting steel frame. Source: The Architectural Review, July 2010 | By Ruth Slavid

www.mmstechnology.co.za www.aerontec.co.za

THE moment you weren’t waiting for – A number of polymer traders in the UK and Germany have fallen victim to Oriental hoods and received shipments of sand, a problem encountered by a number of unfortunate importers earlier this year in South Africa. A Chinese trading company going by the name of ‘Habei Leiao,’ claiming to be an agent for Sinopec, sent containers of sand in 25kg PE bags instead of polymer to at least two traders +! Š^{ �‚Q ‹  Š Ž Q ‹# $ deals were apparently paid for in advance, and the unwelcome shipments arrived in # ‚ $ it’s very costly.

Astrapak recovery on track ASTRAPAK results for the half year › = ; & progress’ on the group’s turnaround strategy with debt reduced to R248.5million. • & ` Plastics, fell 5.7% to R 252.3 million. AA R295.4-million provision for insurance proceeds was previously › ment of R311.4-million was agreed with no restrictions on utilization. The $ East Rand Plastics. DECEMBER 2013 / JANUARY 2014 9

UMP’s

The expansion has resulted in the UMP factory more than doubling in size from 2300m² to 5000m², which has allowed for the creation of additional workshop space and new machinery for the polyurethane and engineering divisions at the Edenvale company

state-of-the-art factory opens INDUSTRY NEWS

POLYURETHANE expert Urethane Moulded Products (UMP) has substantially increased its existing production capabilities, while expanding into engineering and fabrication services as a result of its advanced new R12-million manufacturing facility in Johannesburg. The upgrade of the ISO 9001 accredited factory – which was opened at a ceremony hosted by the company in November – has resulted in UMP’s scope of polyurethane supply expanding to include products, in addition to the fabricated steel components. UMP director Trevor Carolin said: “In the past, complex moulding required the client to supply steel inserts for their polyurethane. These inserts are now fabricated and machined on our premises, &

or rubber-lined, then bolted, assembled and crated for delivery.â€? Carolin highlighted the fact that the factory upgrade also forms part of UMP’s ongoing plans for expansion in South Africa and beyond. “The expansion has resulted in the UMP factory more than doubling in size from 2300m² to 5000m², which has allowed for the creation of additional workshop space and new machinery for the polyurethane and engineering divisions.â€? According to Carolin, the UMP engineering and fabrication division is now able to service considerably larger projects. “We now have the ability to lift components that are up to 12,5 tons in weight and up to 10m in height under one crane. In the past, these types of projects would have been outsourced, as a result of our limited capacity. We are in a position to manufacture anything from machines to structural components.â€? “Improved internal manufacturing capabilities lower the cost of production thanks to an increase in volumes, while improving QC, as a result of all processes remaining entirely in-house.â€? UMP will increase its focus on pipelines as well as expanding into the export UMP sales manager Dion Simonato with CEO Trevor Carolin, who said the company’s increased capacity offers clients a valueadded service offering as everything is completed according to its exact 10 DECEMBER 2013 / JANUARY 2014

markets across Africa, North America and South America. “UMP is currently in the process of establishing a dedicated North American branch in Ontario, Canada, to service the well-established mining sector in the region. With development taking place in the South American mining market, I believe that UMP can gain market share in the region by consolidating on its success in Canada,� he added. From a local point of view, Carolin pointed out that the South African market remains relatively subdued, despite showing signs of recovery. ™ & | as the most prospective market for new projects and growth possibilities. As a result, we will continue to place a high emphasis on expanding our reach in this market moving forward,� he added. About UMP From humble beginnings in 1974, UMP today is recognised as one of the most established polyurethane moulding companies in South Africa, and remains one of the largest urethane pipelining companies, with over 200km of urethane lined pipes being supplied since 1980. UMP manufactures and serves the local and global markets in base metals, gold, coal, diamonds, platinum and power generation. PU Mouldings and medium to light engineering are just two distinct services that UMP offers to its clients.

www.ump.co.za

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WEBSITE: www.cabletech.co.za

Top showing at Gold Pack Awards Spec Tool & Die, JJ win the main award THIS YEAR’S Gold Pack Awards, presented at a posh night at the Wanderers Club in Johannesburg on 22 October, showed again the prowess and world-class standards of the South African packaging sector – with plastics entries grabbing by far the biggest share of the awards. Of the 19 gold, silver and bronze awards available in six categories in the four main packaging groups (glass, metal, paper & board and plastics), plastics entries took over half the awards presented on the night (13 out of 20) as well as the IPSA Gold Pack Trophy for 2013. The trophy – the top accolade in the local packaging sector – went to tool designer/manufacturer Spec Tool & Die along with convertor JJ Precision, the Astrapak group injection company, for their closure for Robertson’s Spice new spice container cap for Unilever South Africa. The top trophy was shared with Consol Glass, which manufactured the lightweight glass bottle.

Besides that, the overall Gold Medal for Plastics went to Nampak Megapak for its Poltek bird crate, an entry which was not a winner in the transit & secondary packaging category in which it was entered. Of the plastics winners, the Astrapak group achieved exceptional success with four gold and several other medals. “ & received ‘special mention’ recognition from the judges. _ [ [ ž including Afripack, Astrapak, Mpact, Nampak and Polyoak – as well as some of the smaller independent companies (T3, Tropic, Pouch Dynamics, Miller Methods) is translating to technical advances on the ground – that is in the design rooms and production halls around the country. It is possible that more entries were submitted by plastics convertors around the country, since the rival material packaging sectors tend to be dominated by fewer and bigger operations, but plastic packaging manufacturers can and should take pride in the achievements of 2013 – well done to all the players!

GOLD PACK TROPHY 2013 Overall winner! – The winner of the IPSA Gold Pack Trophy for 2013 was the new Robertson’s Spice container from Unilever SA. This is a two-piece container with plastic cap and glass bottle. The

mould for the closure was designed and built by Spec Tool & Die and moulding was handled by JJ Precision, both Durban companies. JJ is part of Astrapak group. The 100ml container is 10% lighter than its previous version, which in itself was an accomplishment, but the real feat was the construction of the mould for the orientated # $ was to prevent cross-contamination and extended shelf life, but achieving that in a fast cycling multi-cavity mould was daunting for Dave Murgatroyd and the Spec team. The two covering lids need to " ] • € mould cores as a result needed to be adjustable. The result is this neat container that achieves practically zero moisture penetration. The container was also the winner of the Ambient Food category

www.spectool.co.za

www.astrapak.co.za

Gold night! – Vanessa van Holdt and Bill Marshall were the stylish compères of the Gold Pack banquet at the Wanderers Club in October. The programme was shorter than in previous years, with only the winners receiving their medals on stage, which left more time for the guys in their penguin suits to waddle around ‌ err, network later that night

12 DECEMBER 2013 / JANUARY 2014

INDUSTRY NEWS

for

plastics Co’s

GOLD MEDAL PLASTICS Gold for plastics – The Gold Medal for the plastics categories overall went to Poltek for its Live Bird Crate. Moulded by GOLD Nampak Megapak in partnership Custom Moulders (owner of the Poltek brand), the crate is used to transport live chicks, with the intention that this be handled in a humane and hygienic manner. The crate was designed locally, but the mould was built in China. The lightweight crate’s halves separate and are stackable, which also allows for easy cleaning. The white mesh hatch is moulded separately for post-assembly, with the entrance opening fully to allow the young birds to exit easily after transport. The $ – Q ] category

www.custommoulders.co.za www.nampak.com/Plastics-Megapak

BEVERAGE CATEGORY €\ � † ' &€ ' * label for Fair Cape group’s dairy and fruit juice containers. With its small amount of pre-applied pressure-sensitive adhesive with tight register, the ACF labels set a benchmark for the labelling of PET bottles

GOLD MEDAL WINNERS

Beverage

Nampak Bevcan

Ambient food

JJ Precision (Astrapak) / Spec Tool & Die / Consol Glass

Perishable food

Marcom Plastics (Astrapak)

Health & Beauty

Plastop KZN (Astrapak)

Household

African Closures (Polyoak)

Transit & Secondary

Nampak Cartons & Labels

Packaging Achiever of the Year ‌ The ‘man from Nam,’ Jeremy Mackintosh (originally from Namibia) received deserved recognition at the Gold Pack banquet when he was named ‘Packaging Achiever of the Year’ for 2012/13. Besides overseeing the development of the Polyoak group into one of the top rigid plastics packaging manufacturing operations in southern Africa, Jeremy has also been actively involved in industry services activities with Plastics|SA and the Plastics Convertors Association

DECEMBER 2013 / JANUARY 2014 13

2013 winners! ‌ Ashwin Ramsudh, R+D packaging development manager at Unilever; Dave ? $ – ‚ > ‚ ' \ " manager and GM respectively of Astrapak JJ Precision Plastics. Their companies were partners with Consol Glass in the production of Robertson’s Spices new spice container which won the Gold Pack Trophy, the top award in the packaging industry in Southern Africa for 2012/13

CATEGORY

uppe marketing A08303

Fresh portfolio. Colour your world!

BASF's Official Distributor: Lake International Technologies Sherisha Ramruthan Sherisha.Ramruthan@lake.co.za Tel: +27 11 409 5000 (switchboard) Fax: +27 11 388 6423 (direct ) CALL CENTRE: 0860 99 00 11

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

INDUSTRY NEWS

PERISHABLE FOOD CATEGORY Parmalat Presto Astrapak Plastform won gold in the Perishable Food category for its range of thermoformed yoghurt container sixpacks for Parmalat Presto. The individual containers in the punnet are squeezable, which allows for the yoghurt to be consumed from the pack, which achieves ‘brand proposition and offers consumer convenience’

GOLD

Plastform won a second BRONZE medal, in this case the bronze, in the Perishables category for its range of thermoformed tubs for Danone yoghurt, making it the big winner in this important packaging market. The label is a full-length sleeve that achieves ‘maximum branding and shelf impact’

SILVER

Afripack Consumer Flexibles took silver for its ‘velvet’ touch packs for NestlÊ’s ‘Heaven’ ice cream wrapper. The judges said this added to the ‘consumption experience’

Astrapak’s leadership in the thinwall packaging market was emphasised with a judges’ special mention going to Astrapak Marcom Plastics for its injection moulded oval tubs, with inmoulded labels from Alex White, for Parmalat group. The ‘Royalty’ range designed for export to Zambia

Astrapak Peninsula Q ] the perishable food category for its revolutionary introduction of the potato bag that ‘combines the best of netting with the best of printing LDPE’

‘Stadium’ lid – The Dairypack Tubs division of Q ] in the Perishable Food category with its range of Butro tubs for Clover. The new tubs feature a tilted lid and tub shape that is similar in appearance to the Green Point stadium. The solution has the advantage of making the lid label more visible, enhancing appeal

Miller Methods and Universal Labels were

perishable food category for their caps for Enterprise polony. This is a promotional item that has been well received by consumers

DECEMBER 2013 / JANUARY 2014 15

- passionate about the plastic industry. Supplier of:

ty t o G

Injection Moulding Machine

Servo Klockner

Rebuild

VICTOR MACHINERY

Tel: +27 11 824 3103 - Fax: +27 11 824 6018 email: sales@sescc.co.za - www.sescc.co.za Unit 1, 16 Davidson Place, Wadeville, 1428

INDUSTRY NEWS

HEALTH & BEAUTY GOLD

Gold in the Health & Beauty category went to Astrapak KZN Plastop and Ferroprint for the ‘Dawn’ range of cosmetic products for Unilever. The ‘structural and graphic designs have come together to uplift an affordable product, giving it the image of a luxurious brand. The production quality of the shrink sleeve from Ferroprint, including the ‘distortions and the visi-strip employed, lightweighting of the bottle, design and engineering of the closure plus the good collaboration between the brand owner and the convertors has resulted in a positive market response,’ the judges said

HOUSEHOLD

Consupaq, the Astrapak tubes BRONZE manufacturing business in Durban, took the bronze in the Health & Beauty category for its ‘Lucid’ jars and tubes for Annique. The application of foiling, particularly on the tubes, was assessed as very high standard by the judges

' Q \ $ range of ‘Hoity Toity’ personal care products for Indigo Brands. This was a joint venture involving Evotec, Mpact Plastics and Tadbik, the latter being the supplier of the in-mould labels

The African Closures business of Polyoak group won the gold in the Household category for its child Q

Ž ˜ Q # GOLD African Closures is one of the leaders in the local closure development and production sectors, and here it again showed high levels of ingenuity. The child-resistant closure is used for the effective sealing of potentially problematic liquids and combines both a visual and audible signal to the closure’s functionality. It is available in a variety of seal options

Cinqplast and Winplas took BRONZE the bronze in this category for their range of ‘eco superior’ packs for Woolworths, in the process of which they also created a market for recycled material. The judges commended the products’ on pack communication which will help ‘drive recycling’ Q ] / category for its range of shrink sleeve labels for Wynn’s Oil €# $ ‡ ™ that solves ‘crushing’ and ‘lifting’ issues with promotional banded packs as each pack is essentially shrunk in its own pocket creating a š

$› Q 50ml jars for ‘Justine’ cosmetic products for Justine/Avon. These injection moulded twin-wall jars feature high standard foiling and graphics and are produced in SAN

TRANSIT & SECONDARY PACKAGING Twelvepack – Silver SILVER in the Transit & Secondary Packaging category went to Q " Ž

business Tropic Plastics of Durban for this pack for two sixpacks, that allows for easy handling throughout the supply chain

DECEMBER 2013 / JANUARY 2014 17

INDUSTRY NEWS

AMBIENT FOOD CATEGORY Nampak Flexible was a

€ Food category for its resealable packs for Cadbury chocolates. The feature is clearly communicated on the pack, which the judges liked

Mpact Plastics Atlantis received a judges’ ‘special mention’ recognition for consumer convenience in the ambient food category for its honey bottle for Woolworths

Polypet marinade Braai time! – Polypet Ambient Food category for its resealable PET packs for its range of braai marinade sauces for South African Breweries. Polypet is a division of Polyoak group

Nampak encourages next generation of packaging designers THE three winners of the Food Science and Technology Category of the 2013 IPSA Student Gold Pack Awards all demonstrated insight into how packaging can be used as an eye-catching and user-friendly tool to promote products and attract consumers. With its emphasis on the development of and education in food science, Nampak is the primary sponsor of this category of the awards. As part of the competition, Students of Stellenbosch University and Cape Peninsula University of Technology (CPUT) were given a brief to design

* & &

[

semester of the Food Science Product Development module. www.nampak.com Claire Kirkby of Stellenbosch University (middle), receiving her Nampak Gold Trophy for winning the Food Science & Technology Category IPSA Student Gold Pack 2013, presented by Kirsten Tyler of Nampak Group Marketing and Johan Visser of Nampak R&D. The Rosendale Labneh is a concentrated yoghurt product " ' # of Labneh was preserved and protected in an individual PETG petal shaped shell, which extended shelf life to point of consumption. The aesthetically appealing pack was made to look like petals in a "

Jessica Kemp from Stellenbosch University won the silver award for her Bean Bites, a falafel style snack sold in party packs " ' # $ ] ' Q�€ the consumer to take the product straight from the freezer to the oven. The container can be added to the compost heap for decomposition after use.

The bronze award went to Zaharan Hussein + ' ? Atmosphere Packaging for fresh pom-arils. ? € Q ] Ž the shelf life of arils from pomegranates adding convenience and preserving the fruits natural sensory attributes. The packaging was an ideal integration of lightweight, recyclable and compostable materials into a low cost preservation technology that relies on an integration of natural product respiration and package permeability to extend shelf life. The judges were particularly impressed with the extent of MAP research and level of technical detail presented in this project DECEMBER 2013 / JANUARY 2014 19

JUST BRIEFLY

www.harrogate.co.za

Thermoformer Harrogate buys assets of Kiley Baker HARROGATE Plastics of Benoni, a leading Johannesburg fabricator of point of sale and other thermoformed plastic items, has bought most of the assets of former rival Kiley Baker Products. Kiley, established by Messrs Kiley and Baker in 1969, was one of the oldest thermoforming businesses in Johannesburg, but the operation became uncompetitive and eventually closed in December last year. Enter the picture, Robert Rugheimber of Harrogate, who purchased the bulk of KB’s equipment on auction. Former KB manager Peter Hawkins is now production manager at Harrogate. Harrogate (established in 2004) manufactures point of sale items, dispensers, signage, name tags and other thermoformed sheet goods and is involved in digital printing as well as vacuum forming of fairly large plastic sheet items.

Robert Rugheimer of Harrogate at the company’s premises in Johannesburg

www.bicworld.com

BIC plant in DRC closes BIC South Africa is now the only the BIC plant operating in Africa following the closure recently of the global group’s factory in Kinshasa. The plant in the Democratic Republic of Congo became unsustainable more as a result of the & &

particularly regarding transporting product from the site, than due to any other factor. The BIC group started in France in 1945. It is now an international operation manufacturing pens and other stationary items, lighters, shavers and promotional items. The South Africa operation, which started in 1957, operates from Industria, Johannesburg, and manufactures only pens. 20 DECEMBER 2013 / JANUARY 2014

Lomotek Polymers celebrates 10yrs Lomold group processes over 1500 tons/ month LOMOTEK Polymers, the compounding arm of the Lomold Group, has just celebrated its 10th year in operation – a decade which has witnessed it becoming one of the top plastics compounding operations in Southern Africa.

The compounding business is a subsidiary of the Lomold group, which patented its Lomold™ technology for the production pallets

Lomotek developed out of a requirement for the vertical integration of the Lomold Group. Entering the market in 1998 with its low-pressure injection moulding technology, a local market gap was & Â

& & Lomotek Polymers in Cape Town in early 2003. Lomotek Polymers supplies customer-spec colouring for both milled and compounded LLDPE materials to the roto moulding sector. Due to the high quality of the roto materials and services, it started to rapidly expand both its services and comprehensive range of materials to accommodate all end users across the entire polymer market. “ & ” • ” * the group’s acquisition of Plastamid’s compounding facility in Elsies River, Cape Town, in 2010, which created a platform for the group to increase capacity as well as develop and manufacture new and advanced materials. A fully spec’d lab service operated at the Elsies River plant, which became ” & [

formulations for the powder, recycling and specialty grade sectors on demand. In addition to its very wide range of products and services, Lomotek

& ” | _ ¤¼ reinforced thermoplastics for use in the Lomold process as well as various other automotive applications. In total, the Lomold group processes an excess of 1500 tons per month. Continuity The business suffered a major setback earlier this year when the group founder, Pieter du Toit, passed away. Du Toit was the motivator for the group’s strategy and all of its primary initiatives, but thankfully – in a rare incidence – three of his sons remain employed within the group to carry the legacy forward. Werner du Toit has succeeded his father as CEO, Wouter du Toit is now the sales and marketing director and Ruan du Toit heads up pallet sales for the Z & * &

& # accounts manager, Riekie Vorndran, are both sisters of Du Toit. So it’s truly a family business, with cousins and various other relatives all involved in making the business a success. Du Toit treated all of his employees as family, with it becoming a truly wonderful aspect of tenacity and perseverance within the group of companies. “Pieter provided us with the tools and many lessons in business, and our goal is to put these into practice and continue with the development of the businesses in the Lomold group,� said Wouter du Toit. www.lomold.com

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

INDUSTRY NEWS

UV Tooling celebrates

25yrs Only perfect will do – Uli Vogeli in the toolroom at UV Tooling in Killarney Gardens, where the company’s toolmakers produce high standard tools for technical components

Produces tools that function optimally and achieve production targets – or better

22

DECEMBER 2013 / JANUARY 2014

UV TOOLING, one of the Cape’s most reputable toolmakers, recently celebrated 25 years in operation. Gaining a good reputation is no easy matter for a toolroom in South Africa, such is the pressure on lead times, costs and expertise brought on particularly by toolrooms in China which have been offering local brand owners and product manufacturers exceptional deals. However, UV has managed to remain competitive through this challenging period. The 25-year milestone is a happy occurrence for UV founder Uli Vogeli (‘UV’), who got the show on the road in 1988. Originally from Switzerland, Vogeli completed a toolmaking apprenticeship there before he came out to Africa for a bit of holiday and fun. He joined Drago Plastics, working for the successful ‘Yugoslav’ proprietor, Drago Srdic. The company moulded television set housings and the manufacture of the comparatively large tools with extensive

= & experience. Then, after what was effectively a further 12-year apprenticeship (as well as two extended global sailing trips, one on a yacht he built himself), Vogeli went on his own in ’88, operating from the garage of his home. He was a one-man-band for just six months, however, as UV Tooling began to gather momentum. He was sought out for his toolmaking skills and made tools for a wide range of products, focussing on technically shaped parts like electrical and electronic housings. Tool trials Œ tool trials, but production has become a mainstay of the business since. The basis for the company’s success to date is mainly due to good relationships built up with customers – in respect of the quality of tools produced, lead times and low error level – which Uli realized at the outset was most important. Toolmakers in South Africa are positioned midway between Europe and

Tools for complex electrical and irrigation parts are the norm

the Far East: costs for the manufacture of tools are comparatively high in the former and lower in the latter ‌ but the only way &

* & is to produce tools that function optimally and achieve production targets – or better! UV Tooling has shown that it is able to make tools that match all these criteria and has as a result progressed steadily. UV Tooling moved to its own dedicated premises in Killarney Gardens in 1995. €"€ year. It moved again in 2005 to larger premises in the same area, where it still operates from today. Congratulations to Uli and the UV team!

www.uvtooling.co.za Tools for electrical and electronic housings are produced, and in some cases, UV handles the moulding as well

Andrew Bannatyne of Plastichem presented a gift to Uli on the occasion of the company’s 25-year celebrations

Karl Musik is the self-taught designer at UV Tooling who has excelled with development of complex tools

INDUSTRY NEWS

Alpine grows Starts vacuum forming, and exports to China CAPE converter Alpine Injection Moulding has moved to far larger premises and added vacuum forming to its range of services. The company moved earlier this year from premises it ‘outgrew’ in Epping to a fully refurbished 4000m² site in Parow Industria where it is able to accommodate its bank of injection

€ * ‚ ' „ * new and neatly renovated factory in Parow Industria; the company has also recently � ]

Q ž ?� consistent cycle times

moulding machines as well as the new large-dimension vacuum work it has commenced. Alpine also conducts extensive assembly work on site, necessitating the extra space. The site was previously occupied by Macbean Plastics. And Alpine’s Dave Roberts’ recent & time appears to have been vindicated. The SML robot from Plasquip is being used for the injection moulding of a housing in polystyrene where the 29-second cycle times needed to be maintained (cycle times always need to be maintained!). Mouldings were previously removed manually, which on occasion caused interruptions to cycle  & &

however, the machine maintained the 29-sec rate for a full 24-hour period and produced just a single scrap part, not bad for beginners! www.alpinemouldings.co.za DECEMBER 2013 / JANUARY 2014 23

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Design

Manufacturing

We specialise in the manufacturing of plastic injection moulds using CAD/ CAM and CNC machining to produce mould sizes of 546mm x 796mm and smaller. We also offer product design and mould design.

Our workmanship is based on international standards provided  staff. We are recognised for our high precision manufacturing. We are also an accredited training facility for the practical training of apprentices in the industry and are a proud member of TASA (Toolmaking Association of South Africa).

Production We have over 20 production machines ranging from 12 tons to 250 tons. Our moulds are of the highest quality and are always ready to operate. Quality products need quality workmanship, so we use only the best.

Contact 22 Lauda Road, Killarney Gardens, Cape Town, South Africa, 7441 P.O. Box 6406, Parow East, South Africa 7501 Tel: +27(0)21 5560315, Fax: +27(0)21 5560316 Email: info@uvtooling.co.za

UV Tooling specialises in precision plastic injection and die casting mould making and production. The company has served the plastics industry in South Africa for the last 25 years. " ] #

INDUSTRY NEWS

Eco Polymers ups PP recycling rate ECO POLYMERS, the polypropylene recycling operation in Alrode, Johannesburg, has succeeded in lifting tonnage turnover nicely since the business was established 18 months ago. The company was set up by Victor Nash, Asheen Singh and one sleeping partner. The line, built around a 130mm extruder and wash plant, started as a turnkey operation in mid-2012. PP has up till recently not been widely recycled, but that’s not because it isn’t popular: rPP is used in furniture, crates, household goods and a wide range of other applications. Use of a percentage of recycled material in the cores of mouldings or multi-layer structures offers a price advantage for PP converters. The factor that has prevented rPP’s more widespread reprocessing is the challenge of sourcing material from the post-consumer stream. Eco Polymers as a result started off right by having an expert within operational experience in this area, Victor Nash, together with a well-known material expert, Asheen Singh, to establish its collection system.

Much of the material is & requires coordination with both dedicated and informal collectors. Polypropylene mouldings can be hard to identify in the waste stream, since a wide variety of components are produced in PP and, unless prior sorting is conducted, these & But it appears that recyclers are moving towards a solution: PP recycling rates have increased Victor Nash monitoring production of PP pellets from an estimated 26 500 tons in from recycled material at the Eco Polymers plant in Alrode, Johannesburg 2005 to 47 000 tons in 2012, which is a major rise.

& ›= Nash, who was previously The demand for Eco Polymers material involved in PP yarn extrusion as well as outstrips supply pushing this newly bulk PP recycling, has carried those skills founded company into the next stage of over at the Eco plant since relocating to its plan, to further increase processed Gauteng. He has succeeded in setting volumes to 180 tons and to develop new up a functioning system which has seen markets for the range of rPP polymers it’s tonnages move up to the 140 tons a supplying. month range. Training of production and Eco Polymers, phone 011 468 4871 / collection staff, as well as the incentivising 082 880 5900 of particularly the latter, has been an important part of the process. Production scrap from PP virgin convertors forms a

Collected polyprop material contains an incredibly diverse range of products, from crates and buckets to furniture and toys, which in itself makes the collection process challenging. One of the plusses is that PP tends to have a high weight-to-mass ratio

24

DECEMBER 2013 / JANUARY 2014

Washed and granulated material – including PP labels, containers and a variety of other common products – tends to be mainly white with a sprinkling of other colours; here operator Lukas prepares granulated Ž

Recycled PP from Eco Polymers is supplied in bulk bags

INDUSTRY NEWS

SA recycling rates increase More than 9% increase in plastics recycling _§ ` &

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90 149 39 855 27 907 20 869 798

2011

NonPackaging

Packaging

11 305

2012

NonPackaging

11 825 17 744 15 032

89 493 46 276 27 108 21 549 587

2 038 376 40

1 218 805 1 891

7 696 189 728

6 359

Packaging

NonPackaging

11 871 18 734 16 117

93 464 50 280 36 316 21 716 631

9 633 25 365 16 181

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196 760

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30.1%

29.9%

33.5%

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Packaging and non-packaging tonnages recovered in South Africa from 2010 to 2012

2009 Total tons converted Total tons recycled

2010

2011

2012

1 280 000

1 312 700

1 300 000

1 370 000 268 548

228 057

241 853

245 696

Recycling rate

17.8%

18.4%

18.9%

19.6%

Waste exported

5 575

9 054

9 758

14 744

233 632

250 907

255 454

283 292

18.3%

19.1%

19.7%

20.7%

Total tons diverted from Recovery rate Table 1:

Plastics Recycling and Recovery rates for 2009 to 2012

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Rotational moulding Masterbatch and Compounding

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DECEMBER 2013 / JANUARY 2014

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INDUSTRY NEWS

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Composite solution for container quay Biggest single composite job ever completed in South Africa

32 OCTOBER / NOVEMBER 2013

AERONTEC, Cape-based composite materials supplier and distributor, recently completed a massive 300-ton contract of

* [ Aerontec designed, manufactured and installed a special composite deck on one quay of the Cape Town container terminal to increase the height of a section of the concrete deck Q¨J ™ & * & ever been undertaken in the world, and I believe it was also the

[ Z & š • “ ' The Transnet National Ports Authority, through a local civil engineering company who was busy with the construction of a new section of the container terminal, approached Aerontec to [ \  The cable tray which houses the electricity cables for the large gantry cranes along an area of over 1200m and about 3m in width, were considered a serious trip-hazard to workers on the  & * & & * ' Blyth explained that the quay is a cantilever deck and the piles & \ \ [ ™

& Q¨J * [ § [ presented too many disadvantages: weighing in at about 1000 tons of concrete and rebar it was too heavy; too costly; too long to construct and too long to wait the prescribed 28 days for the concrete to cure, not ideal for a working quay with ships berthing š Realising an innovative resolution was urgently needed; the engineering company and civil engineers approached Aerontec &

_ Q> solution had to be: light weight cost effective quick and easy to install able to allow waves to wash over the panels and allow water to drain away quickly underneath the panels strong enough to endure loads of up to 40 tons in the event a

The problem! The cable tray which houses the electricity cables for the large gantry cranes along an area of over 1200m and about 3m in width, were considered a serious trip-hazard to workers on the quay

Composite solution! 1161 GFRP panels weighing in at just 250 tons proved to be the ideal solution to the tricky problem of raising a

container was dropped or placed on the panels weather resistant safe and have a slip-proof coating fastened onto the existing deck surface without damaging the surface or the rebar lattice such that damaged panels can be replaced \ › points The solution After various designs, proposals and testing, a design was agreed on which made use of resin vacuum infused solid GFRP

[ [ ›

_ Œ ›" • = ›

The solution! A gap was left between the panels adjacent to the rail and the panels at the water’s edge where a Panzer belt had to be installed to cover the electric crane cables. The Panzer belt is lifted by a special belt lifter attached to each crane to withdraw the cable, and to nest the cables back into the hidden cable cavity as the crane passes down the rail system

INDUSTRY NEWS

Before work began to install a special composite deck on the quay to "

& \ \ › ordination to ensure everything went as planned: various panel % & % & › 1161 panels, the process of bonding the feet on, transport, * & around the bollards, as well as manufacture of the light-weight & › ›

_

[ * %% _ & >‹J &  _ Q> Aerontec has recently been granted the rights to sell, & & §

[

Z & ||Z Technology, specialists in infusion of large solid composite

&

& the panels at the water’s edge where a Panzer belt had to be [ _ % lifted by a special belt lifter attached to each crane to withdraw the cable, and to nest the cables back into the hidden cable [ “ \

Y> • ` _

& “There is an undulated variance of about 80mm over the \  – [ [ crane rail to eliminate any trip hazard, so countless GFRP shims had to be made and bonded in place to keep the GFRP panels [ š www.aerontec.co.za

NICO van Wieringen joined Aerontec at the beginning of September as the import and purchasing manager. Nico has extensive experience in the purchasing and freighting arena, previously working for more than 12 years for the Southern Wind Shipyard in Cape Town which designs and manufactures 100ft and larger composite yachts for the European market.

www.mmstechnology.co.za DECEMBER 2013 / JANUARY 2014

33

ARALDITEŽ epoxies & RENCASTŽ polyurethanes – Resins & adhesives

Tooling / machine boards & tooling systems

DIVINYCELL PVC and PET rigid structural foams We now stock DIAB DivinycellÂŽ core materials, that we can cut to your thickness requirements from 2mm to 60mm

Plastic Honeycombs Nidaplast Honeycomb is a polypropylene honeycomb used as a core in structural sandwich panels

Supplier and distributor of composite materials and related technologies Epoxy Resin systems Fiberglass, carbon & Kevlar Core materials

Vacuum bagging and infusion materials Tooling Systems Technical and Processing advice

TELEPHONE +27 (0) 21 671 2114 / +27 (0) 21 674 6325 FAX +27 (0) 21 674 6622

EMAIL info@aerontec.co.za

INDUSTRY NEWS

Peter and Riaan Steyn outside their Upington Recycling depot which opened in February this year

Northern Cape recycling ‘indaba’

34 DECEMBER 2013/ JANUARY 2014

Huge potential to grow recycling industry in the area RIAAN Steyn is a man with a vision to alter the face of recycling in the Northern Cape – and he’s determined to make his vision a reality.

between towns and the high cost of transport, as well as the lack of recycling infrastructure and knowledge of the potential of the Northern Cape.

Currently there are only a handful of recycling companies operating out of the area, mainly from Kimberley and Upington, and these focus mostly on industry and retail outlets. However, Riaan believes the potential to grow the recycling industry achieved by involving the communities of surrounding smaller towns. To help kickstart the ambitious project, Riaan and his son, Peter, recently hosted the two-day ‘Green Kalahari Recycling Indaba’ in Upington. Major roleplayers in the recycling industry – including Mpact, € _€ †Z * – were invited to spend the two days visiting Upington Recycling, which Riaan and Peter own, as well as smaller more informal recycling projects which Riaan hopes to incorporate into his vision. A day was also dedicated to educating around 600 of the communities’ schoolchildren about recycling and the role they can play in helping to clean up their environment. According to Riaan, the main challenges facing recycling in the Northern Cape are the long distances

The project There are 82 small towns in the greater Northern Cape area, with a population of about 1.1 million. Riaan has spent close on two years researching his vision which will concentrate on 40 of these towns, all of which will be new sources of recycling. He estimates that the average monthly volumes of recycling currently generated by each of these towns to be: Box – 5 tons PET – 2.5 tons Plastics – 2 tons HLI – 2 tons (tin) Glass – 15 tons “I realise this is very little. However, if multiplied by 40 towns another picture emerges which will grab the attention of Consol, Mpact and Extrupet,� he adds. Riaan’s vision is to establish a recycling buy-back centre in each of the 40 towns at businesses, like general stores, that are currently well run and accessible to the community. Individuals will then be encouraged to collect materials which can be recycled and take it to the buy-back centres where they will be paid cash determined by the

Non-mechanised baling! – Workers at the Raaswater Recycling Project, about 20kms from Upington, use ‘muscle power’ to compact the PET recycling they collect. ˜ ‚ Q  €* sustainability, remarks on the effectiveness of their efforts

25 tons of material was processed by Upington Recycling in September, which opened in February. Here Riaan Steyn Ž ? ˜ €] '

weight value of the recycling they deliver. Upington Recycling will implement a system which, simply put, has a truck with a mobile baler travelling a logical circuit to each of the 40 towns where collected material will be baled and taken to Kimberley Recycling (also owned by the Steyns) or to Upington Recycling. “We will also provide ongoing guidance and advice to the buy-back centres to ensure that the project is sustainable,� says Riaan. “It’s going to be a costly start-up, but has the potential to be a long-term sustainable venture,� he adds. Need for recycling plan in smaller areas recognised # Z †Z ' of sustainability, says that industry tended to focus on recycling volumes and therefore on the bigger centres. However, he realized the need to extend the focus to the smaller areas. “There’s a real need for a good recycling plan for the smaller areas and I believe it could be a success if it has a champion like Riaan driving it,� he added. “The potential to build a culture of recycling exists here and this [ coming out of these smaller towns.� Riaan Steyn, tel: 082 053 9741, email: kimberleyrecycling@gmail.com

‚ Q  € ] explain the intricacies of PET recycling and the products that can be made from recycled PET to Upington schoolchildren

NOW AVAILABLE IN SOUTH AFRICA

100 ton Servo machine in stock

KAWAGUCHI injection moulding machines are well known for their reliability and longevity. This world-renowned brand is available in a variety of models. KMB3 – servo and hydraulic KMB4 – servo and hydraulic KME – full electric machines All of these models use the KAWAGUCHI EZ8000 Hitachi controller with touch screen. For more information contact Dave Moore on 083 675 8325 CALL NOW FOR YOUR QUOTATION, PRICES ARE COMPETITIVE!

ADDIS turns 100! An enduring story – lessons in manufacturing in South Africa USABCO, local manufacturers of household icon ADDIS, is celebrating its centenary this year by reinvesting in the country, the company and the brand that has become part of the lives of generations of South Africans. For one hundred years, USABCO has been manufacturing household products that make our lives easier – from food and home storage containers, plastic kitchenware and laundry products, the most comprehensive and innovative range of home cleaning products, paint brushes and the ever present South African staple, the cooler box. USABCO products have been available in virtually all of South Africa’s leading supermarkets and hypermarkets from the

_ Z “€ manufactures over 1000 product lines out of its world class plant in the Western Cape, supplying thousands of stores throughout South Africa and Africa.

Reaching the 100-year mark is a remarkable achievement for any company, but particularly so for a manufacturing company not just in South Africa, but anywhere in the world, in the face of ever changing threats of cheap

= \ hungry competitors. _ [ its ability to retain employees through thick and thin, which adds a depth of experience and commitment to the company that is seldom seen in the manufacturing environment. “USABCO is proud to reach this remarkable milestone, which we could not have done without the constant and enduring support of our staff, our partners and our loyal customers – and we cannot thank them enough,� said USABCO’s chief executive Errol Z ™_ & our personnel, a culture of innovation, commitment to excellent service and world-class manufacturing.� “If you invest in training and building

skills among staff at all levels, as we have, it is possible to create the capacity to be competitive on the global stage and not regard one’s self as a South African company which de facto is limited in size and growth by the perceived constraints of a lack of world class expertise in a smaller market removed geographically from the world environment,’’ added Stern. USABCO is headquartered in Bellville in the Western Cape, operating out of a 40,000m² state-of-the-art manufacturing plant which employs over 750 staff. _ ' of quality and innovation, it supports a product design and development industry in the Western Cape and is closely & * As a sign of the company’s commitment to the future, USABCO has ensured that the plant is equipped with the latest machinery, new products and moulds and a new state-of-the-art Enterprise Resource Planning (ERP) system from Oracle, which will streamline

NCG CAM software system for manufacture of moulds now in SA

36 DECEMBER 2013 / JANUARY 2014

! "

" " NCG CAM, a cutting edge computeraided manufacturing (CAM) software system used in steel cutting and for the manufacture of moulds, is now available Z & _ “ › integrates readily with existing CAD and CAM systems. _

NCG CAM Solutions of Witbank. NCG CAM is suitable for all types of forms, creating an optimised, smooth cutter

motion ideal for 3D HSM machining, which will help to extend tool life, minimise wear on the machine tool and produce

\ & NCG CAM has a user-friendly interface, with a typical learning curve of just a single day being required to machine a ‘live’ job. It is ideal for the high-speed machining of moulds, dies, prototypes and precision surface machining. 5 axis machining of Ž (Picture courtesy of NCG CAM User: ORODJARSTVO Gorjak, Slovenia)

Features include: several advanced 3D machining routines, rest roughing and 3+2 capabilities for all tool paths (a simultaneous 5-axis add-on module is available); & & including core roughing and adaptive clearance; advanced drilling routines – includes automatic hole detection and/or user ‚ \ \ \€? ] Š' ‚?‹ ‡ (Picture courtesy of NCG CAM User: LTH Castings, Slovenia)

INDUSTRY NEWS

$ + €†\ ' ^``` ‰ \ € €

both its manufacturing and business processes. ™_ ` Z at the forefront of world class manufacturing, allowing us to optimize our processes, reduce

& && [ to changing market conditions,� said Stern. _

Z “€ \ future, and to bring awareness of its excellent products and brand and South African roots, the company has also embarked on a 360-degree marketing campaign, including television advertising, a new website and a national retail competition, which aims to stimulate the purchase of homegrown products. “Reaching the 100-year mark has & Z “€ ' Z Africa,� added Stern. “It has re-energized us to ensure that we are not ‘100 years old’, but rather a nimble company committed and focused on its future.� USABCO’s is entering its next century as a [ & # # #[

all machining routines are fully gouge protected for both the cutter and the tool holder;

& minimise any air cutting; available as both 32 and 64-bit versions (both are multi-threaded). NCG CAM’s latest release, Version 12, includes new features such as the ability to machine selected surfaces, the ability to generate ruled surfaces, thread milling, a tool size guide, core horizontal area passes, multi \ * ÂŒ ` € _ÂĽ

creator, as well as many enhancements. A demonstration version of NCG CAM v12 is available for download at http://www. ncgcam.co.za/request-a-demo.html For more info, contact Nicole Geldenhuys on `}› Œ`’ }’’› \ \€? ‡ (Picture courtesy of NCG CAM User: LTH Castings, Slovenia)

# # #[

Makoro Tanks starts in Botswana “ _Z– " * manufacturer Makoro Bricks has opened a subsidiary operation, Makoro _ * manufacturing roto moulded tanks _ New tank maker = ‚ Q „ „ ? Bricks operation ? ] $ ] was previously the „ € Botswana agent ] & $ $ _ * Rudy Schuhardt, owner of the businesses, said they had decided in 2012 to commence with the production of tanks themselves. | * _ * › & & Reinhardt of India. Supplied by the well-known Dhanu Patell of Reinhardt, who managed the commissioning process, the machine is able to produce a 5000-litre tank in 26 minutes, which is an impressive cycle time. _ &

& * | * offers tanks for industrial, chemical, and fertilizer # ] # # storage solutions. DECEMBER 2013 / JANUARY 2014 37

Lanxess converts to ACE technology New line has capacity of 95,000 tons per year comprises seven € › ª ™_ The largest production line for the Keltan-branded EPDM synthetic rubber at the Lanxess site of Sittard, Geleen, The Netherlands, has introduction of these been successfully converted to the company’s innovative ACE grades from the technology (Photo: LANXESS AG) _›Y result of an extensive monomer compositions and molecular technology and product validation š # ™ [ including several test runs on one of the high ENB grades, for fast vulcanization, smaller production lines at the Geleen } \ ~ [ › › › site,� said Torsten Derr, head of Lanxess’ weight grades, for excellent elastic � }� ”~ properties.� #| [ Lanxess’ Changzhou plant in Jiangsu automotive industry for door sealants Province, China, starting up in 2015, will or coolant hoses. According to Lanxess * € › _ estimates, approximately 7kg of EPDM is used in every car. The product is also used will have a capacity of 160,000 tons per year and represents an investment of ₏235 million. construction and oil additives industries. Its ” \ Z properties include very low density, good Plastichem resistance to heat, oxidation, chemicals and weathering as well as good electrical insulation properties. www.lanxess.com ™_ € & the production of the complete EPDM www.plastichem.co.za grade portfolio, including a wide range of DECEMBER 2013 / JANUARY 2014

39

The Stelton jug is known worldwide for its functional rocker stopper which opens automatically as coffee is poured. The Stelton vacuum jug has sold more than 10 million units to date

A RECENT success story for Elastron thermoplastic elastomers was the approval received from Danish manufacturers to use Elastron thermoplastics to seal Stelton vacuum jugs for coffee and tea. After a long and complicated testing and validation

[ Z & • QJJ ‹‹ " seal in the cap of the jug. Stelton is one of Denmark’s ›* & =

Â? _ ;_ =

' & � | € [

Z “Z ›= low fogging, low odour and excellent surface grade of G103.A63.B

[ & Â? Z =

­ Z DH Polymers. Contact Deon at 083 677 0852, deon@dhpolymers.co.za

POLYMERS CPE

WEIFANG

FLUORO ELASTOMERS

CHENGUANG

PER FLUORO ELASTOMERS TPE ,TPV AND TPR

ELASTRON TURKEY

EPS

SHINHO ,TAITA, HYUNDAI ENGINEERING PLASTICS (DONGBU) , SUSHOU CHANGLE(DONGBU Technology)

PS & HIPS

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LDPE & LLDPE

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EVA HDPE PIPE PE 80/100 SILICON RUBBER

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MAGNETITE ENGINEERING POLYMERS REWORKED AND REPALETIZED MATERIALS

www.elastron.com KIA use Elastron’s new G103.A63.B grade in its "

DH POLYMERSCC Contact: Deon Cell: 083 677 0852 Fax: 086 578 1830 • Tel: 011 760 1089 deon@dhpolymers.co.za

INDUSTRY NEWS

THE largest production line for the � › #| at the Lanxess’ site of Sittard, Geleen, _ " & converted to the company’s innovative ACE technology. The German pioneer in synthetic [

[ â‚Ź12 million to convert the production line & [ ° ›" [ [ € › The new line – EPT 3 – has a capacity of 95,000 tons per year. This is more than half of the total capacity at that plant. It is currently the world’s largest EPDM plant with an annual capacity of 180,000 tons. The ACE process, using outstandingly [ ” \ [ \

& [ › | #| ž  › free and with high degrees of purity. The process consumes less energy and produces no catalyst waste, which makes › Lanxess’ current range of EPDM

INDUSTRY NEWS

DuPont honours innovative

# $ ' body coated with expanded DUPONT has honoured $ %&'*

the innovative use of The high compressibility of the

PTFE type used ensures that gas, architectural and aviation the FRG conforms even to industries with this year’s highly corroded and damaged DuPont Plunkett Awards. *

Flexitallic, Cleckheaton/ the need for any costly UK, with its Flange Rescue

Gaskets (FRG), providing an * unsurpassed maintenance Second prize went to solution for the chemical and GmbH for its new

proprietary extrusion technology Kunststoff GmbH, Ochtrup/ for manufacturing coloured and Germany, with its new structured ETFE architectural manufacturing technique for * +

producing coloured ETFE

! " # $ % & Flexitallic impressed by the fact that

'

* + / 2 "*/2#

effect; and Draka Fileca, + + + ' + 4 5 7 " # % & 2 89 from 100% recycled material Sainte-Geneviève/France, with ' & + ' + – obtained from a proprietary its ultra-lightweight quad data 4 ; *; ' $ 7 " # recycling technology developed cable with outstanding electrical

' % & Draka Fileca 4 +' +' < 8

:"

properties, are the winners of

' 5 overall environmental impact. the DuPont Plunkett Awards Draka Fileca received third 2013 in Europe, Middle East prize for its newly developed, ultra-lightweight quad data cable and Africa (EMEA), which coincides with the 75th anniversary for the aviation industry, which is 25% lighter than currently used

quad cables, while still offering enhanced electrical properties. Plunkett.

An international jury of experts met in September at the environmental impact of aircraft and helicopters. DuPont Geneva Innovation Centre in Meyrin, Switzerland, to “Once again we were positively surprised by the innovation select those entries that best met the judging criteria of degree of potential of this 75 year old material, which became known innovation, breadth of commercial application, sustainability and < = #*

optimum use of the materials’ potential. underlines the statement of Dr Plunkett, who discovered The Flange Rescue Gaskets (FRG) by Flexitallic, which won "

! " #

imagination,� said Sylvie Gallou, director DuPont Chemicals & oil and gas industry to be replaced easily and cost-effectively. Fluoroproducts (DC&F) EMEA. This patented system has a precision manufactured metal

( ) " MEDIA reports have abounded recently about the use of cash declining and individuals making more and more use of mobile and electronic payment methods. The big debate now is whether to introduce plastic banknotes to replace their paper equivalent. Most recently the Bank of England

whether people would be ready to accept plastic banknotes. The recently appointed 40

DECEMBER 2013 / JANUARY 2014

8

= + ' ' 5

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governor of the Bank of England, Mark Carney, brought in polymer bank notes in his previous role as head of Canada’s national bank, while Australia also has polymer notes in circulation. Jan Visser, MD of Deter-A-Dye Security of Johannesburg, which uses technology to dye and track banknotes, said there are predictions that the use of cash will decline. “We see this with the advent of mobile payment features becoming available

on your mobile devices, such as a cell phone, and the use of credit cards, as well as the increased use of EFT payments,� he adds. The Bank of England said polymer banknotes would stay cleaner longer, would possess advanced security features making them harder to counterfeit and would last at least 2.5 times longer than existing paper notes.

INDUSTRY NEWS Owing to its light weight, Weholite structured wall pipe provides for easy installation, even in complex installations where challenging conditions are presented, often removing the need for heavy lifting equipment and reducing health and safety risks

Marley introduces

42 DECEMBER 2013 / JANUARY 2014

Weholite structured wall pipe WEHOLITE is known world-over as the preferred structured wall pipe solution for various applications, from water distribution to gravity sewers, rehabilitation projects and manholes to marine pipeline applications. Now Marley Pipe Systems is bringing this renowned pipe system into the South African market with license to manufacture from Uponor Infra (formerly KWH Pipe). Recognising demands for a lightweight, low " "

Weholite represents the latest technology in both material and manufacturing. Its unique structure offers a range of ring stiffness’s and pipe diameters from 280mm up to a massive 3500mm. Weholite is manufactured in Finland, Sweden, Poland, South Africa, the United Kingdom, Canada, Malaysia, Oman, Iceland,

Italy, Chile, Japan and Thailand and is steadily gaining ever wider acceptance in other countries around the globe. The pipe design allows for a minimum ?Q

and installation parameters and the material selection process is the same as that used for pressure pipe applications. Research has shown that the service life of Weholite is 50% greater than concrete in stormwater applications, and at least 100% greater than concrete in corrosive applications. Weholite pipes are designed, manufactured and installed in accordance with Uponor Infra and Marley internal standards which conform to EN 13476 and SANS 21138, and form part of an SABS ISO 9001:2000 quality management system. www.marleypipesystems.co.za

SMEC excels in trenchless technology know-how

Numerous trenchless technology options are available for the rehabilitation and replacement of sewer and water infrastructure in South Africa

Z[\]^[

_`&{

in South Africa that boasts appropriate skills and expertise in the design and application of trenchless technology in water and sewer infrastructure projects. _`&{ " Z "

noted that numerous trenchless technology options are available for the rehabilitation and replacement of sewer and water infrastructure in South Africa. “One of our focus areas is on horizontal directional drilling (HDD) design and planning. This involves the installation of underground pipes, conduits and cables in a shallow arc along a prescribed bore path, using a surfacelaunched drilling rig that exerts minimal impact on the surrounding area�, he says. “Another technology that we focus on is pipe bursting which entails the replacement of existing underground pipes of various materials with a new pipe of similar or larger diameter.� SMEC was awarded the Southern African

Society for Trenchless Technology Award of Excellence in 2010 for its involvement in the Plumstead municipal water and sanitation infrastructure upgrade project in Cape Town. The Plumstead sewer is a 3km trunk sewer, comprising of 375, 450 and 525mm diameter * |

narrow residential streets at depths varying between 2m and 6m. The rehabilitation of the sewer was a challenge because point repairs in open excavations would be costly and disruptive to the neighbourhood. Alternatively, full-length trenchless lining between manholes would have been too costly. SMEC technical specialist, Mike King, } } } ${| '

as the most suitable trenchless option. CIPP entails the liner being applied to the inside of the pipe before being cured by either heat or ultra-violet light to harden. The end result is a smooth pipe interior with no joints that reduces #

without the need for digging.

www.smec.com/our-business/divisions/africa/south-africa

INDUSTRY NEWS

New grade of PhoenixPET soon Intrinsic viscosity will be same as virgin polymer THE quality of Extrupet’s award-winning PhoenixPET, its premier food grade rPET resin, is set to reach fresh heights next year with the introduction of a new

higher intrinsic viscosity (IV). It is estimated that the new product range will be introduced during the second quarter of 2014 and will boast a much higher IV level of 0.82 – the same IV as virgin polymer – compared to the 0.76 being offered now. This transition could see PhoenixPET competing with virgin PET in that the new range will allow convertors to use it without blending it with virgin polymer. The refurbished version of PhoenixPET will cater for a wider spectrum of customers, including the mineral water and carbonated soft drinks market. Extrupet is now running trials on the material to decide on the most suitable blend ratio for the new grade

PhoenixPET. The organisation will also have to expand its existing recycling operation to cater for the production of the new grade rPET and to house the new machinery commissioned. PhoenixPET premium quality resin

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recommended choice for ‘food grade’ packaging. PhoenixPET continues to shine PhoenixPET has done it again, following Q€€ _

African Plastic recyclers’ organisation $_^ \' * This year Extrupet was honoured

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dishwashing liquid bottle made from 50% recycled PET and 50% virgin PET, ƒ & %

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44 DECEMBER 2013 / JANUARY 2014

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

Automotive

Electrical

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Consumer

Compounding Service

Experience PR E MI E R P OL YM ER SOL UTION S with exten siv e A PPL I C A TION DEVEL OP M EN T and expert T E C H N IC A L SER VIC ES Visit www.plastamid.co.za for further information. 021I 914 9042 Johannesburg 922031 1600701 / Durban 3445 75 278 CPT 021Cape MEHTown MNHF JHB 011/ 922 1600 I 011 DBN 9546 I031PE762 08000

INDUSTRY NEWS

Save money on your energy bill * " " $ " SOLAR energy is the future of power in South Africa. Eskom’s rates are

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with the upcoming carbon emissions A photovoltaic installation with a storage system allow operators of PV installations to + $

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Saving you energy, saving you money ‌ Bart Schurink and Ed Young are partners ' 8 Z; ; + & ' ' specialises in the supply of photovoltaic solar panels

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INDUSTRY NEWS

New master toolmaker programme Part of the Insimbi NTI Skills Development Programme SPECIALISED skills development in the South African manufacturing sector will reach an important milestone next year with the introduction of a new Master Toolmaker “ * ` #

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well as an interest and training or experience in one of the ‚ ‰

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TASA East Rand session

Gary Longshaw (Intrinsys) with Anthony and Jarrad Barnes (Gantech Tool & Die cc). Jarrad addressed the meeting and explained how TASA had assisted his company in improving productivity

Henk Snyman (GTI) (far right) and his team are doing an excellent job of assisting and promoting local tool makers in trying to keep

+ € ' ' ; 9

"/ 4J' Holdings) and Vusi Mkhize (TASA Gauteng Chairman)

SERVO DRIVEN INJECTION MOULDING MACHINES

from 90 Ton

to 2800 Ton

• • • • • • • •

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

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

Cambrian celebrates 21 years

Since starting out in the procurement of specialised chemical products, Richard Phillips has spent 21 years in the company that developed from that

CAMBRIAN Chemi-Trade of Johannesburg celebrated 21 years of operation in October with a party in the Altstadt in DĂźsseldorf during the K show. Cambrian proprietor Richard Phillips ‘cut his teeth’ while at AECI group in the 1980s when he was tasked with procuring a variety of chemical products. The man with the strong Welsh accent was so good at it that he managed to develop the model into a sustainable business. The company started in 1992, as an opportunity to service the South African polymer and chemical sectors with top line products to serious buyers requiring good value, and has resulted in a sound operation over two decades. {

in the supply of initiators and additives to both

the polymer producing and converting industries, as well as developing sales of niche products to a number of other markets and end users. “From the outset Cambrian has always tried to position itself as being the ‘best-in-class’ when it comes to representing its overseas principals and their products,â€? said Phillips, who has a BSc Hons specialising in organic and polymerisation chemistry. What started as a dream in mid-1992 and took real shape with a visit to the K fair in DĂźsseldorf that year, has resulted in the ‘coming-of-age’ function in Dusseldorf again in October 2013. Cambrian has been involved in enduring local business relationships with Croxton Cape and Sun Ace SA over the past two decades.

Tuks student wins IOMÂł world lecture competition

The lecture competition at the Hong Kong Jockey Club on 31 October was tight, but Cornelis van Niekerk was apparently a clear winner; plus he was able to explore the city’s nightlife

SOUTH African student Cornelis van Niekerk won the IOMÂł Young Persons’ World Lecture Competition in Hong Kong in October. The competition played out at the Hong Kong Jockey Club with competitors from Brazil, Hong Kong, Ireland, Malaysia, Singapore, South Africa, UK and the USA. These are all nations with IOMÂł branches. Cornelis, who is doing his Masters Degree at the University of Pretoria in the Department of Materials Science & Metallurgical Engineering, presented his winning paper, ‘Novel Technique for in-situ laser alloying of AISI

www.iom3.org

410L stainless steel with nitrogen during laser cladding’ before a + * +

Hong Kong prior to the competition with various activities arranged for them, including visits to a recycling plant, a local university, experiencing the underground construction of the MTR (underground transport system), and a visit to HAESL a company specialising in the overhaul and repair of Rolls Royce aircraft * +

cruise to Lamma Island and experienced Hong Kong’s night life. Cornelis will continue his studies towards a doctorate, well done!

50 DECEMBER 2013 / JANUARY 2014

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PEOPLE

" # " $ ‘Oupa’ was popular among trainees in the Cape

Marthinus du Toit has assisted young trainees in the Western Cape to gain practical intelligence and made training a fun process; here we see him with deaf students from the Whisper Boat Academy

PLASTICS|SA bid farewell to one of its most popular trainers, Marthinus du Toit, at the end of August. For a man who was known as the ‘oupa’ by many trainees in the Western Cape, Marthinus belies his 65 years and is

ž By the time he became involved in training in 1997, Marthinus had already been working in plastics converting for over 30 years. At that point, however, he realized he “didn’t know muchâ€? about the processes he had not worked with ‌ and the urgency to learn more has characterized his training ‘style’ since. €¥¢Â„

‘The Graduate’ (with Dustin Hoffman) in which one of the performers suggested that ‘plastics is the future’. He took the proposal quite literally and has been involved in the industry for 45 years since. He #

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Vynide in Somerset West where he worked in all the PVC processes for another 15 years. When Vynide closed in 1997 he was employed by the then Plastics Federation of SA on a part-time basis to run courses in the extrusion area. It clicked for him, and his need to learn more about blow and + " " * His biggest focus was in urging the young individuals to learn to take responsibility, hence the Supervisor Management course he conducted. “Supervisor management in a factory is not for sissies,� said Marthinus. “Supervisors are key people when it comes to strategic implementation.�

New faces at Safripol Anli Smith has been appointed as product manager at Safripol in Bryanston. Anli has been with Safripol in Sasolburg where she was involved with HDPE and PP quality control for the past four and a half years. Anli has an Honours degree in Polymer Sciences and enjoys competitive cycling and running

Danelle Kok has joined the Safripol sales team in Bryanston as marketing assistant. She has an MSc and joined the industry from the South African Police Services where she was a forensic analyst. Her duties are to ensure that customer forecasts and demands are accurately translated into a dynamic SOP process

Mark Berry joined Safripol after time spent in the coatings industry where he worked for Dulux and Plascon in a variety of roles in both the technical, operational, marketing and sales arena. Based in Bryanston, Mark is responsible for all of sales and marketing

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BOOK EARLY BEFORE THE DECEMBER SHUTDOWN

dean@relloy.co.za

PEOPLE

Neelin Naidoo is new MD of Mpact Plastics MPACT group has appointed Neelin Naidoo as managing director of its Plastics business. Neelin (50), who holds an MBA from Herriot Watt ~ ~ÂŁ “ " ˆQ

years’ experience in the packaging industry. He is a member # { _ ^ + `

MCG Industries where his last position was that of CEO. “We have no doubt that, given Neelin’s depth of experience and understanding of the industry, he will contribute tremendously to the development of our Plastics business and to the Group as a whole,� said Mpact Group CEO Bruce Strong. Neelin replaces Ray Crewe-Brown, who has retired from the group.

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VENTURE PLASTICS of Wadeville, one of the most 5 $ 5 + '

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+ + ' $ Steve Coetzer (right) recently joined the ‘Venplas’ team headed by Geoff Watson, who has run the company since 1988. This means that Watson will, after 25 years at the helm, be loosening the reins for once. Venture is involved in extrusion, blow and injection moulding and thermoforming, making it one of only a few companies to be involved in such a wide range of processes. But Geoff has proven that, rather than specialise in one area, he looks at what the application requires, and then doesn’t shy away from the technical challenge. Venture as a result manufactures a wide range of products and is well established in several different market niches. For Steve, who has spent most of his career in the bucket moulding market, it’s obviously a challenge, but he has proven he has the ability to develop effective solutions. He had just days before the appointment completed a 2-year restraint of trade period applied by his former employer, Rheem group, which had purchased the company he started in Cape St Francis, Kouga Plastics, in 2008. www.ventureplastics.co.za

' $ ( )*+ GRANT Crosby-Emery +

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association’s new technical trainer for the Western and Eastern Cape regions, with effect from 1 October. Grant will be based full-time at the ` { * Born in Canterbury, England, Grant left with his family for the warmer temperatures of SA at a young age. He attended Wynberg Boys’ High School in Cape Town, after which + _ _ ‡ “ *

“I left the hospitality industry after 7 years because of the " | #"’ + # * Grant’s foray into the plastics industry began as a setter with ] | ‰ + "

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Plastics in the PET department and was in charge of the Aoki machines and production. During his 13 years at Hilfort, Grant was responsible for in-house training of the company’s setters.

New DPI MD JUAN Muller has recently been appointed managing director of DPI Plastics. With more than 30 years of experience in the manufacturing sector, Muller is committed to implementing the ‘Lean Manufacturing’ process at DPI Plastics. “DPI Plastics has always been a strong competitor in the civils market in particular and, given the increasing demand for water infrastructure upgrades across Africa, I believe that we are well positioned to achieve measurable growth in this sector,� said Muller. DPI is a leading manufacturer of PVC and HDPE water |_\

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Koos cracks it KOOS Bekker of Nasionale Pers has most certainly cracked it, if you haven’t already heard, with earnings that have sent records tumbling. Established in 1915, Nasionale was formerly involved in newspapers and print media but became involved in pay TV as one of the co-owners M-Net in 1990. Bekker became chief executive in 1997, and immediately began to switch the group’s focus to internet media. Bekker completed post-grad studies in the USA and appears to have interpreted lessons learned there ” {&\

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in the pay TV businesses Tencent Holdings of China and Mail.ru of Russia. These group’s have delivered above-average returns. Nasionale has made several other investments in internet media businesses, and the results have been startling: Nasionale’s market value has increased by about $34-billion (about R344billion) since 2003. Bekker, who doesn’t get a salary and relies rather on returns from shares, owns an estimated 4% of Nasionale with 11.7 million share options plus a further 1.1% stake through a family trust. If you have a calculator at hand, try to work out how ‚ Œ ž

Early farewell for Designer Ideas man WE regret to report the passing away of Paul Olver of Designer Ideas of Johannesburg. Paul was an expert in the silicones area, particularly as regards the production of silicone rubber moulds for casting in polyester resins. His skills lay at least partly in the creative area, for the moulding of artistic creations, which led Paul to exclude himself from the mainstream plastic industry. Designer Ideas conducted training courses, for the production of silicone moulds and casting in silicone materials, which made the technology accessible to the wider public. Paul was only in his 40s, so his departure scene is disappointing.

$ WE’VE learned with shock and sorrow that Maggi Stuart-Howie passed away suddenly on 25 September while in London on holiday visiting friends and family. Maggi had worked with PlastiColors as their agent in Cape Town for the past 20 years and was dedicated to the plastics industry and her customers, many of whom became personal friends. Born in Queenstown, her family moved to the UK in the mid60s where she became an international model, returning to SA in the late 80s. She was a long-time member of the Plastics Institute of Southern Africa (PISA) and took a deep interest in the growth and development of the plastics industry. Her ready smile and cheerfulness will be sorely missed by all. DECEMBER 2013 / JANUARY 2014 53

PEOPLE

On the move ‌ Ian Edwards + ` Š # ^ " ˜ "

manager. Ian last year moved from Cape Town to Alberton with Cibapac. He is making a return to Versapak, as he actually started his career in plastic manufacturing at the original Versapak plant in Paarl in 1980.

PLASTIC EXTRUSION WELDERS

reliable

Floors Coetzee has been appointed KZN branch manager for Ferrostaal group. He has transferred to Durban from Cape Town and is taking over from Rex " ‰ # %

KZN. At this stage Floors, who’s been involved in plastics equipment sales for 15 years, stands to learn a lot from Rex, a 40-year veteran of the sector. Rex turns 65 early next year and will remain as a consultant after that. % ‰ ÂŁ Š ÂŁ

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Claire Gibson has left Masterbatch SA in Cape Town, after seven years, and ‰ ” + | " | "

Enterprise Information management solutions. Both Patrick Munyembate and Vijay Gramoney have returned to FIMA. # ` Š + ]\

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printing and manufacturing business in Selby, Johannesburg, in mid 2012, but were recently rehired at FIMA. Patrick is now involved in a sales role at FIMA.

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Shane Russell has retired from Performance Colour Systems in Cape Town,

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_ ‰ ‰ * Peter Rebello has left the polymer supply business in Cape Town and moved to a family-owned electronics manufacturing business. Peter was with Sasol + _^]|{ {

stint with Manuchar group.

performance

Terry Sutherland, one of the best known plastic drum and large container sales guys in Gauteng (the biggest market for these products in Africa), has departed from M&S Plastics and set up as an independent consultant to this market.

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Barfel or Omega Africa Plastics (which is now Megapak). After spells at Aerosol $€¥•€'" #

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up as MD of Kohler Drums. He was involved in the launch of the 210-litre L-ring drum into the SA market with great success and, after Mega bought Kohler Drums in 1989, was involved in the start-up of M&S in 1990. Initially the company

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went back into 210-litre drum production in 2006.

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cans, which were supplied to UNICEF and other disaster-relief organisations (sold over 3,5 million), and the plastic ‘chicken nest’ (sold over 250 000 to date). Terry’s personal achievements include converting various industries from steel or metal packing into HDPE product. The cooking oil and lubricant oil companies are top examples of this switchover, as was converting HTH to plastic drums.

powerful

He can be reached on 083 325 0313. Kieran White, part of the White family team in the industry in Port Elizabeth, has moved his toolmaking business, Precision Moulds, over to the Principle Plastics’ site in Markman township on the eastern outskirts of PE. Peter Wessel + ‡ ‡ $_^' ` "

‡ + _ ^ "

and back-up in KZN. He was until recently with GF Plastic Machinery Services, which was formerly the Haitian agent. Peter started his career in the industry with Reckitt & Colman and then moved into equipment sales with Internatio. Following that he moved back into the converting sector at Fontana Art Metals in Umkomaas, before returning to the machinery business with GF. DECEMBER 2013 / JANUARY 2014 55

(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

Many visitors from and unusual sources Highest proportion of trade visitors from Asia WITH over 3200 exhibitors and an estimated 218,000 trade visitors from just over 120 countries, the stats for K 2013 represented a change in attendance compared to the previous event in 2010, when there were fewer exhibitors and more visitors – 3,094 exhibitors and 222,486. The number of international visitors rose again, to 58% (126,000 trade visitors), with just under half of all foreign visitors coming from outside of Europe. There was an increase in visitor numbers from relatively unexpected sources, such as the African countries Angola, Burkina Faso and Malawi

the Falkland Islands, Yemen, Nepal, New Caledonia, Oman, Peru and Turkmenistan. The proportion of trade visitors from Asia accounted for the largest group of foreign visitors – some 30,000 came from South, East and Central Asia as well as from the Near and Middle East. Visitors from India

were once again the largest group while the number of trade visitors from China, Indonesia, Iran, Japan and Taiwan rose considerably. These trends suggest that production capacity outside of the plastics industry’s established leader centres, such as Europe, China and Japan, is set to increase. ^

of visitors from North America: some 8,100 visitors were registered from the USA and Canada – 1,300 more than at K 2010. Some 11,000 specialists came from Latin America, about as many as came three years ago. Forming the largest contingent were experts from Brazil, Mexico, Argentina and Colombia. Comment Ulrich Reifenhäuser, chairman of the Exhibitors’ Advisory Board for K2013, was extremely pleased with the results: “We had not expected visitors’ willingness to invest to be this high. Many customers are extending capacities and are investing in new technologies to sharpen their global competitive edge.

Werner Dornscheidt, CEO of Messe DĂźsseldorf (organiser of the event), said “Foreign visitors to K 2013, in particular, showed an extremely high willingness to invest and one in two visitors came ÂŞ

intentions in mind. Visitors came from all key user sectors

56 DECEMBER 2013 / JANUARY 2014

Plastichem principals impress THE Plastichem principals Bayer, Lanxess and Styrolution had especially impressive stands at this year’s K, according to Helmut Oellermann of Plastichem. Bayer’s stand was “futuristic� and its theme of ‘Sharing Dreams’ was convincingly conveyed, remarked Helmut. He was especially interested in their strategy to build integrated solar cells: in the future, solar cells will be integrated directly in the walls and roofs of buildings. And, instead of glazing, building facades will consist of a single element with coated solar cells to cut weight and costs, while increasing energy * ‘Gateway to Africa’ – Stuart Gibson and Helmut Oellermann of Plastichem visited the stand of their European partner, Grolman Distribution; here we see the J ' + 2

The Styrolution stand was very modern and interactive. “Lanxess’ recent acquisition of Bond Laminates is sure to raise a lot of interest in the years to come,� said Helmut. “Products are sold under the TepexŽ brand and can be co-processed with the Durethan nylon range as required.� In contrast to other composites, Tepex materials are laminated in a process that is suitable for volume production yet follows the principles of manufacturing tailor-made goods. www.plastichem.co.za

Less is more ] ‡ ? $ ++ + ' & but polystyrene manufacturer Styrolution proposed exactly that at the K

TECHNOLOGY

the East,

New pigment could transform

The K (‘Kunststoffe’) has been presented in DĂźsseldorf, Germany, 5 ' \= ' ' & ' + + ' +' '

' & ' 5 8 replayed on every occasion

– from the building and vehicle construction areas, packaging as well as electrical and medical engineering through to agriculture. Overall, visitors gave high approval grades to the range on show €¥ ‰ ” ¥¢Â†

fully achieved the goals of their visit. 4

Good result for Sun Ace Jˆ‰ 2 + ;

/ + J ^' 8 9 Š ' + 8 8 + ‹U suppliers exhibited and or visited K, so this was an ideal opportunity to

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www.huntsman.com Z 2 presented a fundamentally + 4 5 5 + ' assembly applications in, particularly, the aviation and automobile industries. The =V + ' < ‘ + ^ plastic parts in serial production. Here we see + 8 + ' channel on an automobile instrument panel with ' ”= + '

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‘X-Mould’ from SIPA ; ' + JQ ^' 8

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www.sipa.it DEC 2013 / JAN 2014 57

BLOW MOULDING

Aoki demos new neck detail method

Kelvin Mills (on the right) with delegates from Aoki Technical Laboratory of Japan at the K; this ISBM machine manufacturer has succeeded in further reducing cycle times

58 DECEMBER 2013 / JANUARY 2014

Neck is blown out of the blow mould and is not Injection moulded AOKI had three machines in operation at the K and also showed samples of containers that have been produced on Aoki machines from all over the world. The main technology demonstrated was the production of #" #

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commonly done. The main advantage of this is a huge material + " ?

material as well as a time saving – 3sec was shaved off the $ € •"¥ '* Aoki also showed how it is able to create areas on a container " “

certain functions. It also showed how technology which is enabling it to achieve higher output on its machines. Aoki says it is driven by the goal of producing containers as *

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which is to eject the container from the machine. It is has been proven time and time again that the manufacturing cost of a container is less on the Aoki system " # * “

container is also extremely good. Aoki is represented by Hestico. www.aokitech.co.jp

Kenneth Saruni Kasero of Nairobi-based MBT East Africa visited Dick Coates of MBT South Africa on the MB Barter & Trading (Switzerland) stand

Old friends meet – Evert van Schuppen of Poly Services Australia, Peter van Duyn, MD of Isowall SA and Eric Tick of Thermoware Netherlands

Aaron Bart, Nicholas Clark, Yaacov Gozani, Paul Clark, Lowrie Sharp, Itzhak Livini and Sito Safran on the Sysmetric stand; Adex was appointed agent for Sysmetric, the Israeli manufacturer of materials conveying, dosing and control systems John Craw and Darrin Botha of Seecor met up with Robert Chang of SIKA of Taiwan, a top manufacturer of blow moulding machines

Bioplastics such as PLA can be used in high-heat electronics applications where the right choice of raw materials is made, in this case, materials from Corbion Purac were developed and have achieved favourable results

60 DECEMBER 2013 / JANUARY 2014

PLA materials now boast performance characteristics to rival their oil-based counterparts SUPLA, which announced plans for a 10kT polymerization plant earlier this year, has developed optimized PLA (poly lactic acid) compounds for the consumer electronics industry based on lactides from Corbion Purac. The launching application is the ‚

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housing of this computer is made from high-heat PLA. Corbion Purac, the global leader in lactic acid and lactides, showed the mouldings at K2013. Heat resistance is one of the key challenges for biopolymers today, as this has limited their suitability for consumer electronics in the past. However, lactide monomers from Corbion Purac form the basis for improved performance PLA. In addition to increased heat resistance, the PLA blends used for the monitor screens also bring improved impact resistance, ‰ " *

Corbion Purac’s lactide monomers are sourced from GMO free, renewable feedstocks such as sugarcane and form the basis for

The SABIC stand had a futuristic design, showing the Saudi materials producer’s intention to invest strongly in developing its technology and growing status as one of the top global suppliers to the industry

high performance PLA bioplastics. The resulting homo polymers have already proven to withstand boiling water. As a result, PLA can replace oil-based plastics such as PP, PS and ABS. Corbion is the global market leader in lactic acid, lactic acid derivatives and lactides and a leading company in functional blends containing ! " " *

high performance bio-based products made from renewable resources and applied in global markets such as bakery, meat, pharmaceuticals and medical devices, home and personal care, packaging, automotive, coatings and coating resins. Corbion operates 10 production plants, in the USA, the Netherlands, Spain, Brazil and Thailand, and markets its products through a worldwide network of * | Q€ " {

sales of â‚Ź753 million and had a workforce of 1,800 employees. Corbion is listed on the NYSE.

www.purac.com

www.corbion.com

The stylish Mervyn Moodley and Morgan Naidu were in high spirits and thoroughly enjoying the exhibition

Kurt Lammel with partner Gunther Rumes on the Mactec stand; Mactec has been building bagmaking machines in Johannesburg for eight years now (in cooperation with Gunther in Austria) and Kurt says customers are now recognizing MACTEC equipment Theo Moolman, Bernadine Symonds, Jacques Kleynhans of DemaPlasTech and Stephen Craig of Pailpac on the Sumitomo Demag stand

SA Plastics magazine’s Lowrie Sharp with the promotional team

K2013

Freeformer’ live: innovation from Arburg

THE WORLD premiere of the freeformer technology from Arburg – for the production of fully functional components from commercially available plastic granulates without a mould – caused a sensation at the K show in Germany in October. The unique machine, the ‘freeformer, and the new, patented Arburg Plastic Freeforming (AKF) process offer “complete freedom: plastic formed without a mould,� according to the suppliers. As the name suggests, no moulds or “

forming of plastics. ƒ ^ÂŁ%" ˆ {^

directly by the freeformer, standard plastic granulate is melted in an integrated manner as in the injection moulding process and droplets are generated from the liquid melt. These droplets are then used to additively build up the fully functional component layer-by-layer, without requiring a mould. This enables the cost-effective individual manufacture of parts completely without injection moulds from batch sizes of a single unit upwards. Conventional granulates Arburg has taken a practical look at additive manufacturing and has implemented the resulting knowledge in the form of the unique new AKF process. First of all, it was important to be able to use conventional plastic granulates rather than ready-made forms of supply such as powders or strands, which make the material, the processing and therefore also the parts expensive. The minimum material requirement is also a result of the optional 5-axis component carrier with which the part can be produced as far as possible without support structures. This saves on resources and ensures cost-effective production, ‰

functional parts. There is no need to re-invent proven things. This is what the Arburg technicians also thought when developing the freeformer. They provided the new machine with conventional material preparation, 62 DECEMBER 2013 / JANUARY 2014

Two of the revolutionary new machines that manufacture onecomponent and twocomponent parts were on show at the K

Two materials or colours can be processed on a single freeformer equipped with two discharge units. As a result, even movable hard-soft combinations, for example, or parts with a special appearance or texture can be produced, in which both

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which operates essentially in the same way + *

with standard plastic granulate. A heated plasticising cylinder ensures an optimally prepared plastic melt in the so-called discharge unit. This features a patented nozzle closure with high-frequency piezo technology, which enables rapid opening and closing movements in order to produce the plastic droplets under pressure. These join together to form additively the required plastic part. The principle of moving and stationary machine components was re-thought. In the freeformer, the discharge unit and its nozzle ‰

component carrier moves. In addition to a standard component carrier that can move ‰ " ‰

is available (for example, for implementing undercuts without the need for a support structure). The major advantage of the 5-axis version is that no support structures are required as a rule. This makes it possible to form new geometries

J + $ melted and the functional part is then produced layer-by-layer from plastic droplets via a clocked nozzle and a movable component carrier

which may not be realizable in injection moulding. Furthermore, the components are immediately ready for use after manufacture, without any reworking. Complex technology, but simple to use Finally, with the freeformer, Arburg has made complex technology simple to use and developed it in-house. This makes industrial additive manufacturing brilliantly simple. The parameters required for the layer-by-layer construction of the parts are generated using the in-house-developed freeformer control system. This receives the 3D CAD data for the components to be _ [ "

processes it automatically through slicing, and production can start. No special programming, processing knowledge or extensive training is required. The gesture-controlled multitouch screen makes working with the machine even more enjoyable. The components are produced on the freeformer by the liquid droplets, completely

free from dust and emissions. The machine is therefore suitable for virtually any application environment, " "

or a clean medical technology environment. No ‰ “ “ * One-off parts and small-volume batches The implementation of the freeformer takes Arburg one step further towards the broadening of industrial production range in plastics processing. While customers have long been able to rely on the company’s injection moulding expertise and therefore on the high-volume production of plastic parts, the same now applies to the cost effective production of small batches } * High quality, low unit costs and therefore production

of additive manufacturing. Regardless of the industry, the new freeformers and Arburg Plastic Freeforming (AKF) offer exactly the same new freedom to all customers. Arburg is represented by Hestico. www.arburg.com DECEMBER 2013 / JANUARY 2014 63

VIRGIN POLYMERS & RECYCLED MATERIAL " # " $ '" * * +/:+ " / " + # "

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Moulding versatility from Nissei ASB

The new ASB machines achieve lower energy consumption

Absolutely no scratches, deformation or contamination

64 DECEMBER 2013 / JANUARY 2014

UNDER the slogan ‘It’s time to step up’, Nissei ASB presented a host of premium injection-stretch blow and doubleblow moulding platforms. Its signature technology, the PF24-8B 1,5-step series machine combines the advantages of traditional one and two-set systems within one machine. Once the preform is made, it’s partially cooled, temperature equalised, reheated and blown in a ‘cool parison’ system. “The PF24-8B 1,5-step is a modern compact platform with lower energy consumption than a two-step machine,� said Karel Keersmaekers-Michiels, MD of Nissei ASB Europe. “In terms of quality, it produces the preform without it leaving the machine for the blowing stage. There are absolutely no scratches, deformation or contamination. Another big advantage is cost of production compared to a twostep system with the same productivity.� Two variants of the latest 1,5-step machine were available on the stand: % "

24-cavity mould, the highest-output Nissei ASB machine so far, equipped with E-tech, a heat equalising technology

that adjusts the temperature of injected preforms and maximises the quality of * ^ ?QQ

bottle weighing 9,8g, with a 26mm neck diameter, was produced with ease at an ÂĄQQQ

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feature of these models is the ability for the user to convert it from 12 to 24-cavity during mould changes, meaning that the machine has great versatility. 2-step, reheat stretch blow moulding unit Also dÊbuted was the HSB-2M machine – a two-step, reheat stretch blow moulding unit with a double blow function. The machine is suitable for producing heatresistant jars of up to four litres. The heat-resistant PET jars moulded on the HSB-M system enable either hot }

various foodstuffs such as jams, pickles and pasta sauce. Filling temperatures

CornĂŠ Pretorius of Nissei ASB South Africa hosted Eugene Barnes and Clynt Levin of Boxmore on the ASB stand

of up to 95°C are possible depending * Š

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jar, with 82mm neck diameter and 66g weight, being moulded at an output of € ——Q

š * Its sister machine, the HSB-6M is already in the European market moulding ¢Âˆ # ˆ?Q + #

under the Marks & Spencer premium food brand. The popular ASB-12M one-step machine also made an impression on the stand by moulding wide mouthed jars in the shape of Jack ’O ’Lantern pumpkins just in time for Halloween. It is capable to mould a wide range of containers for pharmaceuticals, cosmetics, liquor and foodstuffs, in PET and other materials. The ASB-12M uses two servo-driven hydraulic pumps that Nissei ASB says reduce energy consumption by more than Q† "

machines.

www.nisseiasb.co.jp

Harish Mehta (Clearwater Capital), Ivan Ortlepp of Cibapac, Paul Clark of Adex and Rick Basson (banker) on the Mamata stand

ASB-50MB

More than one step ahead

ASB-70DPH / ASB-70DPW

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

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

Entry level machine ideal for small bottle production with exceptional capabilities ASB-50MB An all-time favourite which is continually upgraded for improved versatility and productivity. Over 1,500 units delivered in the first 9 years of production. PF6-2B / PF8-4B

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

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

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

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

ÂŽ

Intarema

from Erema:

Core technology for a new dimension in plastic recycling The revolutionary Counter Current system

66 DECEMBER 2013 / JANUARY 2014

EREMA, celebrating its 30th anniversary, launched a new core technology at the K: IntaremaŽ is based on its newly developed and globally patented Counter Current technology. The name comes from INverse + TAngential technology and it brings together, in an unparalleled way, high " ‰

operation with considerably lower energy consumption. The central core technology of the INTAREMA system is the patented Counter Current system which shows its impact in the border area of the cutter/ compactor and tangentially connected ‰ * | š "

rotation of the rotor disc forms a rotating spout so that the material is circulating the whole time. In the Counter Current system, this material spout – unlike the previous technical standard – moves against the ‰ * ^ "

relative speed of the material in the intake zone (i.e. when passing from the cutter/ ‰ '

‰ ‰

in the same way as a sharp cutting edge which now cuts the plastic. The result of this inverse tangential ‰

handles more material in a shorter time and is much more independent in terms of the pre-compacting level of the material. To date, the worldwide technical standard has been a system in which the material in the cutter/compactor moved in the ‰ *

forces arising in the process were used for

Two of the revolutionary new machines that manufacture one-component and two-component parts were on show at the K

‰ "

warm material was thus ‘packed’ into the ‰ *

the Counter Current system, on the other " ‰

}

preheated material. Michael Heitzinger, CTO at Erema, describes the positive impact which the new system has on productivity and the quality of the recyclate as follows: “The screw basically ‘takes what it needs,’ the ‰

" #

much better to regulate.� Improved material intake over extended temperature range Why do INTAREMA systems offer ‰

able to react to faster input changes when

Dean Toi with Brent Hean of West African on the INTAREMA stand. Brent to provide details.

recycling to make valuable secondary raw materials? Inside the cutter/compactor the feed material is buffered and ‰

process. The material is cut, homogenised, warmed, dried and above all compacted ‰ * ‡

it is crucial that the temperature inside the š

of compacting of the material: the higher the temperature, the higher the degree of plastic material compacting. With the Counter Current system, ‰

cutter/compactor hardly depends on the compacting level of the plastic material, which in turn considerably broadens ‰ *

This means that the recycling system is ‰

the operation point, it is also much more reliable in operation. >>

Peter Waldburger and Eric Bossert from EnviroServ on the Erema stand

where quality is action

A-PET

68 DECEMBER 2013 / JANUARY 2014

<< Results from development trials (in cooperation with customers of many ' } [[ &

#

ˆQ² " {

Current system on the increased process " ‰

new INTAREMA plant. ‘] ‰ "

stable and sensitive recycling process is essential to be able to ensure recycling rates of 100% high-quality recyclate in virgin material grade, particularly when processing clean in-house waste from "’ ‰ ‡ ! * Figure 1 shows throughput as a function of the processing temperature in the cutter/compactor and illustrates the effects of the improved material intake. With the system used previously, the packing and pressure had the risk of sticking, especially in the case of very light materials with low energy content (such as

# '

with a very low softening point (such as [^'

intake. With Counter Current technology, thanks to the improved material intake, capacity is not only increased, it also stays at a constantly high level over a much broader temperature range. The operation range for optimum

‰

considerably. Constant output despite input INTAREMAŽ technology also represents “ } consumer recycling. Although the input

terms of moisture, compactness and other parameters, the new technology ensures that the throughput and quality of the recycled pellets produced remain at *

in post-consumer recycling result not ‰

compositions, moisture, viscosity, type and degree of contamination but also especially from differently printed and laminated materials in the packaging sector. The new system likewise gives you the ‰

materials with particularly high input moisture and contamination levels (such " ‰ " '"

} # $ &}[ "

&}[[ " &}‡ '"

such as paper, wood or metals and also thick-walled regrind materials from waste " _

& *

FIGURE 1: Improved material intake with Counter Current technology Throughput stays at a constantly high level over a considerably wider temperature range, as shown here with the example of an Intarema 1108 T <* [[\] ^ #_` > >"X q {>X "|< } ~

The recycling of car batteries, for ‰ " ‰

application. The INTAREMA T recycling ‰ $

‰ ' š

tools optimized especially for this application offers the perfect technology for $ '

car batteries which are recovered, washed and broken up into chips. As these are very thick-walled, moist particles (Figure 2'"

in the cutter/compactor are very important

thoroughly and homogeneously. With this application-oriented INTAREMA plant, the particles are optimally dried, completely and thoroughly warmed, forwarded to the ‰

‰

minimum shearing strain. Counter Current technology comes

"

}

materials such as regrind materials. Whereas the screw was previously "

increased shearing forces and signs of "

now counteracts this problem. Erema is represented by Relloy.

=$>? @; * H * J $ / ŽT and Counter Current technology { ~ < > > ]] #  # "#; *+ _ X * <* ^ #| < " ^ >> ‚ { ~ # > > X ?Xƒ > + < # " " * > ‚ { ~ <* #* "> * #

„ " " * >

Mark Daynes of Plastix Engineering had his hands full, quite literally, dealing with Beatrice Ferrara and Rossella Fochesato on the NegriBossi stand ‌ and it didn’t seem to worry the Negri agent at all

www.erema.at Robbie Butschi is doing well at Limax in Malaysia, where he has literally continued from where he left off in Johannesburg ‌ developing bag making machine systems as best he knows

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

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

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

K2013

Future is built on ‘telling consumer stories’ ‘Intangible’ aspects of plastics can transform products

70 DECEMBER 2013 / JANUARY 2014

BY ANGIE DEROSA, K2013 CONFERENCE DIRECTOR

THE iPhone 5c illustrates a point several speakers made at the Design Chain @ K conference at the show: that materials, chief among them plastics, will help drive consumer stories. Individualization and unique branding are where Apple excels, said conference chairman Chris Lefteri. “What they’ve done a very good job at is to tell us how we feel,� Lefteri said. “The future is built on telling consumer stories.� When Jony Ive, Apple Inc’s design chief, said the iPhone 5c was “unapologetically plastic�, it earned the attention of not only the plastics industry but of industrial designers, and

Brian Fetting of Forma Packaging with Jean Lin and Jennifer Haung of Kai Mei, the Taiwanese blow moulding machine manufacturer, and Colin Whitaker of Plasquip

The Sunshine Solar Charger was designed by Ryan Mesorley at V 8

& ' ' – ? that collect enough energy to charge a smart phone or tablet. The ' ' + � ? / J polymers, a family of polymer blends, where durable polymers such as polycarbonate or ABS are blended with polymers derived from renewable sources, such as polylactic acid

hinted at where plastics are headed. It’s the intangible aspects of plastics that will make it so powerful in this new consumer mindset and transform products. How does the product make a person feel? Will it make life better? Does it deserve to exist? Still, the ultimate challenge is to turn consumer needs

Dr Heidi Richards, Marius van Rensburg, Michael Maine and David Rule of PlastiColors were on the lookout for developments in the colour and additive masterbatch area

into successful products and take out as much risk as possible, a point illustrated by speakers Oscar Brocades Zaalberg, managing director of BPO, a product

based in Delft, Netherlands, and Ulf Trabert, unit manager of cosmetic brand packaging with Gabriel-Chemie Deutschland GmbH of Austria. Zaalberg’s company uses advanced simulation technologies to work out kinks well before any * ‡

Heineken convert a beer keg to PET, and Samsonite develop a thinwalled polypropylene suitcase. In Samsonite’s case, the goal was to cut the weight of the suitcase by 20%. “You can use simulations to be on target. Through all those simulations, we could make adjustments in the design process, not in the tool,� he said. “This was a huge success for Samsonite.� Gabriel-Chemie’s Trabert said consumers are overwhelmed at the point of sale. It is challenging to make products stand out on the shelf. But through decoration, colour, special effects and other techniques, that can be achieved. In a world with constantly changing dynamics where the riches are in niches, consumers also want personalization. One example: Uvex Winter Holding GmbH of Germany, has used laser decoration in its line of protective glasses. These are intended for safety, but even in

Peter Wolber of PMS on the Boy stand. Boy introduced a 100-ton machine, a slightly larger machine that it has produced up till now

that environment, consumers want individualization. Laser decoration offers a high level ‰ "

surfaces of the plastic glasses. It is the emotional connection and how it is expressed through products, said Lefteri, that matter to consumers. "

partnered with plastics. Lefteri and Marcel Dartee, global marketing director of sustainable solutions and biomaterials at PolyOne Corporation, explored a solar power charger project in a joint presentation at the conference. Lefteri and PolyOne worked on the project with Xindao, a Netherlands company that traditionally has sold inexpensive gifts made by manufacturers in China. But Xindao’s new strategy is to make original "

design team to help achieve its goals. The Sunshine Solar Charger was designed by Ryan Mesorley at Xindao to resemble a plant, where the  Â‚

collect enough energy to charge a smart phone or tablet. The plastic parts of the charger are made from PolyOne’s ReSound polymers. This is a family of polymer blends, where durable polymers such as polycarbonate or ABS are blended with polymers derived from renewable sources, such as polylactic acid.

Fest ive Greet ing s

www.k-online.de

Gian Paolo Repetto and Simona Abbasset of MouldsPluss of Italy, the manufacturer of Ultra Purge, which is represented by PlastiChem

DECEMBER 2013 / JANUARY 2014 71

Energy-saving ‘EconPlast’ plasticizing system from BOY BOY premiered its EconPlast plasticizing system, a novel system that requires about 50% less energy when processing thermoplastics. With the combination of the servomotor pump drive, the control Procan ALPHAŽ 2, a two-platen clamping unit and the EconPlast system, processors +

moulding machines at their disposal. The patent pending EconPlast

plasticizing system has, in addition to its energy saving ability, many further advantages:

?Q† ! basic principle of electric resistance

—QQ{

“ faster and even more precise

BOY 100E machine running with EconPlast plasticizing system

+ A small calculation program is integrated in the Econplast website through which the energy saving potential can be calculated individually. Besides the 25E, which replaces the previous 22E, BOY presented four new machine models (the 50E, 60E, 80E and 100E units) – with clamping ranges ?Q €QQ :

K2013. BOY is represented by PMS Plastics. www.EconPlast.de

Energy saving achieved with EconPlast

72 DECEMBER 2013 / JANUARY 2014

Additive extension Roller system combines pluses of rubber, ceramics CORONA treatment has proved to be a reliable process which does not require any chemical additives. However, the rollers in ' 5 $ <

they are subject to severe stress during application. Inometa, the German rollers specialist, has developed the new PROTEK layer for corona treatment, which combines the functional safety of a rubber coating with the wear advantages of a ceramic coating, creating a roller surface that meets the high stress requirements. One way to improve wettability is corona treatment, in which

' $ & ^ & changed from non-polar to polar.

www.inometa.com

Songwon introduced its SONGXTEND™ general purpose stabilization packages, which allow polypropylene producers and processors to maintain high temperature manufacturing while safeguarding the desired properties of the polymer. At the same time, SONGXTEND stabilizers will assist in avoiding degradation and discoloration under severe processing conditions. Stability is assured from reactor

^ ' ' +' ' ' often encountered. The stabilization package continues to be effective during conversion and end-use applications. As such, moulders and 5

$

+ speeds and elevated temperatures

www.songwon.com

More space as bottle MAER of Spain presented a complete restyling of its range of bottle trimmers for single standard bottles. Renamed the SB series, the machines are especially useful ' + ^ 8 bottles for use with foodstuffs (milk, dairy products), where the trimmer is integrated into

' + + 8 ' $ +˜8

+ stage. The main change made has been the minimization of the structure or primary chassis of the device, with a cubic or cabintype shape, which provides a much more aesthetic design.

www.maer.es

TECHNOLOGY

Unique cutting geometry PRIMO 200E is a new single-side mounted 4 % ' ^ 4 + cutting width of 200mm from AutomatikMaag. It achieves both user friendliness and high productivity levels. Its unique cutting geometry, with the shortest unguided length between the feed rolls and the cut, enables optimum straight cutting of both hard and very soft plastic strands. The pellet dimensions can

be quickly changed by means of an optional automatic pellet length adjuster. This is done using a second drive motor for the feed mechanism with an integrated speed control. • Automatik-Maag is represented Africa by Joesten International.

www.maag.com

Smart materials

Starlinger showed off its state-of-the-art tape ^ 5 + + of PET recycling equipment

Stewart Knight of REP of France, who is responsible for sales of its injection moulding systems into southern Africa, in front of what ' ' – ^ ' ? ' show, a 500-ton V10 unit

Brent Hean of West African Group with Jan Kurilla of Synthos of Poland; WAG sells J

' ? € 2

' 88 + 8 direct indent and also keeps stock DECEMBER 2013 / JANUARY 2014 73

TEL: +27 (0) 11 462 2990

SOLUTION

MACHINERY (PTY) LTD “One total solution for Injection Moulding�

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

Large Middle East presence at K way of promoting their polymer grades Middle East producers happily supplied material to exhibitors, an effective

BY DR NIALL MARSHALL

FEATURE

FOR eight days every three years the centre of the polymer world moves to Germany, and, # "

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large contingents from the Middle East ‰ "

of the 3 200 exhibitors in the 19 halls of ` ÂŞ } hand view of who is doing what in the *

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74 DECEMBER 2013 / JANUARY 2014

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to an end; after eight days the polymer

* _

Q€¢" ^ ƒ ÂŞ ž NIALL CAN BE REACHED AT: NIALL.MARSHALL@EVERSPRINGME.COM Dr Niall Marshall was formerly based in Johannesburg where he worked with Sasol and Ciba. He subsequently moved to Bahrain in the Middle East and joined Everspring Middle East, one of the largest manufacturers of polymer stabilisers, and X-ponent Three, which supplies a complementary range of additives and pigments and provides technical and business consulting services

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PRODUCTS

ambient yogurt uses

barrier technology Pourable yogurt with six-month shelf life EMPRESAS Polar, a leading Venezuelan food and beverage manufacturer, has broken new ground with the commercial

Venezuela. The non-refrigerated pourable " ` Z " #

" „?Q

&

from Amcor Rigid Plastics. }

has an extended shelf life of six months and requires no refrigeration prior to opening. _ " ` Z

+ +

exceeding expectations, according to Manuel Capdevielle, a director of Empresas Polar. ^ #

} # "

& * ^

“ $ €—Q%'

light-blocking capabilities to prevent

product and maintain its nutritional value. With no refrigeration required and an extended shelf, there were also major

control, distribution, and point of sale. The new barrier PET container represents a

major development in ambient foods, offering a unique packaging solution that opens up new business opportunities in the food and beverage market. Amcor met Empresas Polar’s barrier requirements while also incorporating a unique hour-glass design * ` "

‚

!

!

elements were maintained and optimized PET material distribution throughout the *

container. considerations were made to maintain a “Uniform material distribution is vital

for effective light-blocking performance,� aseptic sterilization process. explained Chris LaBombarbe, senior The barrier PET container features technical manager for Amcor Rigid Plastics. } ˆ•

Through a unique preform design, Amcor induction seal and is wrapped with a was able to achieve optimum material vibrant shrink sleeve label. distribution. “A uniform material distribution Empresas Polar plans to expand the permitted us to achieve sustainable ` Z }

material use while at the same time €QQ ?Q "

} # "Â’

{ * | "

LaBombarbe. „?Q

Amcor also overcame processing

‚

Venezuela. pigmented, opaque structure www.amcor.com www.espresas-polar.com

}

Learning from nature

76 DECEMBER 2013 / JANUARY 2014

^ –&ƒ ]

MaterialScience for designing a vehicle’s exterior skin is aiming at the construction of lightweight but

"

" “

*

] ` _

trunk lid which is characterized ‰

* |

development was modeled on nature: With its smooth, dense outer skin and foamed core, the part has a lot in common with a bone. But the similarities end with how the parts are made: While natural bones " ]

MaterialScience draws on plastics processing methods for the development of sandwich elements. # "

* ^

‰*

#

*

blends such as MakroblendÂŽ #

"

" }“ * |

“

desired appearance, for example with

] ` _ * In a second step, the top and bottom of the trunk lid are joined and

] ÂŽ * |

makes the component so lightweight. _ "

adheres to the entire outer surface, ‰

to minor damage. But that is not all: Antennas can be

* ~ # "

“ * ^

functions, up to and including lighting, can be integrated into the sandwich component. www.bayer.com

Student designed

To-go cup

syringe for disaster zones

Convenient and crumb free! ‡& _ $„? '

Z #

"

product presentation being enhanced

} #

sleeves. The use of this particular

advantages. The look and feel of the _

to different products and occasions, minimizing the turnaround time on client requirement changes. The Soletti cup is a perfect #

* |

# # " "

built-in cup holders. The re-closable lid ensures that Soletti Pretzel Sticks remain fresh and delicious ‌ and

This innovative thermoformed cup manufactured by Greiner Packaging offers convenience in a product that meets the needs of today’s active and on-the-go lifestyle

broken product is now a thing of the past. Apart from being convenient, this new packaging addresses another ” |

suited for on-the-go snacking. www.greiner-gpi.com

^ _ ~ &– } "

created for use in disaster zones, Q€ˆ |

$ | ' * { – "

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MaterialScience at its headquarters in [ # " Z * ‡ + _

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DECEMBER 2013 / JANUARY 2014 77

www.addis.co.za

The Power to Create

info@objet.com www.objet.com

Behind every successful pr

oduct there's an

Objet 3D Printer

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ASSOCIATION NEWS

Recyclate value via A few simple tests give a plethora of valuable data on ‘health’ of material material received by the recycler needs to be regarded as an IMPROVING the quality of recycled plastics requires changes important raw material, not just as scrap to be converted into in approach to recycled materials and the addition of small amounts of performance enhancing additives. This is the view pellets. “Once this mind-set is achieved, it is important to know what of Tim Cooper of Addivation, who presented a talk entitled you are recycling. Apart from just separating and washing the ‘Extracting Value from Recyclates by using Additives’ at a material, the initial quality of the material must be characterised. recent SAPRO meeting. The presence or absence of residual He referred to two important trends in Recyclate is an additives, especially antioxidants and light & ” !

Q Q"

stabilisers needs to be ascertained, so well as the trend towards so-called ‘quality important raw that these can be topped up if necessary. recycling’. material, not just ‰  } ‚

“While South African circumstances are scrap application should be measured, and the different, such that a goal of no plastics $

'

"’ ‰ * $ &

| " "

plastics waste is sent to energy recovery plants), the goal of ‰ $\| '"

improving the quality of South African recycled polymers is a carbonyl absorbance give a plethora of valuable data on the very real possibility,� said Tim. health of the material and enable informed decisions on what “However, improving the quality of recycled plastics needs to be done to upgrade recycled materials. Based on a and articles made from it requires changes in approach

to recycled materials and the addition of small amounts of application, suitable upgrade strategies can be developed. performance enhancing additives.� In terms of additives, Cooper demonstrated how recyclates { "

can be upgraded, in some cases enabling them to compete in applications which up to now have been the exclusive domain of virgin polymers. He presented real-life examples and case studies, by using additives to arrest degradation, improve processing, compatibilise mixed waste streams, improve useful lifetime and in some cases even achieve a partial repair of damage } * These included re-stabilisation of polymers to arrest processing induced changes in rheology, upgrading PP from used battery " &

# "

[ & "

# # #

the real thing, renewing exposed HDPE bottle crates and waste bins, and preventing colour change in recycled PVC. Given the change in mind-set and the technical requirements to be achieved, the upgrading of recyclates need not be cost

78

DECEMBER 2013 / JANUARY 2014

additives

Merit award

Tim Cooper of Addivation’s presentation was of particular interest and relevance to Delanie Bezuidenhout (SAVA), Douglas Greig (Tuffy), Annabe Pretorius (SAPRO) and Oscar Baruffa (PETCO)

prohibitive. Cooper provided some examples of the costs involved in the different case studies, and showed that quality recycling can compete, while *

™{ " "

and sold as upgraded materials along

*

He concluded that by viewing recycled materials in a different light, testing and requalifying, developing a suitable upgrade strategy, including addition of additives at the correct level, retesting and certifying, considerable extra value remains that can be extracted from recyclates. www.addivation.co.za

At the recent SAPPMA AGM, Renier Snyman, DPI’s technical and product manager, was presented with his 5th Merit Award. Renier also received this award in + ' $ 5 5 the pipe industry.

DECEMBER 2013 / JANUARY 2014

79

Plastics|SA spearheads ‘recognition of prior Practical knowledge and valuable expertise will be recognised IN recognition of the fact that the South African plastics industry employs many skilled workers who have many years of practical, hands-on experience that should be credited as part of a formal “ " Âś_^

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prepare RPL candidates for an Integrated Summative Assessment. The process starts with learners assessing themselves against “

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Summative Assessment is conducted against the exit level “ * "

and after internal moderation, the merSETA is then called in to externally moderate the results and the candidate is in line to

DECEMBER 2013 / JANUARY 2014

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ASSOCIATION NEWS

learning’ initiative – {

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clearly being recognised as companies enlist increasing numbers of "Â’ _ ! _ "

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are away from the job to attend a course to learn about a skill they can do with their eyes closed. The RPL creates a win-win situation for us all as it takes place on our premises, during working hours

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the country for learners who are able to produce evidence of their competence against the exit level outcomes of a particular “ ` –™% } –™% ?"

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produce evidence of their competencies against the listed exit level “ " * www.plasticsinfo.co.za

DECEMBER 2013 / JANUARY 2014

81

32nd Foundation Lecture ‡& ˆ % [

Division of the Institute of Materials, Minerals and Mining, Southern Africa will address the topic: How has globalisation and the Economy impacted on the South African Rubber Industry? ÂŁ ] "

Protea Polymers, will deliver the lecture. The IOM3 Northern Branch will host €ˆ ` Q€—" €¥ ˆQ

at the Birchwood Hotel at the OR Tambo Conference Centre in Boksburg. ˆ„?

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Contact Alpha Plast For all your cable and exible needs Sales & Marketing Manager: Ken Price Tel: +27 11 933 3200 Fax: +27 11 933 3306 Email: ken@alphaplast.co.za 118 Gibbs Road, Devland Johannesburg 1832

Contact Elco Plastics For all your rigid, bottle and exible needs National Sales Manager: Ewert Schnetler Tel: +27 21 948 8008 Fax: +27 21 948 8022 Email: info@elcoplastics.co.za 11 Danie Uys Street, Stikland 7530, South Africa www.elcoplastics.co.za

ASSOCIATION NEWS

SAVA visits Germany for recycling tour Sustainability was top of the agenda THE Southern African Vinyls Association $_^Š^'

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tour to Germany. SAVA CEO Delanie Bezuidenhout was accompanied by two local recyclers and SAVA members, Thammo Schulz of Capcorv Recycling and Dewald van Breda of Potch Plastics. “We were fortunate to be able to time our trip to Europe with the much talked ÂŁ}_ "

show that takes place in Dßsseldorf,� Delanie explains. During their two day stopover in Dusseldorf, the SAVA delegation visited many of the stands at the expo, and also held meetings with their South African clients and European colleagues who attended this international showcase and trading platform. ‘ £}_

more that we had expected it to be. Despite the various and exciting technological advancements that were on display at the show, it was noticeable that sustainability was top of the agenda.

We were impressed and inspired by the way in which the European plastics role players package their sustainability message to the market, but also felt encouraged by the fact that South Africa is not lagging behind in this regard. We need to continue with our efforts to educate the consumer market about the good news of plastics, whilst also pressing on with our sustainability efforts,� she says. ^ £}_ "

the group had various factory visits planned, ƒ %

in DĂźsseldorf, who recycle cable scrap #

tile solutions, and Veka AG – the world’s largest ‰ Š{

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PVC each year, and we were therefore eager to learn how they structure their

Delanie Bezuidenhout outside the K-Show in Dusseldorf, Germany

PETCO joins forces with Georgetown University & Sappi ReFibre Buy-back centre launched in Langa A GROUND-breaking partnership has been formed with Sappi % " Z ~ ‚ ` _

Business, PETCO and other local companies to launch a buy back centre in Cape Town’s oldest township. The project was launched at the Gugas’thebe Arts & Cultural Centre in Langa and aims to encourage entrepreneurship and assist the local community with access to sustainable livelihoods. _ % $ # _ ƒ '

responsible for the recycling of used paper and paper products. Georgetown University’s McDonough School of Business provides a transformational education through classroom and experiential learning, preparing students to graduate as principled leaders in service to business and society. Three students from Georgetown University’s McDonough School of Business &‰ ` ‚ [ $&`['

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resource centre in Langa. As part of their EML global business experience, students { " %

entrepreneurship in Langa. They will be educating local 82

DECEMBER 2013 / JANUARY 2014

community members on the value of waste. The trio felt it was imperative to partner with key industry role players in order to make this project a success. ‚ * %

reason, they plan to have an experiential learning approach. This will be achieved through partnering with local recycling companies to educate community members on the value of recycled commodities. ÂŁ { ƒ [ ] ] #

the purchasing of recyclables from the centre which is being managed by a local businessman, Temitayo Abiodun Odutayo, known to locals as “Tayoâ€? who takes pride in furthering his people and helping the local community. The once rundown Tsoga Resource Centre now represents fully functional Buy-Back centre ‡[^¡^ | { * “There is a need for more visible, accessible infrastructure in the form of drop-off facilities, buy back centres and materials recovery facilities. PETCO is proud to sponsor the project with a bundu bailer, as well as an Extruwood recycling station,â€? said PETCO CEO, Cheri Scholtz. www.petco.co.za

Southern African Vinyls Association (SAVA) CEO Delanie Bezuidenhout c. 082 444 6866 e. delanie@savinyls.co.za

Chairman Gary van Eck p. 011 552 6200 c. 082 882 3333 e. gary@sunace.co.za

businesses and manage the collections. To this end, our guests graciously took us on factory visits through their facilities and joined us for in-depth discussions about their products, processes and the challenges they face in terms of collecting used PVC products for recycling,� Delanie says. The SAVA delegation also held meetings with AgPR, the Association Š{ % {

Europe that is responsible for collecting } Š{

Germany and some other European countries and the SAVA equivalent in Germany, AgPU, that is based in Bonn and forms part of Vinyls Plus. The Managing Director of the AgPU, Werner Preusker, serves on the Global Vinyls Council with SAVA’s Delanie Bezuidenhout, and their discussions centred around how to structure the industry effectively and creating opportunities to learn from each other. “Before our tour we admittedly had

Thammo Schulz (Capcorv Recycling), Dewald van Breda (Potch Plastics), Delanie Bezuidenhout (SAVA), Andrea Landers (MD of WALLA FLOORS), Ralph Bernitz (Walla Floors), and Werner "U + ˆ# < =4 2 $ 8 ›R +

certain preconceived ideas about what we thought the challenges would be and ‰ & *

However, we weren’t long into our trip before it became clear to us that we are all facing the same challenges, and use the same processes and equipment. How we deal with those challenges make the difference and it is always good to learn from others’ experiences. Plans for a visit to South Africa within the foreseeable future were discussed, as well as various joint projects aimed at improving the image of PVC in the marketplace, such as: Regular communication to the market about the facts of PVC and PVC recycling

Increasing the collection and recycling ‰ Š{ Preventing used and discarded PVC from being exported to other countries Using technology to effectively connect PVC waste with PVC recyclers “We might be oceans apart, but the challenges we are facing here on the southern tip of Africa with regards to plastic recycling in general, and PVC " “ *

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encouraging to see that we are on the right track with what we’re doing in South Africa, and in some cases we were even able to help and educate our European cousins,� Delanie added. www.savinyls.co.za DECEMBER 2013 / JANUARY 2014

83

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

THE DESIGN FACTOR‌

Simple or sophisticated

+ design = PROFIT THERE is a truism that businesses are run by accountants, salesmen or a ‘creative marketing man’ with a MBA. The other side of this stereotype is that manufacturing is not, but should be run by engineers or designers. Whichever side of the fence you stand, consensus could possibly be reached along some basic fundamentals. The function of manufacturing is to make things that people need, products that people can use and products of quality that will perform well over time. The ‘number crunchers’ are important, but it is the designers and creative engineers that understand the fundamentals of producing successful products.

by bringing in container loads of simple plastic products to the detriment of our own tool making and thermoplastic injection moulding industries. Looking around it is easy see that things are not as they should be: 8 out of 10 basic, simple plastic products are imported.

1

84 DECEMBER 2013 / JANUARY 2014

2

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

The countries of origin vary from Taiwan, India, China and even New Zealand; all enjoy a place in our markets. SIMPLE + DESIGN In pursuit of the ‘money pot’ and recognising the credible activities of TASA in their endeavour to kickstart the SA tool # ¤_^

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* A few case-studies exemplify the fact that design is a fundamental element to success. Apple is one. The turnaround of this company from a loss-making computer company in the mid-90s to the second largest company in the world, and recently as the leading brand in the world having knocked Coca–Cola off its throne, is a consequence of a design-led approach to innovation. Similar examples at the sophisticated end of the textile market include the turnaround of the clothes retailer Burberry to become a top performing company in the FTSE 100 over the last six years. In the case of Burberry it is recognised that it is the mutual understanding at board level of the importance of design in line with the objectives and modus operandi of the CEO that has resulted in the consistent growth of the company. Leading UK manufacturers, such as Dyson, JCB, Russell Hobbs and Jaguar all regard design as essential to their expansion in highly competitive global markets. SOPHISTICATED + DESIGN ] " "

Christopher Bailey MBE, has used designled innovation to rejuvenate its brand offer from a traditional British clothes manufacturer into a leading luxury brand in less than a decade. The company fully integrates the fashion, materials and process elements of their operations with the use of the latest communication tools, such as digital social media, to extend its brand reach and appeal to customers. | Q€Q" ] +

a 36% increase in global retail sales, driven largely by high-end consumers in emerging markets, and Q€€*

company’s turnaround shows a UK business using design to succeed in an increasingly competitive global market. (Source: UK Design Council)

Apple (1) and Dyson (2) all regard design as essential to their expansion in highly competitive global markets

DESIGN

INNOVATION + DESIGN = SUCCESS An independent evaluation of the design service industry in the UK recently showed that every ÂŁ1 invested in a + Âľ ?

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secured by companies that have explored and pursued design initiatives include accelerated business growth, increased market share and successful new product, service and brand development with an increase in employment opportunities.

design. Product design is paramount to every company involved in the manufacture and marketing of physical products of any type. Design is the key stone to all current and future initiatives _``&

base. We are not going to be able to compete against the Apples, Sony’s or LG’s of this world but with the acceptance, recognition and application of design we will be able

to conceive of better products that will: sell more increase market share obtain wider distribution improve margins and carve out new opportunities develop more employment opportunities All of which will increase revenue and, potentially, also decrease costs, improve the countries bottom line and have a positive impact on the level of our GDP.

Mike Wythe is an industrial designer and lecturer for the Industrial Design Programme at the Tshwane University of Technology (TUT). Mike is a graduate of the Royal College in London where he completed his Masters in Industrial Design Engineering.

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Product design is paramount to Russell Hobbs (3), as is evidenced by the highly acclaimed line of household appliances

DECEMBER 2013 / JANUARY 2014 85

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ORGANIZATIONAL HEALTH

The last competitive advantage in business How to build a healthy organisation ALL the competitive advantages we’ve been pursuing during our careers are gone. That’s right. Advantages such as strategy, " #

are gone. No, those disciplines have not disappeared. They are all alive and well in most organisations. And that’s good, because they’re important. But as real differentiators that can set one company apart from another, they are no longer anything close to what they once were. That’s because virtually every organisation, of any size, has access to

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strategy, technology and related topics. Companies use the same consultants, go to the same conferences and business schools and managers leave one business # *

In this digital age, with information and

86 DECEMBER 2013 / JANUARY 2014

anything else a business does, and even more important. Why? Because the smartest organisation in the world, the one that has " " #

and technology, will eventually fail if it is unhealthy. This happens again and again. When it fails, the cause is mostly attributed to a poor strategy, but the real truth is that it was undone by politics, confusion and the internal behaviours of its people. But a healthy organisation The healthy organisation "

A healthy organisation is one that because without politics and confusion, has all but eliminated politics and it will inevitably confusion from its ‘When politics, ambiguity, become smarter environment. As a and tap into result, productivity dysfunction and confusion every bit of and morale soar, are reduced to a minimum, intelligence and and good people people are empowered’ talent that it has. almost never leave. So if all this is For those leaders true and our experience informs us that who are a bit sceptical, rest assured it is, then why haven’t more companies that none of this is touchy-feely or

soft. It is as tangible and practical as organisational health? For starters, it’s hard. It requires real # " "

and it must be maintained. On top of that, it’s not sophisticated or sexy. Moreover, in spite of its power, organisational health is hard to measure in a precise and accurate way. It impacts so many disparate areas of an enterprise that it is virtually impossible to isolate it as a single variable and quantify its singular impact on the bottom line. But the biggest reason that organisational health remains untapped is that it requires courage. Leaders must be willing to confront themselves, their peers, and the dysfunction within their organisation with an uncommon level of honesty and persistence. They

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uncomfortable situations and address issues that prevent them from realizing the potential that eludes them. # " ‚

impossible to sustain an advantage based on intellectual ideas. In short it is no longer just the best idea and smartest people that set a company on a winning course. There is one remaining, untapped competitive advantage out there, and it’s more important than all the others ever were. It is simple, reliable and virtually free. It’s called organisational health.

FEATURE

Four disciplines What exactly does an organisation have to do to get healthy? There are four simple

" * ” 1. Build a cohesive leadership team –

leaders of the organisation to behave in a functional, cohesive way. If the people responsible for running an organisation, whether that organisation is a corporation, a department within that corporation, a start-up company, a restaurant, a school or a church, are behaving in dysfunctional ways, then that dysfunction will cascade into the rest of the organisation and prevent organisational health. And yes, there are concrete steps a leadership team can # * ƒ #

these in detail in next month’s article. 2. Create clarity – The second step for building a healthy organisation is ensuring that the members of that leadership team are intellectually aligned around six simple but critical questions. Leaders need to be clear on topics such as why the organisation exists to what its most important priority is for the next few months. Leaders must eliminate any gaps that may exist between them, so that people one, two or three levels below have complete clarity about what they should do to # *

Clarity precedes mastery and when the top team does not have absolute clarity the rest of the organisation suffers. 3. Over-communicate clarity – Only

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answers to the six questions. Leaders of a healthy organisation constantly and patiently repeat themselves and reinforce what is true and important. They always err on the side of saying too much, rather than too little. This quality alone sets leaders of healthy organisations apart from others. 4. Reinforce clarity – Finally, in addition to over-communicating, leader’s must ensure that the answers to the six critical questions are reinforced repeatedly using simple human systems. That means any process that involves people,

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designed in a custom way to intentionally support and emphasize the uniqueness of the organisation. In addition to these four steps, it is essential that a healthy organisation get better at the one activity that underpins

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others, and create opportunities that they couldn’t have expected. At the end of the day, at the end of the year, employees are happier, the bottom line is stronger, and executives are at

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www.leadershipworks.co.za DECEMBER 2013 / JANUARY 2014 87

Build a Healthy Organisation and High Performing Teams Leadership and Organisational Consulting

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WORLD NEWS

Lanxess on track with EPDM project in China LANXESS is progressing to plan with the construction of its world-scale EPDM (ethylene propylene diene monomer) plant in Changzhou (Jiangsu Province), China. The German specialty chemicals company is investing ₏235-million in the plant – the largest investment it has made in China to date. Some 45% of the investment total will be spent by the end of 2013. The plant will have a capacity of 160,000 metric tons per year and the investment will create up to 200 new jobs. The plant is expected to achieve mechanical completion at the end of 2014 and will probably start selling products to customers as of 2015. Lanxess is the world’s leading producer of EPDM, marketing its products under the brand name Keltan. China is the world’s largest market for EPDM, driven above all by automotive and construction industries. The new EPDM plant is located at the well-established Changzhou Yangtze Riverside Industrial Park. Lanxess will use Keltan ACE technology

to enable sustainable production at its new plant. In comparison to conventional technology, the Keltan ACE catalyst technology reduces energy requirements for production and it does not require catalyst extraction as a result of high *

enables the manufacture of new EPDM rubber grades, such as oil-extended EPDM and special high molecular weight EPDM. The new plant will produce in total ten premium grades of EPDM tailored to Chinese customer needs. Lanxess already operates EPDM production sites in Geleen, the Netherlands, Marl, Germany, Orange, USA and Triunfo, Brazil. EPDM is used in the automotive industry as door sealants, hoses, belts or antivibration parts. The product is also used in " "

construction and oil additives industries. Its properties include very low density, good resistance to heat, oxidation, chemicals The EPDM plant in Changzhou will create an and weathering as well as good electrical additional 160,000 tpa of the sought after rubber insulation properties. material for Lanxess www.lanxess.com

Ascend’s new compounding operations

Ascend’s Vydyne resin being packaged at the world’s largest fully integrated PA66 production facility in Pensacola, Florida

In Pensacola, Florida, Ascend boasts the world’s largest fully integrated PA66 production facility

ASCEND Performance Materials Inc., a leading producer of PA66 resin and chemical intermediates, has added a world-scale compounding line (30k tons/ yr) in Pensacola, Florida. The new line adds state-of-art capabilities for producing unique, high-performance compounds. Since 2005, Ascend has more than doubled its resin capacity making it one of the largest PA66 resin producers in the world. In recent years Ascend has also invested capital and resources to expand production of VydyneÂŽ compounds. In 2013, Ascend State-of-the-art compounding technology on the new Pensacola line is producing material

in viscosity and mechanical properties. In addition, parts moulded from these compounds are yielding 50-75% less mould-deposits (‘plate-out’), offering

in high-volume applications with intricate part geometries. www.ascendmaterials.com 88 DECEMBER 2013 / JANUARY 2014

Dow sells PP licensing business to WR Grace AMERICAN chemical giant Dow Chemical has sold its PP licensing and catalyst operation to WR Grace for $500-million. The deal is part of a planned divestment process. “This is another of Dow’s focus on selectively shifting our portfolio away from

optimising their value,� said Andrew Liveris, Dow’s chairman and chief executive. “Our accelerated strategy is focused on narrowing our market participation and preferentially funding our select growth businesses with strong competitive positions in attractive markets such as electronics, water, packaging and agricultural sciences. We are planning further proactive divestments in the next 12 months in our relentless pursuit of rewarding shareholders.� Dow said that since 2009 it had sold off non-core businesses representing approximately $8-billionn in revenue, most recently the disposal in January of the stabilizers component of its plastics additives business.

Precision in sealing technology CHINA’s automobile industry is growing rapidly: By 2017, China will be building around 27 million vehicles per year. Meeting the challenge for a vastly increased demand for automotive components, Kaco, manufacturer of high precision, application-oriented sealing solutions for the automotive, engine and machinery industries, Kaco developed the Fred radial shaft sealing rings that has commissioned a new enable performance by minimizing friction loss. The piston production line at its plant actuator for dual clutches and automatic transmission _ "

consumes less and provides greater comfort in mobility. for transmission component The plasma-activated PTFE seals are a new approach to seals. sustainable manufacturing solutions with high functionality. These components are resistant to temperatures of up to The requirements for the 150°C. The outer diameter is between 100-300 mm products to be manufactured were not possible using 200cm3 and an injection pressure of 2,500 commercially available elastomer bar. The clamping force is 3,200 kN. machines. The range of very different Automotive applications constitute 95% diameters added demands to the high of Kaco’s products. Main applications are process reliability and performance, and radial shaft seals, piston and rod seals, end the combination of 1K parts and 2K parts face mechanical seals and piston actuators of a machine. Kaco sourced a specialised with an outer diameter of about 6mm to just machine builder and liaised with Maplan below 300mm.

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touch control. HNBR (hydrogenated nitrile rubber), ACM The specialised machine consists of (acrylic rubber), AEM (ethylene acrylic an overhead injection unit with 200cm3 rubber), and NBR (nitrile butadiene rubber) and a horizontally arranged FIFO based. www.maplan.at injection aggregate also with a volume of

European recyclers face problems

MANY hands make light work‌ if the hands are cheap and the material being sorted is lightweight post-consumer low density * ] &

“the hands aren’t cheap enough�, according to Renaud Pfund, head of recycling and recovery at French environmental services company, Veolia Propete. “Europe needs to develop automated washing and drying technologies but it’s not easy,� he explained. “The thinness of the [ & #

wash and dry mechanically, although people are looking at addressing this problem with growing degrees of success. “However, current quality levels are not high enough�, he explained. “And no one

wants a warehouse full of recycled material you can’t sell.� A major part of the problem facing Europe’s plastics recyclers is the depressed state of both the construction and automotive sectors. But according to Pfund there is some good news – both buyers and sellers of recycled plastics are looking at ways to make the market work. “But we really don’t know what the market will be like in 12 months’ time,� added Pfund, “and the situation with China and its ‘green fence’ will be the changer.� Material is no longer being bought by Chinese recyclers as a result of local legislative changes but the infrastructure in Europe isn’t ready to handle the waste that had previously been exported out to the Far East. Until this is addressed Europe’s mandated recycling levels are “not realistic�, Pfund believes. (Anthony Clark, PRW)

AROUND THE WORLD Husky buys SchĂśttli group HUSKY Injection Molding Systems is to purchase SchĂśttli AG, a Swiss global leader in medical and closure mould making. The transaction is expected to close in early December. The industrial investor CGS took a majority stake in SchĂśttli in 2008 with the goal to form a global leader in mould making for medical applications and closures. Together with the company’s former owner, Martin SchĂśttli, a ‘buy-and-build’ strategy was implemented with add-on acquisitions in China and the United States.

Everlasting plastic NORNER, the Norwegian Research Council, is attempting to develop a plastic substrate that will last at least 500 years for use in digital storage media. Current storage media and related hardware and software need updating at least every 5-10 years and require more and more investment, said Norner. The integrity of data is at risk every time it is retrieved and re-stored. The organisation and its partners are therefore hoping to create a

digital information. www.norner.no

Baerlocher to produce PVC BAERLOCHER has begun construction of a new manufacturing facility in Akhisar, Turkey. The plant, which is targeted to start production end of 2014, will have a capacity in excess of 40,000 tons and will produce both calcium-based and lead stabilizer additive one-packs. The manufacturing operation will be supported by a state of the art technical application laboratory. Baerlocher’s regional expansion with this new facility supports its position as the global leader in calcium-based PVC stabilizer systems. www.baerlocher.com

Bayer ends nano projects BAYER MaterialScience is to bring its work on carbon nanotubes (CNTs) to a close. Precisely how the research results and knowhow for the production and application CNT will be used further will be determined shortly. Researchers from Bayer MaterialScience had collaborated with external partners in recent years to resolve complex issues related to

nanotubes. Methods for scaling up the production processes were developed, as were new generations of catalysts and new types of products. www.materialscience.bayer.com DECEMBER 2013 / JANUARY 2014 89

BOOKS

Plastic bottles ever more popular European market to increase to about. 170 billion units in 2020 PLASTIC bottles are an important packaging material in many sectors. Beverages, foodstuffs, cosmetics, and pharmaceuticals as well as household and industrial chemicals can be packaged and sold in plastic bottles. Market analysts at Ceresana expect the volume of the European market to increase to approx. 170 billion units in 2020. The bottle industry is capitalizing on the popularity of singleuse PET bottles in particular, which has considerably gained market shares in the previous eight years already. The quality of plastic bottles is improving continuously; thus, they gain access to segments that traditionally used other materials. Plastic containers are becoming more important, not only in the segment beverages, but also to the foodstuffs, cosmetics * –

and the development of heat-resistant PET bottles open up new possibilities and options. While PET bottles are very common in the sector beverages, cosmetics, sanitary products, and detergents are predominantly sold in bottles

Market Study: Plastic Bottles Europe

made of polyethylene. This polymer is also used in the production of bottles for milk. Analysts at Ceresana forecast the largest growth potential in Western European countries for the pharmaceutical and cosmetics sectors. Ceresana forecast demand in this segment to rise by more than 2.4% per year�. The study provides a presentation and analysis of the market for plastic bottles – including forecasts up to 2020. It also provides substantiated analysis of individual application areas for plastic bottles:

" ‰ ?Q *

www.ceresana.com/en/Market-Studies/Ă?ndustry/Plastic-Bottles-Europe

SAPPMA releases technical manual for 2013-2014 THE Southern African Plastic Pipe Manufacturer’s Association (SAPPMA) has released its revised 20132014 Technical Manual for engineers. According to Jan Venter, CEO of SAPPMA, the purpose of this annually updated manual is to provide basic, relevant and updated information when engineers and other professionals need to select and specify plastic pipes that are to be used in water supply and waste-water disposal applications. Apart from covering the differences between the various types of plastic pipes and explaining the basic procedures that need to be taken when engineers selecting of specifying the correct pipe, the 2013-2014 edition is

developments coming out of the overseas plastic piping industry aimed at quicker and safer installations, reducing manufacturing costs, reducing down time and improving *

| ‡ &

+ ‡ &*

Copies of the publication will be made available to design and civil engineers via SAICE or can be purchased directly from SAPPMA at a cost of R200.00 per copy. • For more information, contact Louise Muller at Admin@sappma.co.za

90 DECEMBER 2013 / JANUARY 2014

Rubber examined ‡&

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Q Q* Market analysts at Ceresana have included the most important types of rubber in their newest report: styrene butadiene rubber (SBR), polybutadiene rubber (BR), acrylonitrile butadiene rubber (NBR), butyl rubber (IIR),

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rubber (CR), and polyisoprene rubber (IR). % " #

complete overview of all relevant data and facts as well as background information : y d tu concerning individual types S t Marke of rubber and sales markets. Synthetic Rubber The study provides a basis for the strategic and operational planning of producers, processors, and traders. By far the most important type of rubber is SBR. In Q€ " ?*—

tons were processed; the second is BR that accounted for about a quarter of global market volume that year. ` +

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accounting for almost 70% of consumption. The study offers a description and analyses of the global market for the synthetic rubbers SBR, BR, NBR, IIR, & `" { " | Q Q*

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also examines the rubber market in the 18 largest countries in more detail. Individual application areas are discussed and the study also offers an analysis of demand for and revenues generated with different types of rubber. www.ceresana.com/en/Market-Studies/Plastics/ Synthetic-Rubber

DIARY

QUADRANT Engineering Plastic Products (EPP), a global leader in machinable & ' ' 8 $ < processing applications at Semicon Europe 2013 in Dresden in October. Its breakthrough SemitronŽ U / + $ ' + traditional wet and dry semiconductor processing, particularly in the most 5 5 ' 8 J U / semiconductor production: it’s less expensive than ceramics, stronger than breakage-prone quartz, survives aggressive plasma chemistries, and is ultra clean in nature, according to EPP global market segment manager Scott Williams. The ' ' & – ' ' &? ' 8

2 KW plasma samples displaying mass loss; all the samples started at approximately the same size. Shown here are PEEK, PAI, polyimide and Semitron MPR 1000

www.quadrantplastics.com NOTE: A semiconductor is a material which has electrical conductivity to a degree between that of a metal (such as copper) and that of an insulator (such as glass). Semiconductors are the foundation of modern electronics, including transistors, solar

cells, light-emitting diodes (LEDs), quantum dots and digital and analog integrated circuits. A semiconductor may have a number of unique properties, one of which is the ability to change conductivity by the addition of impurities (‘doping’) or by interaction with another phenomenon, such

< "> " q * # ?X>‚ >X ^ > | semiconductor very useful for constructing a device that can amplify, switch, or convert an energy input. The modern understanding of the properties of a semiconductor relies on quantum physics to explain the movement of electrons inside a lattice of atoms.

THE 8th international Airtec aerospace supply fair for the aerospace industry, held from 5-7 November at the Exhibition Centre Frankfurt, Germany, showcased a mixture of innovation and information. Exhibitors from 26 nations presented new technical and economical solutions for the aerospace industry -– from design, engineering, testing to simulation and materials, production up to components, systems, electronics and sensors

as well as life cycle support. At the research and development summit held during the fair, two essential main questions were discussed: Future aircraft design focusing on composites. The topic of unmanned aerial vehicles (UAVs) was highlighted this year. An example of this is the ‘Euro ‡ #‚" " ™}— Z

Hawk unmanned aircraft vehicle.

www.airtec.aero

DECEMBER 2013 / JANUARY 2014

91

DIARY

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5 ' + Â&#x;& Japanese cosmetic and skin care brand, using DuPont™ SurlynÂŽ 3D technology. The branding decoration '

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THE ExtruAfrica conference (5-8 August 2014, Pilansberg) is a joint venture involving North-West University in Potchefstroom, the university’s Centre for Advanced Manufacturing (CFAM), the

Department of Trade and Industry (DTI) and other institutions. The conference itself will run over two days, with the &‰ ^ Q€—  &‰

– A cost effective solution for the African

Continent’.

parties are invited to submit abstracts by 30 January. ^ + %

EVENTS Thin Wall Packagking

3-5 December

Maritim Hotel, Cologne, Germany

www.amiplastics.com

€ 8 Z U

3-5 December

Maritim Hotel, Dusseldorf, Germany

www.amiplastics.com/events

EuroMold 2013

3-6 December

Exhibition Centre, Frankfurt, Germany

www.euromold.com

Plastvision India

12-16 December

Mumbai, India

www.plastvision.org

IndiaMold 2013

12-16 December

Bombay Exhibition Centre, Mumbai

www.euromold.com

ANTEC Dubai 2014

21-22 January

Marriott Marquis Hotel Dubai, UAE

www.antecdubai.org

+ + Q

5 R

18-19 February

Sandton

www.specialised.com

Pipeline Coating

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Vienna, Austria

www.amiplastics.com

›R *

—} ¢ %

DĂźsseldorf, Germany

www.amiplastics.com

Sino Pack / Inno Pack 2014

3-5 March

Guangzhou, China

www.chinasinopack.com

^

—}¢ `

Sandton Convention Centre, Jhb

www.eci-international.com

€ R

6-7 March

Lisbon, Portugal

www.pultruders.com

U * Â

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Bangkok, Thailand

www.amiplastics.com/events

;

1-3 April

Kenyatta Int’l Conference Centre, Nairobi

www.propakeastafrica.com

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www.e-t-d.org

ArabiaMold / Plastvision Arabia

7-10 April

Sharjah, UAE

www.arabiamold.com

8 š € *

7-11 April

Dusseldorf, Germany

www.tube.de

Chinaplas 2014

23-26 April

Shanghai New International Expo Centre

www.ChinaplasOnline.com

Interpack 2014

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DĂźsseldorf, Germany

www.interpack.com

CeMAT 2014

19-23 May

Hannover, Germany

www.CeMAT.com

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Sandton Convention Centre, Johannesburg

www.afrimold.co.za

PPS30

8-12 June

Cleveland, Ohio, USA

www.pps30.com

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17-20 June

Lyon Eurexpo, France

mlanteri@idice.mc

Interbuild 2014

20-23 August

Nasrec, Johannesburg

www.interbuild.co.za

€ Â

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Eko Hotel & Suites, Lagos, Nigeria

www.propakwestafrica.com

Propak Cape 2014

21-23 October

Cape Town Int’l Convention Centre

www.propakcape.co.za

2014

92 OCTOBER / NOVEMBER 2013

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are just three of the brand owners and retailers sharing innovations in packaging at the new conference from Propak Africa from 18-19 February at the _ { { Q€—* The conference will feature the thinking and processes behind success stories in standing out on the shelf and selling from Distell and SAB; new approaches to convenience and functionality from Parmalat and Sirane;

and advances in labelling and material replacement to boost recycling from Woolworths and Mars. The agenda is case-study led and features many of the winners of the 2013 IPSA Gold Pack Awards – e.g. Parmalat presto’s innovation in functionality and Distell’s line extensions for the Mainstay brand. Advances in automated production and best practice

will be presented by packaging heads

from Nestle, Coca-Cola and Shoprite Checkers. The development of South Africa’s packaging industry will also feature with contributions from the DTI and PACSA. APO, IPSA, PACSA, PISA, Âź_^" _ {" _^–]ƒ^ ƒ \

fully endorse the event with members able to attend at a discounted rate. For more information contact Zelda Jordaan at zeldaj@specialised.com www.packaginginnovations.com

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Specialised Exhibitions is to present its next major packaging and plastics event, Propak Cape, from 21-23 October 2014. The highly successful regional event will be held at the Cape Town International Convention Centre. This trade exhibition, together with co-located shows, offers an excellent opportunity for exhibitors: to generate sales, gain valuable sales leads and develop business connections.

Although the basic function of packaging is to preserve and protect the pack contents, packaging, particularly in the retail market, has become a fascinating marketing tool that is used to promote and sell products. Visitors will be able to see hot new trends in the area of packaging with a focus on design, extended shelf-life technologies and environment-sensitive advancements. www.propakcape.co.za 93 OCTOBER / NOVEMBER 2013

COMING UP SHALE GAS EXPECT TO HAVE BIG IMPACT ON FEEDSTOCKS

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THE main topic at the Global Plastics Summit in Chicago in November was the dramatic impact expected in the availability of key feedstocks. The biggest game changer, the shale gas boom in North America, is driving a renaissance of the North American plastics industry. While exports are on the horizon for the US, Europe is under severe competitive pressure. Meanwhile, China is leveraging coal-based olefin production to strengthen their economic position. www.globalplasticssummit.com

THE 30th international conference of the Polymer Processing Society (PPS-30) is to be held from 8-12 June at the Renaissance Hotel in Cleveland, Ohio, USA. PPS is an international professional society of scientists and engineers working in the fields of polymer materials science and engineering. Its international conferences are annual events and provide a conduit and common platform for fostering interactions among scientists and engineers working in academia and industry and for presenting exciting research results on unique features of polymeric materials and their processing characteristics. www.ppsconferences.org/rg/login.asp

THERMOFORMING FOCUS AT EUROMOLD A SHOWCASE for forwardlooking technologies for thermoforming will be presented at Euromold in Frankfurt from 3-6 December. The aim is to present innovations along the entire thermoforming process chain. While such processes have traditionally been used to produce packaging, such as chocolate box trays, R‰R ' + ^ ' ' + utensil trays, or yoghurt cups, possibility thermoforming also finds its application in the production of mudguards, dashboards, bathtubs, and casings of all kind. The ability to alter shape, colour, and function is what makes thermoforming increasingly popular. The thermoforming centre in hall 9.0 demonstrates the innovative and diverse applications of this forward-looking technology by presenting the newest products and developments along the entire chain of the thermoforming process. It highlights diverse solutions and benefits for different sectors of the industry. Visitors are able to experience directly the innovative power of thermoforming machines. www.euromold.com

PVC FORMULATION BIG changes are in store for the global PVC marketplace (as indeed for all polymer sectors) with shale gas providing cheap feedstock in the USA and opening up export markets. Besides that, mergers and acquisitions occurring in the European PVC compounding industry, as well as growth in production in China and Russia, are also factors for the PVC business. Several different views of the world markets will be presented at AMI’s international conference on PVC Formulation 2014, which is scheduled for 24-26 February at the Maritim Hotel in Dusseldorf, Germany. To kick off the conference Vestolit will give a market review focused around European PVC and from Brazil, Mexichem will outline the opportunities for PVC in construction in Latin America. www.amiplastics.com

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

/5 #6 $.7 %'() #8 #. #9 ; # /< INTERPACK, which takes place in DĂźsseldorf, Germany, from 8-14 May, is the major inspiration for the packaging industry worldwide and all related process technologies. Interpack 2014 is expected to be even bigger than 2011, with over 2,700 exhibitors from more than 60 countries presenting their latest ideas, innovative concepts and technological visions in equipment and machinery for packaging and processing, production tools for packaging materials, materials themselves, and services for the entire industry. www.interpack.com 94 DECEMBER 2012 / JANUARY 2013

CLASSIFIED ADVERTS Advertisers: Dec 2013 / Jan 2014 Aerontec 33 Alpha Plast 81 BASF 14 Cabletech Marketing 11 Carst & Walker 75 DemaPlastech 73,77 DH Polymers 39 Dispak 61 Engen Petroleum 01 Fukutomi 80 Haitian Huayuan 18 Hosaf 67 Jenowill 03 Karbochem 83 LeadershipWorks 87 Masterbatch SA 26 MBT 29 MGMW Trading 31 Miracle Mould 50,51 Mould Base SA 35 NG Engineering 80 Nissei ASB 65 Orion Engineered Carbons 38 Paradigm Containers 41 Performance Colour Systems 43 Plastamid 45 PlastiChem IFC Plasti-Weld 55 Plastomark 47 Polysaf 21 PPS30 94 Propak 2014 93 Protea Polymers IBC Rawmac 85 Relloy 52 Safrique International 63 SAPY Colours 54 Sasol Polymers OBC SES 16 Sun Ace 69,71 Sysmetric 59 TASA 48 UV Tooling 23 Victor Fortune 25 Welltec 49 West African Group 79

FOR SALE 850Kgs Virgin Hytrel 7248 Price – open to any reasonable offer. New price in excess of R100 per kg

Contact: Dave on 083 225 8277

9;/UÂ?*Â?/UQ‰2 ;R9‰Â?YÂ?2‡ J ›; \ “ ' 2‰¢ GN (Canada): machines for reduced waste and reduced energy; Thermoforming Moulds for GN and other thermoformers ;V /ˆJQÂ?‰ ;R9‰Â?YÂ?2‡ */Â?U 2/Q Â?* Q Y‡ Mono & multi-layer extrusion lines for the production of:

GREENLAND OILS Michael Engels 072 125 4323 Tel: (011) 903-8084 Fax: (086) 665-4323 email: mengels1@ telkomsa.net PO Box 1220 Walkerville 1876

COMPOUNDING CAPACITY AVAILABLE We can compound mineral powders into PP or PE Please call Alon on 021 521 2400

We Buy and Sell Plastic Pallets 083 756 6897 www.premierpallets.co.za

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 { ‚ $ š ' Multilayer sheet for packaging; Semi-foamed sheet for thermoforming U ;/Q YJ *Â?/ 9;/UÂ?*Â?/U; R 2Q‰2 NEW: Octal DPET/PE laminated sheet for FFS packaging lines OPS, PP, PET sheet for general packaging; PP/EVOH/PP for high barrier containers

SUBSCRIBE TO SA PLASTICS, COMPOSITES & RUBBER SA Plastics, Composites & Rubber is published six times a year and is available to people involved in the plastics and polymer industry in South Africa on a subscription basis at a cost of R250 a year. It is available in other countries in Southern Africa at a subscription cost of ZAR500 per year. International subscription, supplied by airmail, is ZAR700. If you’d like to subscribe, email your details to saplastics@iafrica.com or visit our website at www.saplastics.co.za

+ : "" advert please Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com www.saplastics.co.za DECEMBER 2013 / JANUARY 2014 95

SPORTS

Winning innovation for performance yachts

"" #

# $ AT METS 2013 (Marine Equipment Trade Show, \4 ‰ 5 8 in Amsterdam RAI), DSM the producer of ultra high molecular weight polyethylene (UHMwPE), branded as DyneemaŽ, will show how the world of yacht racing will be reaching levels of extreme performance with the introduction of _£¥¥"

made by DSM. “Cutting edge performance in the world of racing yachts demands cutting edge products. Dyneema SK99 is our latest innovation for running rigging,� said Edwin Grootendorst, global segment director at DSM Dyneema. “Naval architects employ super

modeling software to ensure that racing boats can reach their maximum potential speed on all points of the wind. As any rigger, skipper or trimmer knows, transferring wind energy from the sails to the hull is the job of the

rigging. Poor performance rigging can make the difference between winning or losing races and optimum power and acceleration is a matter of millimeters. When it matters, Dyneema SK99 will be there pushing boats faster; helping to win races and we are looking forward to revealing the experience we are building with this exciting product.� Dyneema SK99 delivers the highest tenacity available in a light weight,

„†

_£¥Q Q†

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thinner, lighter weight lines than traditional ropes, or lines with the same

strength. The result is better performance from more compact rigging, which is lighter, takes up less space, lowers resistance and increases speed. The modulus is €Q† _ÂŁÂĄQ ˆ?†

_£„? _£„•*

DyneemaŽ SK99 for running rigging – the

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in modulus translates into lower stretch, better sail performance and thus faster possible boat response. The full range of Dyneema` products, including SK99, will be available for the complete spectrum of yachts and their rigging needs through our licensed partners and can be seen at METS. www.dyneema.com

Why not on a Bicycle? % #

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A REMARKABLE plastic bicycle with more than 20 plastic applications, some of them highly innovative, were just some of the innovations by BASF at K2013. Bicycles made almost entirely from plastic have existed for a long time. What has not existed to date is a concept e-bicycle that incorporates as many different, and sometimes very "

*

On the basis of the Performance Materials platform formed in January 2013 to consolidate plastics from polyurethanes through thermoplastics, foams, epoxy resins and composite products, BASF exhibited a concept bicycle to demonstrate potential capabilities: conceived by the design agency DING3000, the ‘Concept 1865 – Rethinking Materials’ e-bike uses more than 20 different BASF plastics. ƒ ۥ¢?½ ]^_%

pedal bicycles appeared: This is why the functional and ready-to-ride bicycle design study has taken the shape of a historic high-seat bicycle. It embodies a ‘thought experiment’ on the subject ‘Rethinking materials’. The vehicle is an invitation to customers to challenge established products and to develop together with the company new application ideas for mobility and urbanization on the basis of modern plastics. World Solar Challenge – In October the World Solar Challenge will + + 8 ' $ 5 in Adelaide, some 3000km to the south. Solar cars are allowed a nominal 5kW hours of stored energy. All other energy must come ' 8 5 ' + ' 5 ' The elite Challenger class is conducted in a single stage from Darwin

Â? ' ' 5 ' 5 as they can until 5pm in the afternoon where they make camp in the ' 5 ' ' 8

www.basf.com 96 DECEMBER 2013/ JANUARY 2014

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

Fax: +27 (0) 11 842-3700

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