www.saplastics.co.za
VOL 13 ISSUE 4 – AUGUST / SEPTEMBER 2015
H T I W G N I L DEA NS
Boost
TIO P U R R E T N I POWER
for rubber at conference
New MCG tray achieves fruitful solution
TURNING THE TIDE on marine debris
Serioplast plant up and running Mold In Graphics
new MiG5 technology
Easy to handle, WZLFH WKH EHQHÀ W
Belgotex is SAVA’s first Vinyl. licence holder
Office furniture made from EPP 46
54
Lego invests in creating sustainable plastic bricks
86
REWIRING OUR FUTURE with in jackets made from Levapren® PXL Series | New Peroxide Pre-Crosslinked EVM Rubber Grades
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Levapren® PXL series, a new family of pre-crosslinked EVM rubbers, in the form of the ethylene-vinyl acetate copolymers. +L]LSVWLK ZWLJPÄ JHSS` MVY rapid processing in particularly cost-effective, continuous mixing processes – using Buss co-kneaders, for instance, or twin-screw extruders. Among other things, the MYLL Å V^PUN NYHU\SLZ are ideal for reducing mixing times when producing particularly high-quality hoses or cable sheathings.
For more info call 0800 006 772 or go to www.plastichem.co.za
BY THE WAY ...
Publisher: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Editorial assistant: Heather Peplow (heather@summitpub.co.za) Financial manager: Lisa Mulligan (lisa@summitpub.co.za) Designer: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za) Bronwen Moys Blinc Design (bronwen.clarke@gmail.com) Summit Publishing cc t: +27 (21) 712 1408 f: 086 519 6089 c: +27 (82) 822 8115 e: saplastics@iafrica.com Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa 70 Newton Drive, Meadowridge, Cape Town
www.saplastics.co.za GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@summitpub.co.za Printed by: Tandym Print, Maitland, Cape Town SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry. The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either. Copyright: All rights reserved. ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902
Plastics Institute 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
Going with the À RZ – Mold In Graphics of the USA, a world leader in the permanent decoration of roto moulded plastic components, has recently taken the technology to the next level with the introduction of the in-mould MIGŽ5 series. Its graphics have proved extremely popular in the kayak and water sports market, with one of the leading international users being Fluid Kayaks of Parys (on the Vaal in South Africa) which has been using the MIG graphics for several years. See page 58
Beware wrap rage IF YOU haven’t heard of it before, wrap rage is on the increase. That’s what happens when the packaging (wrapping) prevents you from opening a product. Not to be confused with road rage, wrap rage can at times be quite serious, not least because the task seems so simple yet one’s every effort is resisted by the pack. According to Charles Muller of PackagingSA, there are now even awards IRU WKH PRVW GLI¿ FXOW WR RSHQ SDFN 7KH ¾ZLQQHUœ RI WKH VXUSULVLQJO\ named Oyster Awards was the Oral-B toothbrush pack, which a lot of VKRSSHUV IRXQG GLI¿ FXOW RU HYHQ LPSRVVLEOH WR RSHQ And the problem gets worse: many people get injured during bouts of wrap rage. In fact we hear that over 1000 people in the UK alone had to receive hospital treatment for injuries suffered just last year. 2QH SUHVXPHV WKH PDLQ VRXUFH RI WKH LQMXULHV LV VHOI LQÀ LFWHG ZRXQGV by weapons used at the height of battle.
Oil’s down ‌ and even lower 5$3,' À XFWXDWLRQV LQ WKH FRPPRGLWLHV PDUNHW HVSHFLDOO\ WKDW RI crude oil, are making it virtually impossible to predict prices for downstream products such as polymers. During July prices for Brent crude dropped to the $56 region, having hovered in the mid-$60s for several months, and then they went even lower, to below $50 during early August. An unexpected change? Well, if you are involved in the polymers market, no. Some analysts aren’t surprised that FUXGH SULFHV KDYH GHFOLQHG VD\LQJ WKDW SULFHV KDYH EHHQ DUWL¿ FLDOO\ propped up for long. But a number of mid-year plant force majeures resulted in shortages of several polymers, which pushed their prices up again. The knock-on effect for polymers users in this case is that prices will probably go down ‌ and then up again.
0LOOLRQDLUHV WDNH à LJKW VXUHO\ QRW" THERE has apparently been an exodus of estimated 8000 dollar millionaires from South Africa over the past 15 years, which – if it’s true – is certainly not a good outcome. But this is the stat that LIO Global & New World Wealth, a private client investment business, UHFHQWO\ SURGXFHG 7KDWœV D ORW RI ZHDOWK\ SHRSOH WDNLQJ À LJKW LQ D relatively short period. According to LIO, however, we are in good FRPSDQ\ &KLQD VDZ WKH ELJJHVW QHW RXWÀ RZ RI GROODU PLOOLRQDLUHV ¹ 91,000 (enia!) – over the same period. A large number of high net worth individuals (HNWI) also departed from India and Russia. The favourite destinations for these individuals – you guessed it – are Australia, the UK, Cyprus, Mauritius, the USA and Canada. But if these stats are to be believed, very few of the exodees from South Africa are from the plastics, composites or rubber markets. Mostly we see the guys sitting tight and ETHING trying to get a good outcome for their AVE SOM IF YOU H ‌ businesses – it’s just not that easy to TO SAY de: if you e bright si up and leave, or what? Look at th wisdom to e gem of have som to us at ease write impart, pl ica.com fr ia s@ saplastic
VOLUME 13 NR 4
REGLOPLAS
AUGUST / SEPTEMBER 2015
Contents Find out more at www.saplastics.co.za
High-performance temperature control units ‌ for large injection moulds, extruders, rollers, autoclaves and other processing equipment
INDUSTRY NEWS
Contents
Serioplast plant up and running in record time MCG tray achieves fruitful solution Turning the tide on marine debris Rugged, reliable Zerma shredder for Boksburg recycler A new name and back in the Haitian game Aerontec À \LQJ KLJK Polymer, additives research encouraged at Tukkies Miracle Mould triumphs with mould using collapsible cores
6 8 10 14 18 20 24 26
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Temperature control units for water up to 90°C
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ASSOCIATION NEWS IOM: Rubber gets boost in the Berg at annual conference 3/$67,&6Ň6$ National Clean-Up and Recycle Week POLYCO: Plans to invest R9 million in recycling projects PSPC: Entrepreneur boosts polystyrene recycling SAVA: Belgotex is 1st Vinyl. product label license holder
44
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MATERIALS & EQUIPMENT Lanxess EVM rubber for reduced mixing times Clariant launches Licocene toolbox for sustainable hot melts Engel awards for innovation Complex plastic parts for the automobile industry
56 66
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84 86
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WORLD NEWS Carbon core passenger cell in new BMW 7 series Lego invests in creating sustainable plastic bricks
฀฀ ฀ ฀ ฀ set-point and actual value
78
฀฀ ฀ ฀ ฀ heating contactor
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MCG Industries has again shown its ability to develop highly effective materials handling solutions with its recent introduction of a specialised tray for dried fruit production. The ¿ QLVKHG P WUD\ LV PRXOGHG LQ 33 ZLWK WKH GHVLJQ allowing for the individual tray bases to be clipped together to form the whole. Only a single mould is required as a result. – Read more on page 8.
www.mcgindustries.com
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JENOWILL SERVICES ฀ ฀ ฀
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THIS ISSUE
Summer soon ‌ All work and no play makes Jack a dull boy! Yes, we all need to be committed at work, but we also need time to enjoy a bit of time off. So why not plan a summer holiday now, it’s only a few months away – you deserve it! The article is actually about the use of TrogamidŽ CX polyamide (from Evonik) for sunglass lenses (see page 16)
Managing in tough climate presents challenges
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COMMENT
T’S COME as a surprise to me that several commentators as well as many citizens out there are surprised to hear that things are going quite nicely at many of the businesses in our industry around the country. As a matter of fact, even some convertors and suppliers DUH VXUSULVHG WR KHDU WKDW RWKHUV DUH GRLQJ ZHOO ¿ QH It’s inevitable that the mood in the workplace will be subdued during tough economic times. But the impression created in the mainstream media, of non-stop gloom, is exaggerated. There’s no doubt that the present climate is very, bordering on extremely, challenging, but it’s exactly at times like this that well-run businesses are DEOH WR ZHDWKHU WKH VWRUPV DQG HYHQ À RXULVK 'XULQJ WKH industry’s heydays, probably in the 1970s and 80s when there was major annual growth and opportunities aplenty, times were good. Well, it’s not like that anymore. Most countries have survived tough times and for us, armed with the materials of choice for the 21st century, there is no reason why we shouldn’t get through it. In this issue we look at some positive initiatives, please read on. A better power outcome Electricity supply is obviously one of the key crisis areas at present, but our customers don’t like to hear of this as an excuse. Rather, it’s up to us to come up with solutions. And the successful convertors are working around the problem. But you won’t get anywhere unless you actively confront the problem: the article on how to deal with power LQWHUUXSWLRQV E\ 'U 5RELQ .HQW DQ $XVWUDOLDQ HQJLQHHU living in England who specialises in energy management in plastics processing, looks at all aspects of the issue (pages 28-30). It’s an interesting article that is well worth studying – it may enable you to minimise the damage from power outages, both in terms of damage to equipment and personnel management and motivation.
Cathedral Peak in June proved to be a positive step for the industrial rubber sector (pages 32-39 'HYHORSPHQW in the rubber sector for most of the past few decades has focused almost entirely on the tyre sector, and rightly so: to the point where the tyre of today is a marvel of physics that, when used properly, keeps many millions of people safe daily ‌ for very little gratitude, actually. 7KDW LQWHQVH 5 ' IRFXV KDV QRZ VKLIWHG WR WKH industrial rubber sector where, combined with enhanced testing capabilities, it is enabling rubber compounders to manufacture noticeably improved materials, which LV GLUHFWO\ DOORZLQJ IRU WKH SURGXFWLRQ RI PRUH HI¿ FLHQW technical rubber items. Congrats to the IOM organisers for putting together a practical event. Newcomer operating in record time May enable :H ¿ QDOO\ KDYH DQ DUWLFOH DERXW RQH RI you to WKH WRSLFV WKDWœV UXIÀ HG PRUH IHDWKHUV minimise than most of late: the entry of Serioplast damage of Italy to the local blow moulding sector comparison (page 6-7). They from power haven’t just arrived; they’ve gone into outages production in arguably record time. Serioplast is working closely with brand holder Unilever and its investment here is a result of that. South Africa’s blow moulding businesses have been working with the brand groups over many years, but in this case it appears it wasn’t good enough. If anything, the brand groups have played the SA convertors off against each other, leading to erosion of margins and at times destructive levels of competition among the convertors. This is a tough topic for the rival container manufacturers, but Serioplast have certainly shown that they know how to get into RSHUDWLRQ HI¿ FLHQWO\ That’s a high standard, and one which we all need to strive for.
Rubber on the comeback trail The Institute of Materials’ National Rubber Conference at Martin Wells
4 AUGUST / SEPTEMBER 2015
, Publisher
INDUSTRY NEWS
Serioplast plant
up and running in record time
The Serioplast management team – Kelvin Mills (centre), managing director of Serioplast SA, with Sarah Soothoane, logistics manager, Justin Mokwatlo, QC manager, Leigh Fitzpatrick, administration manager, and Willem Slabbert, production and technical manager, with one of the company’s Seriomac machines at the new plant in Boksburg
One of the fastest-to-market projects in the local industry ever
6 AUG / SEPT 2015
THE new Serioplast plant in Johannesburg has gone into production in close to record time. After the Italian group won the ‘Operation Waterfall’ tender process conducted by Unilever South Africa, contracts were signed in October 2013 and – just 12 months later – the company went into production in October last year. That is arguably one of the fastest-tomarket greenfields projects in the local plastics converting sectors to date. Containers produced at Serioplast plant are still being transported to the Old Unilever site in Boksburg until the New Unilever Waterfall site is complete and operational, which is located right next door to Serioplast. And we are talking about serious volumes here, something like 420,000 containers a day. The Boksburg plant is involved in extrusion blow moulding, preform injection and injection stretch blow moulding for the production of polyolefin and PET containers. It also handles the labeling of some
containers on an in-line basis, with a high level of automation throughout the plant. It is not involved in closure production, with all caps going direct to the Unilever plant where filling takes place. Many in the industry doubted the ability of European convertors to be competitive with the SA blow moulding groups, possibly due to the potentially high set-up costs have been unable to work as closely with as well as lack of local market knowledge, the brand groups. If anything, the brand but with Serioplast, it’s becoming apparent groups have played the SA convertors off that their systems are extremely efficient against each other, leading to erosion of and they have gotten through the set-up margins for the convertors phase in record time. and at times destructive Achieves A family business from levels of competition. Bergamo north of Milan, in maximum Serioplast’s advantage the foothills of the Alps, Seriproductivity in appears to be its ability to oplast has been in operation apply its plant blueprint to since 1974. It main recipe shortest achieve maximum producappears to be that of closely possible time tivity in the shortest possible supporting brand companies time, on a virtual ‘plug-andand setting up satellite plants play’ basis. The setup of the new plant in the close proximity of the brand groups’ in Boksburg followed exactly the course filling and logistics plants. designed, with some minor changes – By comparison, the South African blow which are in fact improvements, and which moulding businesses have attempted to could potentially be used the Serioplast do this in several instances, but appear to
‘Flower Power’ returns for relaunch ‘FLOWER Power,’ the multi-purpose home DIY tool, failed to fully blossom on its market debut in 2007 and manufacturer Stevetech of Cape Town is now back for the relaunch … wiser and with reinforcements. There were admittedly some shortcomings with the first launch eight years ago, but the Flower Power dream did not disappear and Stevetech ‘Flower Power’ team – Stephen Peterson of Stevetech and Shandene Ontong of Bright Idea Projects 2907 are geared up for the relaunch of the multi-purpose home DIY tool which they say has at least 12 different uses
JUST BRIEFLY Green light for big Hosaf plant expansion
draughtsmen for future development. The group is at present setting up a plant in Cairo as well, and the layout is likely to be very similar if not identical. A further major advantage for Serioplast is that it builds its own machines: its subsidiary SerioMac builds extrusion-blow moulding machines that we understand are on a par with anything on the market. There is also a clear financial advantage in this strategy, with the plus that machine R+D and technology development is on-going at SerioMac, resulting in ready access to highly productive equipment. And probably the cap on top for the local initiative was the appointment of Kelvin Mills to head up the SA operation. Originally in the blow moulding sector,
Mills spent some 10 years in the production of plastic containers before spending a further 10 years in the machine supply sector where he achieved success particularly in the ISBM area. Mills was able to use his experience along with the support of his highly skilled team, in cooperation with the specialists based at Serioplast HQ to optimize plant layout and build, resulting in a highly efficient plant. However, they still strive to improve and optimize on a daily basis in order to remain on top of their game. The result is that Serioplast is employing an entirely South African team at its Boksburg plant, with only occasional visitations from Italy.
proprietor Stephen Petersen, like a true entrepreneur, is unfazed and back for more. Cooperating with Shandene Ontong of Bright Idea Projects 2907 in voluntary work at their church, Petersen realized that more professional marketing was necessary for success with the product introduction. So they went back to the drawing board and completed reformulated the Flower Power presentation. Now the multipurpose tool comes secure on a printed backing card for point of display sale where its many versatile uses are clearly evident. The uses of the ‘Cape’s answer to the Leatherman’ include: unblocking drains; garden sprayer/sprinkler;
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mini garden birdbath; handheld fine sprayer for seedlings; handheld nozzle for carwash/highpressure water jet; fun toy for kids during spring/ summer; wet-and-dry vacuum cleaner (suction or blower) attachment for upper storey apartments to be launched in the near future.
The team has anticipated virtually all possibilities, including the printing of both SA and international barcodes on the point of sale display cards. But more than anything else, the new focus by Stevetech and Bright Idea Projects is at the core of the relaunch, these guys are determined to succeed.
www.flowerpower.web.za
HOSAF is to expand its PET plant in Durban in a R700-million project which will see it virtually double output to a name plate 245,000 tons a year. KAP Industrial Holdings, the owner of Hosaf, gave the go-ahead for the project in May. The additional capacity will enable Hosaf to supply virtually Southern Africa’s entire bottle-grade PET demand, which is a major boost of the local PET container manufacturing sector. The expansion project involves increasing the reactor and polymerization capacity at the plant in Jacobs as well as the addition of major new conveying and storage systems. Hosaf is to use the same Chemtex/ Polymetrix (formerly Bühler) polymerization technology employed throughout the current plant. It previously expanded the operation in 2009, when the plant’s PET output was increased from 60 000 to 128 000 tons per annum. Hosaf is part of the Steinhoff affiliate, KAP Industrial Holdings, which in turn houses a major variety of manufacturing and logistical operations, including Unitrans and PG Bison.
3D printing in ABS, nylon DEMAPLASTECH demonstrated the latest Stratasys ‘FDM’ technology at the Indutec show at Gallagher in May. FDM (Fuse Definition Modelling) allows users to print or ‘grow’ products in alternative materials such as ABS and polyamide (i.e. not solely the proprietary resins supplied by the equipment manufacturer). Jacques Kleynhans of Demaplastech said this development enabled users to produce mouldings in the materials that would ultimately be used. Up till now the 3D prototypes have resembled finished items in every respect … except material characteristic, which is obviously vital for successful application. www.demaplastech.co.za
INDUSTRY NEWS
New MCG tray achieves
fruitful solution Drying tray took seven years to develop MCG Industries has again shown its ability to develop highly effective materials handling solutions with its successful recent introduction of a specialised tray for dried fruit production. Although plastics have often come out tops in the material substitution arena, and in this case the new plastics tray replaces a wooden tray with inherent difficulties, this was still not a simple process: it’s taken the team at MCG Cape Town seven years to the point where they are at last confident that they have a winning solution. Hopefully the seven good years lie ahead. MCG manufactures a wide range of crates, pallets, trays and furniture with new product development being an on-going activity. In 2007, when the opportunity to Wooden trays have been used develop a tray for the dried fruit sector historically to dry fruit, but first came about, it seemed a given that more recently good quality substitution was necessary and obvious. wood has been hard to come But Gerald Kirsten and the MCG team in by and increasingly expensive Montague Gardens, Cape Town, have had to steadily “cross one bridge at a time” in the project. Wooden trays had been used historically, but more recently good quality wood has been hard to come by and increasingly stretchexpensive. Besides that, the wooden trays er too, are seen to harbour bacteria which can and very attack the sliced fruit segments during the suitable for drying operation. The solution to countershifting flat-lying act this has been treatment of fruit with products easily. Sulphur to deter bacterial growth, but the The finished 1.8m sulphur can also affect the flavour of the tray comprises two fruit. Combatting the effect of sulphur also 900mm x 900mm tray bases presented a challenge for the plastic tray, moulded in polypropylene, with and a special additive solution had to be the design allowing for the individual tray developed to eliminate potential erosion. bases to be clipped together to form the Kirsten and MCG production engineer whole. Only a single mould is required as Chris Meintjies hit problems at the outset: a result (a large machine and mould would their tray was substanhave been needed to tially lighter than wood produce the 1.8 x 0.9m “The biggest (7.5kg vs 15kg), but it product, irrespective of advantage of the new couldn’t hold the weight the depth of the item). of the cut fruit. A chance The composite rods are tray is that it allows observation at a schools then threaded lengthfor substantially better rugby game, when one wise into hoops along ventilation.” of the players was carthe outer edges of the ried off on a makeshift joined mouldings. stretcher of canvas suspended between The biggest advantage of the new tray two poles, provided the inspiration for the is that it allows for substantially better tray: their design features two tray bases ventilation. The base of the tray includes suspended between two composite profile two matrixes: a fine mesh set upon a tubes (lighter than aluminum and extremely wider mesh that achieves easier air flow rigid). The new tray is as such virtually a as well as the required rigidity. This allows 8 AUGUST / SEPTEMBER 2015
MCG Industries’ new Max Dry 180 fruit drying tray
for the fruit to have as little contact with the tray surface as possible. The PP tray is also suitable for use in drying ovens, which is an added advantage over the wood tray. Another main advantage of the new tray is that nails are not required, which was a significant problem with the previous solution as the decaying wooden trays often result in metals ending up in the final product which creates a high risk for the producer and seller.
S SUMMARY OF PLUSSE AY TR TIC AS FOR MCG PL
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better ventilation (faster drying of the fruit); no nails (a major plus in the food sector); fruit pieces do not stick to the mesh surface of the trays; easy to hose down and clean (washing wooden trays took far longer); easily replaceable sections
MAX Dry Fruit Drying Tray
Description Fruit Drying Tray Length 905mm Width
Lightweight - 7 kgs
900mm
Height 78mm
,PSURYHG $LUÁRZ due to design
Weight 7kg (2 pieces clipped together to make 1 tray)
Material PP (virgin – food approved)
Rigid
Temperature Range -20oC to 65oC
Washable Stackable Food Safe Environmentally friendly No wood Increased life span
THINK %,* THINK 3/$67,& THINK MCG Sales Enquiries: Gauteng Patrick Munyembate National Sales & Marketing Manager Tel: 011 677 1212 Cell: 072 787 4692 E-Mail: patrickm@mcgind.co.za
Branches: Kwa-Zulu Natal Durban Tel: 031 701 1212 Western Cape Cape Town Tel: 021 551 2310
Marketing Enquiries: Lenie Coetzee Marketing Assistant Tel: 011 677 1204 Cell: 082 896 6177 E-Mail: leniec@mcgind.co.za
INDUSTRY NEWS
Turning the tide on m Ongoing, collective efforts needed to reduce plastic litter in the oceans SOUTH Africa has what it takes to become one of the world leaders in reducing the amount of litter that ends up in our oceans. Speaking at the conclusion of the 2nd African Marine Debris Summit (AMDS) which took place at the SANBI Research Centre in Kirstenbosch, Cape Town recently, sustainability manager at Plastics|SA and convener of the event, John Kieser, said that he was greatly encouraged by the outcomes of the discussions.
“Not only do we possess some of the most beautiful, diverse and dramatic coastlines in the world – teeming with a wide variety of different marine animals – but we also have private individuals, companies, research institutions and government departments who share a passion for protecting our oceans and coasts and are willing to share expertise and take each other’s hands in a concerted effort to protect our marine heritage for future generations”. The aim of this year’s summit, hosted by Plastics|SA in conjunction with UNEP (United Nations Environmental Programme), the Department of Environmental Affairs and SANBI (SA
National Biodiversity Institute), was to facilitate the formation of a Southern African Network on Marine Debris with the long-term goal of establishing an African network that ties into the global management of marine debris. “We acknowledge that plastics are the biggest challenge in reducing the accumulation of marine debris along shorelines, floating on the sea surface and lying on the ocean floor. However, we are committed to turning the tide on marine debris through forming partnerships with the marine fraternity’s programme on quantifying and understanding the drivers of marine litter through support for coastal clean-ups and various research initiatives,”
10 AUGUST / SEPTEMBER 2015
The Plastics|SA team with Prof Christian Bonten – from left, John Kieser, Andrew Murray, Isabelle Brettenny, Anton Hanekom, Loretta Welcomets, Prof Christian Bonten, Zikhona Nokama, Douw Steyn and Jacques Lightfoot
Dr Holly Nel, who is completing her post-doctorate at Rhodes University on microplastic pollution, presented a paper discussing ‘A quantitative analysis of microplastic pollution along the south-eastern coastline of South Africa’ at the Summit
Hayley McLellan (environmental campaigner at Two Oceans Aquarium in Cape Town) and Katja Rockstroh (co-ordinator of the Two Oceans Aquarium International Coastal Clean-Up Day and chairperson of their Green Team). Katja’s presentation discussed the high mortality rate of Loggerhead turtle hatchlings, largely due to ingesting plastic debris. She said there was an estimated 1000 nesting females in South Africa annually. Each of them can lay up to 400 eggs per season (= 400 000 Loggerhead hatchlings). Out of 400 000 hatchlings, only 400 would make it
Dr Michael Taylor, senior director of international affairs and trade at the SPI: The Plastics Industry Trade Association in Washington DC, on which he presented an interesting overview at the summit
marine debris said Kieser. Anton Hanekom, executive director of Plastics|SA highlighted the importance of supporting platforms where different countries, industries and experts can share lessons learned, strategies and best practices to reduce and prevent the impact of marine debris. The exchange of innovative ideas on topics such as plastics recycling initiatives and communications strategies contributes to scaling up successful approaches to reducing marine debris. This year’s Summit attracted representatives from as far afield as Kenya, the Seychelles, Washington DC and Germany, not to mention more than 80 delegates. The 2nd African Marine Debris Summit once again highlighted that most of the litter that reaches SA’s marine environment originates from actions on land. Keynote speaker, Prof Christian Bonten, director of the Institute for Plastics Engineering at the Stuttgart University in Germany, presented evidence that the eco-efficiency of plastic products is often superior to products made of paper or jute! “The British Environment Agency performed a Life Cycle Analysis (LCA)
of different kinds of carrier bags. It was revealed that paper bags need to be re-used 3 times and jute bags 131 times more often to catch up ecologically with a standard single used plastic bag made from PE-HD,” he said. “In Germany, a multiuse plastic bag is reused only 2,5 times. Nevertheless, this means that a paper bag needs to be reused 7,5 times and a jute bag needs to be re-used 328 times (without washing it), to catch up ecologically.” (www.biodeg.org) Prof Bonten went on to say that biobased plastics “are helping prepare the world and society for a post-petroleum era”. Bio-based plastics are based on polymers derived entirely from renewable resources (biomass). It is important to understand that bio-based polymers are not always biodegradable and biodegradable polymers are not always bio-based. Bio-based plastics made from renewable resources can offer similar, additional or even better functionality depending on its composition. The use of renewable resources as feedstock in the production of bio-based materials is seen as a way of reducing the dependency on fossil resources. >>
“Bio-based plastics are helping to prepare the world for a postpetroleum era”
Dr Jude Bijoux, a fisheries biologist at the Seychelles Fishing Authority and South African Institute for Aquatic Biodiversity. His presentation highlighted how drifting Fish Aggregating Devices (FADs) used by the tuna fisheries in the Indian and Atlantic oceans were a major cause of marine debris along the Seychelles coast. The FADs are made of nylon and plastics and the cost of their removal can be substantial. Dr Bijoux said that studies had shown that 10% of all FADs end up on beaches – a total of 1500 – 2000 FADs a year
Prof Christian Bonten, director of the Institutefor Plastics Engineering at the Stuttgart University in Germany, presented the Summit’s keynote address on the second day. He presented evidence that the eco-efficiency of plastic products is often superior to products made of paper or jute
Prof Peter Ryan, director of the Percy Fitzpatrick Institute for Ornithology at the University of Cape Town spoke about the ‘State of marine Debris in Africa’ – an eye-opening perspective on the extent of the marine debris issue along our South African coast
Karin Minnaar, a PhD student at the University of the North-West in Potchefstroom, is studying the effects of plastic debris and microplastic particles in our oceans. Her presentation on ‘Plastic debris beached on three coral reef islands in the Indian Ocean’ discussed the reasons why the most common debris on three remote Mascerene islands were plastic fragments, plastic bottles and bottle caps, most of which came from distant locations and were potentially hazardous to local ecosystems
AUG / SEPT 2015 11
Rowan le Roux, sustainability manager at Polyoak Packaging and Monique Holzhausen of AIM Marketing
www.africanmarinedebris.com
Heidi Savelli of the United Nations Environment Programme’s (UNEP) marine litter network delivers her keynote speech. UNEP’s Regional Seas Coordinating Office and the Global Programme of Action (GPA) have embarked on the development of a ‘global initiative on marine litter’. Although marine litter is found in all oceans and sea areas of the world, this proposed initiative would concentrate, among others, on the establishment and development of pilot regional activities in regions that are particularly affected. The global initiative would also provide a global platform for the establishment of partnerships, co-operation and co-ordination of activities for the control and sustainable management of marine litter. Read more at www.unep.org/ regionalseas/marinelitter.asp
The summit ended with a cocktail party and awards ceremony onboard the Department of Environment Affairs’ research vessel, SA Agulhas II. Pictured at the function were Cheri Scholtz (PETCO), Douw Steyn (Plastics|SA), Wayne Munger (Ezemvelo KZN Wildlife), John Kieser (sustainability manager at Plastics|SA), Charles Jullies (DPI Plastics) and Karin Minnaar (NWU). The awards were presented by Plastics/SA’s John Kieser to PETCO, Pick ‘n Pay, DPI Plastics and KZN Ezemvelo Wildlife for their continued support over the past few years to remove plastic litter from the marine environment, through supporting events such as the International Coastal Clean-Up Day and other beach clean-ups
INDUSTRY NEWS
Deputy Minister of Arts and Culture (previously Deputy Minister of Environmental Affairs) Rejoice Mabudafhasi with Anton Hannekom, CEO of Plastics/SA. The Summit was officially opened by the Honourable Rejoice Mabudafhasi, who said that she supported the Summit wholeheartedly. “International cooperation is necessary to create public awareness, while developing ways to decrease the amount of debris in oceans around the globe,” she said.
What to do about reducing packaging waste? CHARLES Muller, executive director of PackagingSA, spoke about what the paper and packaging sector intended to do about reducing packaging waste. He said the Paper and Packaging Industry Waste Plan aimed to be industry managed with its primary objectives being to maximise diversion from landfill, provide industry with a steady stream of good quality recyclables and to reduce resource consumption. He emphasised that it was important to develop new recyclable collection systems and to support municipalities in their efforts, as well as to develop labour intensive models to handle and sort recyclable materials, specifically through MRF’s and to develop markets to absorb the various recyclables collected. The plan would also encourage entrepreneurship and obligatory membership of a Product Responsibility Organisation. “The industry is of the opinion that it should be a priority to finalise and implement a waste plan and once
12 AUGUST / SEPTEMBER 2015
in operation consider what economic instruments would best address any shortcomings that might emerge.” However, he pointed out that the recently gazetted Pricing Strategy discussion document proposed that the EPR scheme becomes ‘government managed’. EPR schemes will have two years to align their funding models to the Pricing Strategy. This implies there will be a SARS collected tax, which concerns PackagingSA. “We have formally responded to the Gazette notice and await feedback from the DEA. We have some concerns that with increased government intervention and regulation, including the imposition of SARS collected waste management charges or taxes the paper and packaging industry may abdicate responsibility as industry members are unlikely to pay twice ie. both a voluntary levy as well as a mandatory tax.” Charles also said that there was concern that the many voluntary and successful initiatives, particularly those of the seven
mainstream material organisations, may collapse. “These organisations are all funded through voluntary contributions. Current funding models generally collect upfront, thus delays in funding will see the disintegration of important projects.” Charles added that industry was also concerned that there would be a regression of recycling rates, as international evidence suggests. In Hungary in 2012 recycling rates dropped dramatically from 59% to 49% after the state took over control from privately run Product Responsibility Organisations.
www.packagingsa.co.za
Rugged, reliable Zerma shredder
Not just rugged good looks! Ashley Shub of Polyethylene Recoveries and Jeff Cawcutt of Maritime Marketing with the impressive Zerma ZSS1200, infeed conveyor with metal detector and discharge conveyor. The new shredder has enabled Polyethylene Recoveries to increase its production on solids by 30%
for Boksburg recycler
INDUSTRY NEWS
Production on solids waste increased by 30% POLYETHYLENE Recoveries – a full the plastic Industry have increased considservice plastic recycler specialising in erably in the past 20 months. As a result post-consumer and post-industrial plastics we decided to upgrade our equipment by recycling – recently commissioned a rugpurchasing an additional shredder. We ged and reliable Zerma chose Zerma because shredder to cope with the of its rugged construc‘Some of the solids increased amount of solid tion and reliability, that we have fed into plastics waste it is receivand the wide range of ing from industry. auxiliary equipment this new shredder Polyethylene Recoveroffered by Zerma for have weighed up ies offers a nationwide efficient recycling,” said to 500kg’ service, recycling LDPE, Ashley Shub, managing LLDPE, PP and HDPE director of Polyethylene at its factory in Boksburg where the plastics Recoveries. waste is processed with state of the art The Zerma ZSS-1200 single-shaft shredequipment and technology. der, with heavy-duty infeed conveyor with “The volumes of large polymer lumps integrated metal detector and discharge supplied to Polyethylene Recoveries from conveyor has enabled Polyethylene Recov-
eries to increase its production on solids by an additional 30%. “Some of the solids that we have fed into this new shredder have weighed up to 500kg!” Shub said. The Zerma ZSS-1200 is the first piece of Zerma equipment that Polyethylene Recoveries has invested in. “It’s an excellent piece of machinery and we are extremely happy with it,” Shub added. • ZERMA IS REPRESENTED BY MARITIME MARKETING, TEL: 011 466 1717 www.marimark.co.za www.perecoveries.co.za
BASF in South Africa hosts unique urban space concept exhibition BASF in South Africa hosted its first South Africa & Sub-Saharan ‘Africa Day’ in June aimed at engaging with key stakeholders around global topical issues as well as the broad range of products that the global chemical company offers for every day solutions.
Under the theme ‘Connecting to create chemistry’, the company launched its unique urban space concept exhibition which was attended by over 200 customers, product distributors, members of the media, South African government representatives and BASF colleagues from Europe and Sub-Saharan Africa. The 500m2 exhibition space was divided into living areas applicable to the product offerings. With BASF having recently opened business hubs and production sites in East and West Africa, business experiences of the company in the sub-Saharan markets were shared with visitors. www.basf.co.za The 500m2 exhibition space was divided into living areas applicable to the product offerings. For example here, in the ‘garage’ space, visitors were shown the broad range of solutions applicable to the automotive industry 14 AUG / SEPT 2015
The Lula1000, one of the few manned submersibles in the world that can descend to 1000m to carry out research work. The centerpiece of the ‘Lula1000’ submarine is the Plexiglas® observation dome, manufactured by Evonik
Evonik supports
deep sea exploration
INDUSTRY NEWS
Scientists discover unknown species through Plexiglas® observation dome EVONIK Industries AG, Essen (Germany), will continue supporting the Rebikoff-Niggeler Foundation for two more years. The cooperation between the specialty chemicals company Evonik and the Azoresbased foundation, which began in 2013, has been extended until 2018 prior to the expiration of the current contract. Rebikoff-Niggeler operates one of the few manned submersibles in the world that is able to descend to a depth of 1000m to carry out research work. The centrepiece of the ‘Lula1000’ submarine is the Plexiglas® observation dome that Evonik manufactured. Klaus Engel, chairman of the executive board of Evonik, referred to the past successes of the foundation as a reason for extending the support to what will now be five years. “With our long-term commitment to this work, Evonik wants to contribute to ensuring that research can continue in the fascinating and precious deep sea living environment.”
Over the past years, Kirsten and Joachim Jakobsen, the German couple who are behind the Foundation, have made hundreds of hours of high-resolution films and collected numerous samples from the deep sea around the Azores islands of Faial and Pico. On many occasions, they have been able to document species that were completely unknown, or for which very little information was available before. Their discoveries include the only known living coral reef in the Azores and a more than 500-year-old Neopycnodonte zibrowii deep sea oyster, which is regarded as the oldest living animal in the world. They are pursuing the main aim of their project – to film a giant squid in its natural environment – with passion. Special lighting systems and a feed syringe have been installed on Lula1000 to entice the largely unknown giant of the deep sea. The Plexiglas® observation dome plays a key role in these manned exploratory journeys to the depths of the ocean. Evonik
used a special process to manufacture and shape the 1.40m diameter viewing dome. Plexiglas is not only much more robust than glass, its optical qualities are also superior. The innovative process that Evonik used for the dome of Lula1000 has been further developed and is now in demand among producers of deep sea submersibles. The manned research submarine Jago is now also equipped with a Plexiglas observation dome. Jago belongs to Geomar, the Helmholtz Centre for Ocean Research in Kiel, Germany. US submarine producer Triton also now installs Plexiglas spheres. These spheres are constructed from two hemispheres that are joined (virtually invisible to the eye) by an adhesive which was also developed by Evonik. www.eonik.com www.lula1000.org
16 AUG / SEPT 2015
Sunglasses made of ‘unbreakable’ plastic HIGH-performance polymers such as Trogamid® are making sunglasses highly durable and world-renowned brands are taking advantage of this benefit. Sunglasses have to withstand enormous stresses. Sunglass frames and lenses made of high-quality materials such as Trogamid® CX don’t become brittle or hard, but consistently maintain their quality.
“Our high-end material is ideally suited for designers”, explained Klaus Hülsmann of Evonik Industries, which manufactures the plastic. “It offers a wide range of creative choices, as the material is flexible yet extremely resistant.” Since the substance is also transparent, it can be tinted in any imaginable colour. It is flexible, virtually indestructible, and allows for highly delicate processing. Tests performed by the TÜV Rheinland testing institute have demonstrated just how sturdy the plastic made by Evonik really is. Some test series involved bouncing steel balls off Trogamid lenses – without leaving a trace of damage. Such tests are crucial to determine
the breakage safety of lenses, for example during sports, when a ball may hit a pair of glasses. Breaking glass or splintering plastic lenses would be disastrous in that case. Lighter glasses made of the non-allergenic Trogamid are also associated with fewer problems. A growing number of manufacturers use the material for their production of glasses. “We keep a few models such as Porsche Design P‘8592 by Rodenstock in our assortment that has temples made of Trogamind. The flexibility is nothing short of impressive,” he says. www.evonik.com
INDUSTRY NEWS
Totsiens to lead in PVC pipes AS of the end of July, all manufacturers of SABS approved water pipes are lead-free. The PVC pipe manufacturers around the country have undertaken to make the change, which is in line with a global trend to omit lead from the compound used, and are instead using eco-friendly stabilizer packages in production. It is possible that pipe containing lead will still be produced, but such pipe will not be able to use the SABS approval stamp.
City saving water
JUST BRIEFLY
THE city of Cape Town is saving an estimated 42,000kilo-litres of water daily (enough to fill 17 Olympic-size swimming pools) as a result of its reinvigorated water system maintenance programme. There was a reduction in pipe bursts to 2330 from July 2014 to May this year, 614 fewer than in the same period a year before. That translates to a rate of 24 bursts per 100km of pipe in 2014/15 compared to 31 per 100km. The city’s municipality said in a statement that this was due to its pipe replacement programme (in most cases with plastic pipe) and pressure management initiatives.
Mpact share on a high Mpact’s share price hit a record high of R46,84 on the JSE in July after the group said its first-half profit would increase by as much as 51 percent. The stock jumped by as much as 10 percent on the day of the announcement, 23 July. That’s the highest it’s achieved since the plastic and paper packaging business was unbundled from parent group Mondi in 2011. It said the good figures were a result of improved trading conditions and a lower effective tax rate.
SA Leisure, Winplas have found buyers IT APPEARS that both SA Leisure and Winplas, until recently two of the country’s top converting businesses, have found buyers after encountering difficult trading situations. Based at Isithebe on the KZN North Coast, where it manufactures a range of furniture and housewares, SA Leisure was for long considered one of South Africa’s top plastic convertors. Unconfirmed reports suggests it has been purchased by one of its main rivals, although the terms of the acquisition may be complex. Winplas, operating plants in Alrode in Johannesburg and Beaconvale in Cape Town, was likewise one of SA’s top PET container manufacturers. Rumours swirled that it was about to be bought by one of the national groups, but it is now thought that it has been purchased by a player from outside of the existing market. 18 AUG / SEPT 2015
Were they ever gone? – George Ferreira senior and junior with some of the recently landed Haitian injection machines at the company’s premises in Spartan; they are relishing their role as the Haitian agent in Southern Africa again
George Ferreira Plastics: A new name and back in the Haitian game The George Ferreiras resume Haitian agency, take up where they left off in 2013 THE George Ferreiras have picked up seamlessly where they left off in 2013 when, quite unexpectedly, they lost the agency for Haitian injection moulding machines. Earlier this year, and equally unexpectedly, they were reappointed as the agent for the Chinese machine manufacturer … and just as amazingly, sales of the machines have picked up simultaneously. Up until the 2013 change, GF Plastic Machinery Services had supplied a large number of the Haitian machines to convertors around southern African. The unforeseen change – when Haitian decided to open its own sales office in Johannesburg – created a difficult situation for the company. Overnight it had lost the core of its business. But the canny Ferreira senior busied himself with other activities and started supplying a variety of other production systems, including the Yoison ISBM machines for PET containers. Without specific anticipation, the Ferreiras waited in the wings, suspecting that lack of local knowledge would prove difficult for the Chinese sales technicians
sent out to man the local Haitian depot. Opening the office in Johannesburg was in line with Haitian’s strategy to operate its own sales offices globally. Then, earlier this year, acting just as swiftly as it did when implementing the strategy, Haitian did a 180° about turn and reverted to its previous agent, since aptly renamed George Ferreira Plastics (the previous name was too long). George Jnr has been with the company for 12 years, learning the ropes, and his ‘apprenticeship’ is now complete, according to George Snr. “He has attained all the skills needed to meet the stringent needs to deal nicely with both customers and suppliers,” said the senior partner recently. George Jnr recently managed his first official shipment of Haitians, a major order of 24 machines, most of which have already been sold and commissioned. Now as the CEO, George Snr will concentrate on new supplier developments and focus on the ever advancing technical developments in the injection moulding area by Haitian.
Aston Martin reveals carbon fibre powerboat QUINTESSENCE Yachts and Aston Martin have revealed more details of the first Aston Martin powerboat, which will be completed in September. Both models will be built out of an epoxy resin composite hull, with structural elements made of carbon fibre. The deck reportedly consists of three carbon panels which can be operated by the electronic command of the AM37 key, folding under the aft deck to uncover the cockpit. The AM37 will be available in two models, reaching top speeds of around 44 and 52 knots.
www.advancedpolymers.co.za Johannesburg Sales: Kwazulu Natal Sales: Eastern Cape Sales: Cape Town Sales:
+27 11 397 7979 +27 31 700 4372 +27 31 700 4372 +27 21 552 0477
Stephanie Cameron: stephanie@advancedpolymers.co.za Nikki Esterhuizen: nikki@advancedpolymers.co.za Nikki Esterhuizen: nikki@advancedpolymers.co.za Thea Strydom: thea@advancedpolymers.co.za
PRIME & RECYCLE COMPOUND PRODUCTION
Compounding the world
INDUSTRY NEWS
Aerontec flying high! First and only composites company in SA to be awarded AS9120 accreditation from receipt until delivery. COMPOSITE materials and technology supplier and distributor, Aerontec, has been awarded Evidence of conformance – specific docuAS9120 accreditation – becoming the first and only ments are required by distributors as evidence of composite supply company in South Africa to be conformance. AS9120 defines those requirements. accredited with this prestigious, international quality “We will strive to uphold this prestigious certificamanagement system. tion and improve our service continually to ensure The AS9120 accreditation addresses chain we supply our customers with this international first of custody, traceability, control and availability of class service and the best products at our disposal,” records. Based on ISO 9001:2000, but with nearly said Aerontec’s Graham Blyth. 100 additional requirements specific to aerospace Graham explained that by aligning Aerontec’s distributors, AS9120 provides suppliers with a quality management systems with the AS9120, comprehensive quality system focused on areas the company not only reaps quality and efficiency directly impacting product safety and reliability benefits, but also is better able to meet customer including: expectations. AS9120 accreditation can also provide a competitive advantage by identifying opportunities Splitting – specific requirements for batch for operational improvements and cost reduction splitting and lot splitting, and how conformance to Graham Blyth, Aerontec owner, within the company, improved audit and surveillance specification is maintained. says the AS9120 accreditation will reap many benefits for both efficiency, enhanced performance due to higher Airworthiness certificates – defines the the company and its customers quality products, and a customer satisfaction focus. documents issued by civil aviation authorities that Aerontec were also recently awarded their certifies that parts meet the required airworthiness ISO9001:2008 accreditation. requirements. “We’re very proud and are committed to providing service levels Control of records – record requirements differ significantly that meet and exceed our customers’ expectations,” Graham added. for distributors of aerospace products. AS9120 defines those requirements. www.aerontec.co.za Traceability – defines specific requirements for traceability
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20 AUGUST / SEPTEMBER 2015
concludes significant multi-year contract ASTRAPAK has concluded a multi-year supply agreement in a significant partnership deal with one of South Africa’s largest FMCG companies. This will see the plastic packaging company supply a major portion of their personal care and food packaging requirements. The combined investment is R170m. The supply agreement will involve the operations of three of Astrapak’s manufacturing facilities – Plastop KZN (using state-of-the-art injection blow moulding and extrusion blow-moulding technologies), JJ Precision Plastics (the centre of injection blow-moulding excellence for Astrapak) and Marcom Plastics (thin walled injection moulding and in-mould labelling specialists). Astrapak’s Account Executive, Dave Tyler, said: “This agreement solidifies the long-term partnership between the two companies and shows Astrapak’s commitment to supply innovative, high-quality
plastic packaging solutions to our blue chip clients.” CEO for Astrapak, Robin Moore, thanked all those who were involved in the negotiation process and commended them on their efforts. He added; “This has been a very complex negotiation, which has required professionalism and goodwill on all sides. It involves three of our major operations and requires investment behind all our core moulding technologies. We firmly believe this contract is “win-win” for both parties, which re-affirms our leading position in our core technologies and the personal care and foods end markets.” For Astrapak, this is a major milestone in their future strategy, and confirms the strategic decision made by the plastic packaging manufacturer to embed themselves as a major player in the fast moving consumer goods sector in their chosen technologies. www.astrapak.co.za
Rob Moore, CEO for Astrapak AUGUST / SEPTEMBER 2015 21
PVC Toll Manufacturing Grace is a premier multinational specialty chemicals and materials manufacturing company, known for experienced people, global reach and strong customer relationships. For more than 50 years W R Grace Africa (Pty) Ltd has been supplying the African market with food grade PVC products, in addition to many other food, beverage and general line products. We are looking to expand our PVC product range and are therefore offering a toll manufacturing service for your PVC products with our certified ISO 9001:2008 extrusion plant at our Bellville site in Cape Town.
CONTACT US Please feel free to contact Cedric van Zyl or Kevin Weber to discuss your requirements. Email: cedric.vanzyl@grace.com / kevin.weber@grace.com | Tel: +27 21 951 7011 GRACE®, is a trademark, registered in the United States and/or other countries, of W. R. Grace & Co.-Conn. Talent | Technology | Trust is a trademark of W. R. Grace & Co.-Conn.
TECHNICAL
Answering all your questions about materials management – Storage, drying, conveying, dosing and mixing – all these processes have an important part to play in the handling of raw materials for the production of plastics. And while a handful of specialists may be well versed in the technical ins-and-outs and know all the cost-saving tricks, there are plenty of us for whom certain aspects of materials management remain a mystery. The problem is understanding the main principles of these processes, for example; why is dew-point so important for drying, or what is the difference between synchronous and asynchronous dosing? In Mo’s Corner, we will tackle these troublesome terms and complicated concepts. What’s more, we will answer your questions about real-world issues you face in your day-today work. Mo’s Corner will shine a light on the intricacies of materials management, helping processors to get to the bottom of even the trickiest topics. The goal is to define terms in clear language, explain the underlying technology, and provide practical tips for working with the relevant systems. If you have a question – ask Mo by emailing askmo@moscorner.com
What is meant by ‘dosing’ in the context of injection moulding? Mo explains: Dosing is a way of combining two or more components in the right ratio
THE great benefit of plastic is its versatility and flexibility. By altering ingredients and additives, you can create precisely the right compound for a given application – changing the material’s mechanical properties, resistance to chemicals or its colour. There is a downside to these possibilities, however. On the one hand, because there is such a vast array of ingredients to choose from, it makes little economic sense for the raw materials industry to individually customise their offerings to the many diverse wishes of plastics processors – especially as the lot sizes they want to buy continue to shrink. On the other hand, plastics processors are faced with demands from their end customers, who in light of ever-shorter product lifecycles are clamouring for new materials to be made available rapidly. The solution? Plastics processors can either buy readymade compounds or create them themselves.
Readymade compounds are usually not the most cost-effective solution, as a premium is often charged for small lot quantities. Moreover, they leave little wiggle room if you want to change the composition at short notice. For greater flexibility, it makes sense to mix the material yourself. There are two ways to do this: blend the recipe centrally (manually or automated) or dose and mix directly at the throat of the processing machine (automated). Whichever method you choose, it is imperative that you follow the recipe to the letter: all quantities and ratios must be exactly right. When mixing the recipe manually, the individual components are weighed by hand before being combined often with a cement mixer. On the face of it, there is nothing wrong with this method. But there are serious drawbacks – in terms of wastage and material segregation issues, for example. It can be difficult to correctly estimate how much of the mix you will ulti-
22 AUGUST / SEPTEMBER 2015
Contact us: Address: Unit 6B Coveway Industrial Park, Hammersdale, 3700 Tel: 031 736 1055/56 | Fax: 031 736 1054 Gabriel: 084 446 6384 | Nikieta: 083 229 7161 Email: gabriel@inkuluplastics.co.za
I.P.P Inkulu Plastic Pipes (Pty) Ltd Quality Pipe Manufacturers of HDPE pipe
mately need. And if you get the recipe wrong, you can be left with a significant amount of expensive but useless leftovers. In contrast, working automatically at the throat of the processing machine offers multiple advantages. It allows you to mix recipes on demand and at short notice, changing the recipe is quick and easy, and results are visibly fast. Surplus material is kept to a minimum, and recipes can be easily reproduced. Dosing is an essential stage of this process – combining two or more components in precisely the right ratio. Whether the ingredients are granules, powders, paste or liquid, a number of basic principles apply. A dosing device in the dosing and mixing unit draws an exact amount of material from a supply hopper or similar container and transfers it to a reservoir or directly into the throat of the processing machine. Because it is responsible for measuring the ingredients with pinpoint precision, the dosing device plays a crucial role in the final outcome. The choice of dosing device depends on the type of material and its properties. As solids tend to be the preferred material for injection moulding, the metering device must be able to dose granules, micro-granules or powders. A number of material properties must be taken into account. Rheology – that is, how the ingredient flows – is particularly important: powder can, for example, be free-flowing, sticky or can fluidise. In addition, granules can be rigid or flexible, and they
can be brittle and easily damaged. Regrind has its own dosing issues as it usually lacks a uniform consistency and contains more dust. Dosing screws are suitable for the vast majority of applications. Other forms of dosing devices include cone valves, disc dosing elements, slide-gate valves, dosing chambers and rotary valves. One dosing device that will be familiar to everyone is the measuring cup used for baking. And just as in baking, one rule matters above all else – whatever you are manufacturing, accuracy is everything: components must be measured with 100% precision. Further important factors include whether the dosing system is volumetric or gravimetric, and how the ingredients are mixed – these points and many more will be explained by Mo in more detail in upcoming columns. • MOTAN COLORTRONIC IS REPRESENTED IN SOUTH AFRICA BY MARITIME MARKETING
www.motan.com www.marimark.co.za
AUGUST / SEPTEMBER 2015 23
INTAREMA The e ne new w sy syst stem st em g gen eneration from EREMA.
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Relloy S.A. (Pty) Ltd / 27 Mopedi Road Sebenza / Evendale, 1609 / Gauteng Tel: +27 11 452 3724 / dean@relloy.co.za www.relloy.co.za
TRAINING
info@vactech.co.za
0861 VACTEC (822 832)
www.vactech.co.za
Polymer, additives research
encouraged at Tukkies Pretoria centre collaborates with Algerian university
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THE University of Pretoria is running an active programme of polymer research in which students are encouraged to look into the potential of naturally sourced compounds. The programme, which offers post-graduate degrees with specialization in polymer materials engineering, is coordinated by Prof Walter Focke, director of the Institute of Applied Materials in the Department of Chemical Engineering, University of Pretoria. Prof Focke, who obtained his PhD in Polymer Engineering from the Massachusetts Institute of Technology, is actively researching functional additives based
on nanoparticles. A major focus is on the application of polymer systems for the controlled released of insecticides and repellents in the fight against malaria. Prof Focke is also active at Xyris Technology of Pretoria, a specialized masterbatch supplier which operates manufacturing operations to the east of the city. Experience gained in industry is obviously useful in the learning environment and Focke’s role is partly thus to convey ‘hands-on’ experience in the area of additives for fire retardance, insecticides, repellents, volatile corrosion inhibitors and purging compounds for plastics machinery as well as other aspects of polymers
Intro course on packaging technology )XOO UDQJH RI VLQJOH GRXEOH VWDJH VLGH FKDQQHO EORZHUV 5RRWV EORZHUV available
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info@vactech.co.za 0861-VACTECH (822 832)
THE Institute of Packaging (SA) now offers an Introduction to Packaging Technology certificate course launched in Johannesburg in mid-2015. The course is aimed at those persons who are new to the packaging field and allied industries, who have little or no previous knowledge of packaging. They would not typically have had much, if any, technical schooling, packaging background or experience. Students would probably be working in a packaging environment where theoretical and practical packaging knowledge would be beneficial to them and their employer (e.g. trainee packaging technologist, machine operator, packaging line team leader, packaging material salesman, packaging material buyer, logistics controller or supervisor, or packaging material laboratory or QC assistant.) The course would also be suitable for persons very new to packaging - for
example, school leavers interested in this field as a possible vocation, or perhaps newly recruited employees or first time workers. It is very practical and hands on in its approach. This introductory course will complement and provide a ‘stepping stone’ course to the Institute’s long-running One-Year Diploma Course in Packaging Technology, and the Advanced Packaging Technology course which builds on the latter. These three courses now offer a comprehensive packaging learning ‘ladder’. • Enrolments are now open. For further detail contact the national education officer at email: education@ipsa.org.za, or tel: 041 379 5599, or visit the Institute’s website. www.ipsa.org.za
Composites workshop by DTI on 2 Oct THE topic ‘composites’ is surfacing more and more across the various manufacturing sectors. To understand the overall need and the opportunities regarding the local market, the African market and the broader export market, the Department of Trade and Industry is organising the first Composites Workshop facilitated by the Advanced Manufacturing/ Composites sector desk. The preliminary date for this workshop 24 AUGUST / SEPTEMBER 2015
in Pretoria is Friday, 2 October. Although the official programme is yet to be finalised, likely topics are designation of locally made composite products for local use; local raw material production; industrial classification codes; skills development; standards and specifications; growth strategies; etc. • For more details, contact Kjelt van Rijswijk at email: Kjeltvr@gmail.com
product performance. A polymer research workshop was conducted in May at which students were able to present their research findings into the development of novel FRs, in some cases using renewable materials. One of the papers, for example, looked at the use of Phalaborwa vermiculite in the production of FRs. Prof Mustapha Kaci of the University of Algiers was a guest at the workshop. He collaborates on research dealing with biopolymer nanocomposties based on modified clays from Algeria and South Africa. He was invited to assist with the assessment of the presentations. Algeria, which is the largest country in Africa, has similarities to South Africa in that it too has a high incidence of UV light, which tests plastic products severely. Algerian students face challenges similar to those of students at the southern tip of Africa, in that polymer science is often a wholly new area for them, but this can also be used as a positive in that the students are not restricted by convention.
Both the assessors encouraged the young researchers to be more specific with their research (to give precise additional levels, for instance), but at the same time to also pursue their investigations with enthusiasm and look beyond conventional strategies. The BSc Honours programme in the Department of Chemical Engineering, with specialization in polymers and advanced materials, offers the following courses: Product Design Polymer Materials Science Polymer Processing Additive Technology Fluoro-Materials Science Carbon Materials Science & Technology Particle Technology Chemical Engineeering research project
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The courses are offered in a block format that makes it easy for persons in industry to attend and improve their qualifications.
Prof Walter Focke of Xyris Technology with Prof Mustapha Kaci of Algeria and Dr Herminio Muiambo of Eduardo Mondlane University, Maputo, who presented a research paper at the workshop
• FOR MORE INFO, CONTACT PROF WALTER W FOCKE, DIRECTOR: INSTITUTE OF APPLIED MATERIALS, E-MAIL: WALTER.FOCKE@UP.AC.ZA
AUGUST / SEPTEMBER 2015 25
G for food contact compliance N I T S E T Our ThermoScientific ‘Trace’ 1310 chromatograph allows us to test all packaging materials for food grade compatibility. Forward samples of packaging materials – including films, containers, closures, pouches and any other plastic or composite material that is used for the packaging of food substances or beverages – to us and we conduct full testing to European Regulation No 10/2011 amended as No 1282/2011.
Roediger Agencies cc Analytical Laboratory ● Identification of unknowns ● Additive analysis ● Chemical properties ● Physical properties ● Weathering services www.roedigeragencies.co.za
Contact: Dr Andy Roediger t. 021 887 0010 f. 021 886 4731 e. Andy@roedigeragencies.co.za
A large injection machine, in this case a 780-ton clamp force unit, was used to produce the cylindrical parts
Setting up – The collapsible cores are operated hydraulically; here we see an hydraulic valve being inserted
Complex construction – The collapsible cores form the inside diameter of the hollow part (pipe) and need to be withdrawn before the moulded part can be ejected
Miracle Mould triumphs with mould using collapsible cores Complex solution for mass production of injection moulded components with severe undercuts MIRACLE Mould International of Durban was recently approached by an ablution alternative manufacturer and asked to build an injection mould for a non-standard pee trap. The finished moulded component has an inlet diameter of 75mm with integral seal grooves and an outlet diameter of 110mm. After inspecting the component drawing supplied by the customer, it was clear that the component would require a total redesign to enable mass production by injection moulding. Miracle Mould provided concept sketches and then appointed a product designer
to create 3D models to grow prototypes for functional tests to be completed. Once the 3D models where complete, MMI commissioned its prototype division to grow samples in China. This was done with short lead times and competitive costing. Once the prototype had been tested the mould design was completed. The challenges associated with a mould of this nature are the very complex collapsible core locking and extractions. Previously these types of moulds were only really catered for by European mould makers.
“It is fair to say that that although the mould was designed by Miracle Mould International, the collapsible core technology is a prior art developed by mould makers over many years in Europe,” said Brian Almanza of MMI. Miracle Mould has a policy that dictates that before a mould is designed, it is established where the moulds have been made historically by whom and how. This process ensures that the best available design principles are incorporated into the final mould design. Another fine example is the thin walled mould designs. These
26 AUGUST / SEPTEMBER 2015
+27 (0)31 765 5720 0086 151 685 69018 +27 (0)82 821 4775 brian.miraclemould@gmail.com
INDUSTRY NEWS
The appearance of the mouldings belies the complex process involved in their production
Brian Almanza of Miracle Mould and Environsan’s Brian Lewis with one of the first components produced on the system. The sanitary moulding has non-standard dimensions, an inlet diameter of 75mm with integral seal grooves and an outlet diameter of 110m, which meant that collapsible cores were essential (in order to withdraw the mould core from the interior of the part)
moulds have been made in Europe for a very long time and there is a wealth of knowledge to tap into. Since the pee trap project, Miracle Mould International has produced a lot of these types of moulds and has a collection of happy customers that are growing.
ü Brian Almanza of Miracle Mould ensures
that all moulds supplied to customers are commissioned in his presence. He was the founder of the Durban company Plasmould Plastics, a successful ISO 2001-certified moulding company, and has approximately 37 years’ experience in engineering moulding. The collapsible cores used in the recent project by Miracle Mould make use of a prior ingenious technology which allows for the production of components with severe moulded undercuts by injection moulding (as well as other challenging sections such as internal thread protrusions and cut-outs)
www.miraclemould.com
AUGUST / SEPTEMBER 2015 27
INDUSTRY NEWS
Dealing with power interruptions Power outages are a reality: minimizing damage and getting back into production ASAP are the sole objectives BY DR ROBIN KENT: POWER MANAGEMENT SPECIALIST, TANGRAM, UNITED KINGDOM SOUTH Africa currently sufcondition for re-start; fers from ‘power outages’ or Identify any non-electrical unscheduled power losses energy users and decide where the grid is unable to the actions to be taken. For supply energy to the users. example, if there are gas fired This is not unusual in develop‘flamers’ for PP printing, then ing countries, where the supthese should be turned off; ply network has not kept up Prevent data loss (or corwith the demand pattern and ruption) for all computers and may even become a future controls. This was less critical problem in other countries, in the 1980s when there was such as the United Kingdom, less dependence on computwhere green issues have ers, but now a power outage led to premature closure of can easily lead to loss of data generation capacity. and perhaps even damage Our main work is in energy to machines using computer management to reduce the controls. load needed to process Uninterruptible Power plastics and a power outage Supply (UPS) systems are a can almost be considered the method of providing continued ultimate in energy saving. The power for computers and Been there before? Everybody in the industry has got wiser since the first only problem is that you cancontrollers in the event of a outages, which quite literally plunged us into darkness. Outages at night not process any plastic at all! power outage. They will never (and even daytime) posed dangerous potential hazards in converting My first experience with keep a plastics processing factories, but the continuation of the outages is proving to be a daunting power outages was whilst site operating in the event of challenge for manufacturers working in a rural area of the a power outage because they UK during the 1980s: our supply was extremely unstable and have very limited storage (they are only after all a rechargeevery month the power would fail. We were extruding PVC at the able battery and a rectifier). Whilst UPS units are simply not big time and when the power went off I would look enough for machines, they should be used for at my watch and start counting. If the power all computers (and servers) to prevent data went out for less than 30 seconds we could corruption and loss. I am running one right get the site up and running again with only a now on this computer to cover the rare event loss of about 1 hour whilst we tried to get the of a power outage in the UK. A UPS will last a machines stable again. If the power went off long time, is transparent in use and protects for over 4 minutes, then it was ‘all hands on data. deck’ as we rushed to isolate machines to TIP All office computers (and servers) prevent start-up when the power came back on should be protected by UPS systems. (thrust bearings tend to go when an extruder tries to move hard This can be ‘system wide’ or use individual UPS for each complastic), strip and clean screws from barrels. For the next 8 hours puter. we were committed to simply getting the site operational again. Always gracefully shutdown the computer as soon as TIP Those days are engraved in my memory and not in a good way. possible after the power loss. Do not be tempted to So what can processors do to minimise the damage, get keep working (the UPS will eventually drain and the computer started again quicker and potentially even remove the problem? will stop). Back-up, back-up and back-up again. A power outage TIP Minimising the damage is a nuisance, data loss can be fatal. As a rule of thumb, An unscheduled power outage is just that, it is unscheduled and back-ups should be stored off-site or at least the wing-span of a the power simply stops. Assuming a power outage is going to jumbo jet away from the machine. happen, then setting up systems to minimise the damage is the It is also strongly recommended that all machine computers first thing that should be done. and controllers are also protected by a UPS. These should be Primary actions to prepare for power outages include: wired in separately from the main supply inside the machine or using a ‘system-wide’ approach and low voltage cabling (use the Set/adjust machines to ‘fail safe’ or ‘fail to safe’ conditions. wiring diagrams to find where a UPS can be inserted to protect A power outage can leave machines in an unsafe or unstable the computers and controllers). This will mean that the controlcondition. If it is possible, setting all machines (don’t forget the ler will still be active in the event of a power outage and prevent services) to fail to safe is the prime action; data loss or corruption BUT the machine must still be shutdown Prepare checklists and procedures for all actions in the to prevent activation when the power comes back on. event of a power outage. For example, isolate machines, clear conveyors, clear assembly machines, set machines in correct TIP Fit small UPS to all machines to prevent data loss or
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Complete solution to off-grid question may well lie in tri-generation
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28 AUGUST / SEPTEMBER 2015
corruption. TIP Shut down machine computers and controllers as soon as possible to prevent machine activation in the event of power being restored. Make sure that you have back-up copies of all machine TIP settings and data. As with all back-ups, these should be stored away from the machine. Robots present a specific problem because they use TIP higher power levels. If possible, set up a UPS to take robots to ‘safe’ position. Getting started again faster After a power outage happens, the main thing, obviously, is to get running again as quickly as possible. One of the key issues is the type of material being processed: materials that suffer from thermal degeneration in the barrel or are very thermally sensitive, such as PVC, are much harder to deal with than materials which do not suffer from significant thermal degradation, e.g. PP. Having been brought up processing PVC, I have had the discipline of purging after a run and cleaning screws and barrels drilled into me. Processors running PP or one of the other polyolefins often simply shut a machine down with no purging and start it up again by turning on the heats, running a few shots to clean the barrel and then settling down to produce parts. This is not what I would recommend (training and indoctrination), but many processors still do this. In the event of a power outage, processors of PP and similar materials have a real advantage: they can set the machines in a safe position and when power is restored, provided they have a good UPS on the controller and have all the data, can start up again with few problems. It may not be painless, but it is still better than for PVC processors whose problems, when the power is restored, have only just started. After any significant power outage, processors of PVC will need to strip barrels, screws and dies to clear any material present to avoid black spots and thermally degraded material. For almost all plastics processing, barrel insulation is recommended as a method of reducing energy use. In the event of a power outage, barrel insulation has some other advantages: insulated barrels will cool down much slower and warm up much quicker than uninsulated barrels. For injection moulders, barrel
Figure 1: Energy flows in a typical tri-generation plant
insulation can not only reduce energy use, but reduce the time taken to get processing again. Barrel insulation has a payback (in energy savings alone) of around 15 months, if the speed of recovery is taken into account. TIP Barrel insulation should be fitted wherever possible. Removing the problem Obviously, the best thing to do about power outages is to remove the problem. So why have I left this to last? The simple reason is that the removal of power outages involves some type of self-generation or going off-grid and this is inevitably expensive and needs high capital expenditure. The concept of renewables (solar or wind) is often raised, but the main problem is that a large solar PV array covering the complete roof of most plastics processing sites would only produce enough power to run the lights and would not be large enough to take anything like the complete site off-grid. This is especially true if the power outage happens at night: without a large storage system and equally large extra cost, then the solar will contribute nothing and even the lights will go off! The same is true for wind power, current systems are generally too small, intermittent (the wind does not always blow during a power outage) and would need a large storage system to be off any use. Some processors in South Africa are fitting diesel generator sets for back-up power and these can have start times from between 2 minutes and less than 0.2 seconds. As a general rule, the shorter the delay time the more costly the generator set controls. But how long do you want a power outage in an operating room to be, especially if you are on the table? Diesel generator sets can be very cost effective for short periods or when they are used for ‘peak demand lopping,’ but are very expensive to operate for any length of time due to the relatively low efficiency of the diesel generator (i.e. the heat output from the generator is lost to the atmosphere). As a complete solution to the off-grid question, the solution may well lie in tri-generation. Many people will be familiar with the concept of co-generation or combined heat and power (CHP) where a gas-fired turbine/generator is used to provide both electricity and heat. This technology is widely used in buildings where both the electricity and heat can be used. The electricity can run the services and machines and the heat can be used for both heating and hot water. However, how many people are familiar with the concept of tri-generation? Tri-generation or combined cooling, heat and power (CCHP) is where a gas turbine is used to produce electricity, a linked boiler is used to produce steam from the waste heat and the resulting steam is used either for heating or for the production of chilled water. It is this production of chilled water that holds the key for plastics processors to use almost all of the energy stored in the raw gas input fuel. It may seem strange that steam can be used to produce cold water but the technology is well developed and uses absorption cooling where steam is used instead of the expansion valve in a traditional chiller. The energy flows in a typical tri-generation set are shown in Figure 1. All plastics processing sites use
AUGUST / SEPTEMBER 2015 29
INDUSTRY NEWS large amounts of chilled and cooling water for the process. Chilled and cooling water is normally provided by electrically powered chillers that are very expensive to operate. Tri-generation can generate power, heat (steam) and also chilled water to allow a site with access to good gas supplies to go off-grid for almost all the energy requirements. It would also be immune to power outages. In addition, removing the cooling demand from any site’s electricity demand will dramatically reduce the electricity costs. A tri-generation system does not need changes to an existing chilled water system. A system can be set up as follows: All current chillers remain in place but are set to only switch on at high temperatures in the chilled water sump (≈ 20°C); All current pumps remain in place but system pumps (to towers and chillers) would be turned off; The tri-generation station would generate chilled water via absorption cooling and distribute this to the existing chilled and cooling water tanks; The existing process pumps would be used to distribute the chilled water to the process. The cost for tri-generation with absorption cooling is currently high but falling due to the involvement of many Chinese companies in this area. Going off-grid has undoubted advantages both in terms of current and future power outages (is it going to get better soon?) and in terms of overall energy costs. Tri-generation is not a new technology and is well-known in Europe, the USA
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and Asia. Perhaps the future for South Africa is tri-generation for a multitude of reasons? As Arthur C Clarke once said, ‘The future is already here, it is just not evenly distributed’. Find out more about tri-generation and the benefits of TIP going off-grid via tri-generation. Summary Power outages are very disruptive to operations but with good planning plastics processors can take a range of actions to minimise their effects. With even longer range planning, processors could not only go ‘off-grid’ to remove the effects of power outages, but also reduce their energy costs and environmental impact. Dr Robin Kent is the author of ‘Energy Management in Plastics Processing’, published by Plastics Information Direct (ISBN 978-1-906479-10-7) and managing director of Tangram Technology Ltd, consulting engineers specialising in energy management in plastics processing.
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www.tangram.co.uk
Unique hot-fill PET bottle wins design award AMCOR Rigid Plastics has been named the winner of the beverage/non-alcoholic category in the AmeriStar Package Awards Competition, North America’s most prestigious packaging award competition sponsored by the Institute of Packaging Professionals (IoPP). Amcor captured the beverage/non-alcoholic award for the development of an ultra-lightweight, hot-fill PET container, designed exclusively for PepsiCo-Lipton’s tea drink brand in Central America. The 500ml package weighs only 22g and uses a 33mm finish that features a 50% reduction in material over a traditional 38mm finish.The innovative 500ml bottle sets a new benchmark for heat-set PET containers, enabling manufacturers to achieve aseptic filling packaging weights without the prohibitive investment, while offering a more eco-friendly option. The new product was initially launched in El Salvador and has since been introduced in Mexico and other Central American regions. Compared to a standard 500ml heatset PET container weighing about 34g, the new bottle is just 22g - 30% lighter. Greenhouse gas emissions are cut by 26%, energy use is reduced by 23%, and water consumption is decreased by 24%. The new container also results in a 26% reduction in the amount of waste that could
30 AUGUST / SEPTEMBER 2015
potentially end up in a landfill. Achieving the lightweight properties which could withstand intense vacuum absorption was a big challenge. Amcor applied its vacuum absorbing base (VAB) technology to the base and ERGO technology to the body. The VAB base is a lightweighted diaphragm-like structure that aids in the cooling process by helping to absorb vacuum. The new hot-fill bottle is designed to run on existing filling lines with minimal changeover. Lightest closure for hot-fill Along with the ultra-lightweight container, Amcor and Bericap, in cooperation with PepsiCo, developed the industry’s lightest 33mm tamper-evident finish/closure for hot fill, weighing in at just 3.7g. Amcor believes the unique finish will become a new standard for hotfill bottles due to the 7.9g reduction in weight compared to the standard 38mm. This new finish led to the creation of a Bericap closure with a built-in seal that eliminates rubber liners or induction seal foils, thus reducing overall materials use. The Bericap closure is made of HDPE instead of PP like the previous caps. HDPE is more widely
accepted than PP in recycle streams and the absence of any other barrier materials such as ethylene-vinyl acetate (EVA) or paper/foil increases recyclability. www.amcor.com
INNOVATE ADVANCE EXCEED NUVO™ Rubber Compounders is a bespoke rubber compounding company situated in Kwa-Zulu Natal, South Africa and servicing both the local and global market. Equipped with a research and testing laboratory that far exceeds conventional standards together with the most advanced mixing equipment, innovation is at the company’s core. NUVO’s customer focused ethos and unabated pursuit of technological advancement has placed them amongst the world’s leaders in compounding science. With a personalised approach and decades of experience NUVO™ offer a rubber compounding solution of distinction.
NUVO™ RUBBER COMPOUNDERS Tel: 033 387 1330 35 Willowton Road, Willowton, Pietermaritzburg, 3201 Kwa-Zulu Natal, South Africa info@nuvorubber.com www.nuvorubber.com NUVO™ LV D OHYHO %(( FRQWULEXWRU KDV ,62 FHUWLˉFDWLRQ
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Boost in the Berg for rubber at
IOM conference Technical presentations show there is progress in the rubber market – and healthy progress too
32 AUGUST / SEPTEMBER 2015
THE Institute of Materials’ national Rubber Conference, held in the spectacular surrounds of Cathedral Peak in the Drakensberg in June, was a shot in the arm for the rubber industry in South Africa.
R+D from the tyre sector to the technical rubber market. Up till recently the main focus in the rubber market has been on tyre development, and understandably so. The shifted focus has seen recent developments in the compounding and testing areas of the industrial rubber sector, Perhaps it was the stately venue, the meaning that rubber compounders are now Cathedral Peak Hotel, but the 22nd edition able to better tailor compounds for specific of the IOM3 event attracted both a variety applications. Mixing is now also functioning of cutting edge technical presentations at a finer level, achieving better dispersal from local and international speakers and of fillers, but the main catalyst appears to a good turnout of delegates, 100+ in fact, be that enhanced testing likewise local and global. abilities. “The technical Congratulations to IOM Rubber goods chairman Jaco Smith presentations have had a reputation and his team for their for being static and showed there is organization of the 2-day boring, but now it’s still progress in the conference – and not being realized that it is least for their confidence rubber market – possible to improve the in putting on the show in quality of raw material, and healthy progress the first place. which directly leads to at that.” The technical an improvement in the presentations showed quality of moulded goods. there is still progress in the rubber market Of most interest were the presentations – and healthy progress at that. The by Nuvo Rubber, about how analytical chief catalyst for the renewed interest work is enabling it to improve rubber was the recent trend to translate rubber compound quality; by HF Mixing and REP on energy-saving advances for internal mixers and rubber injection moulding; by Denka on low-heat buildup chloroprene
rubber; and Birla Carbon on carbon black advances. NUVO Rubber of Maritzburg was one of the two platinum sponsors of the conference, and it’s been quite some time since a local company has been a main sponsor of the Rubber Conference – so that in itself was a welcome development. Nuvo was formerly known as Natal Rubber Compounders and its growth into a world-class competitive manufacturer of rubber compound as well as moulded rubber products laid the foundation for its new identity. With that sort of credential, there was expectation that the Nuvo Rubber speaker, Donal Ryan, would have
Int’l winner – Ian Wilson of HF Mixing Group (UK) received the Best International Presenter award from Ron Dunwoodie; HF group includes Farrel, the rubber mixers best known in South Africa
2015 sponsor – Collin Stroberg (right) of Nuvo Rubber Compounders, one of the main sponsors of the conference, chatting with Darryl Walters of Cabot Corporation (UK). Maritzburgbased Nuvo (formerly known as Natal Rubber Compounders) made an important contribution towards the staging of the IOM3 event
Rosalie Akerman (Envande) and Raphael Smith (winner of the SA and International Young Persons World Lecture Competition 2014), who both gave presentations, and session chairman Des Royappen. Raphael won the award for a presentation about the development of a platform for a dual-modality (X-ray and ultrasound) mammography system to detect signs of breast cancer. TPX (polymethylpentene) was found to be the only suitable material for the breast platform and novel bonding methods were developed to accommodate its anti-adhesion characteristics
Peak performance – The well-appointed Cathedral Peak Hotel proved a popular venue for the IOM National Rubber Conference in June, set as it is in one of the most impressive landscapes in Africa. The hotel lies in the valley below the 3004m Cathedral Peak, also known as Mponjwana (Little Horn) by the local people. The conference was by all accounts outstandingly well organised
IOM3 national chairman Jaco Smith (second from left) was the entertaining host for the international dignitaries, including Ed Juline of SASCO Chemical (USA), Martin Cox of the IOM (London), Sebastian Fritsch of Schill + Seilacher (Germany) and Nobunhiko Fujji of Denka Chemicals (Japan)
something especially interesting up his sleeve, and his presentation lived up to the billing.
Optimising rubber compound mixing conditions Nuvo Rubber has made investments exceeding R2.5-million at the lab at its plant in Maritzburg, including the installation of a Rapid Process Analyser (RPA). This is a dynamic testing instrument designed to measure the viscoelastic properties of elastomeric and rubber compounds before, during and after cure.
Dimitri Markoulides (BMGI South Africa), Gerhard Meyinger (Dunlop Rema TipTop), André Cornelius (Orchem), who was a session chairman, and Shale Sefadi (University of the Free State); Dimitri gave a thought provoking presentation about ‘Innovative Leadership’ … which we need lots of
Wolfgang Ruschig of Hans Barbe Chemische (Germany), Bernard Tennant of Protea Chemicals and Rentia Smith of ChemSystems got into the swing of things quite easily
The study at Nuvo in Maritzburg focused on compounds for conveyor belts and tyre retreading. Dynamic durability is critical to both of these applications and even slight changes in mixing cycles can have a considerable effect on final product performance. Mixing parameters such as mixer rotor speed, mixing time, order of addition of ingredients and milling time will be the primary factors included in the study. RPA measurements were carried out on Payne Effect and Time Temperature The Cathedral Peak Hotel organisers created a pleasant ambiance with the theme ‘Winter Wonderland’ for the banquet on the Saturday night
AUGUST / SEPTEMBER 2015 33
COMPOUND
Measured data gives exact information about the processability, performance and cure characteristics of the compound. In the Nuvo study, an RPA 3000 unit was used to measure the effect of controlled changes in mixing cycles on the dynamic properties of selected compounds. Trends in the dynamic data can be related to critical compound parameters such as filler dispersion, end-user processability and final product performance. In other words, far more comprehensive data is yielded in the test than was formerly the case, directly giving the compound manufacturer the opportunity to make important modifications to the material formulation.
Sue Supasar of H&M Rollers and Grant Rosettenstein needed a bit of the morning sunshine to warm up
The ‘manne’ – Crighton du Preez (Anchor Chemicals), Pieter Snyman (Carst & Walker), Lukas Oosthuizen (Karbochem), Sonwabo Bambalaza (Aberdare) and Velogan Muthayan (Carst & Walker) enjoying the cocktail reception on the first night
Toast to the IOM – Tony Hesp, formerly of Rubber Rollers and a long-time member of the Institute, proposed a toast to the IOM3 at the closing banquet
Superposition data. Secondary test data such as tensile properties, hardness and abrasion will also be included in the study. The nett effect of the process is that the quality of rubber and elastomer compounds supplied by Nuvo has achieved significant improvement.
MIXING Energy efficiency in the mixing room In his presentation ‘Energy Efficiency of the Mixing Room,’ Ian Wilson of HF Mixing Group of the United Kingdom looked at the objective of either decreasing or optimising the energy per kg while maintaining (or improving) the compound quality and consistency. This is done by taking a closer look at the way energy is used, considering what is ‘value added’ and what is an unfortunate side effect of the mixing process. “Looking at the cost structure in the mixing room, it is easy to see the majority of the cost lies in materials. If we eliminate this from our figures (material costs are not easily controllable!), then we can see that energy costs make up between 12 and 13% of manufacturing costs in Western Europe (obviously higher in in low cost countries as personnel costs are reduced). This is a significant target for potential optimization,” said Ian. Energy costs associated with the mixer can be roughly divided into four sections, namely drive train; mixer hydraulics (or pneumatics); mixer temperature control units (TCUs); and dust stops. But the majority of the energy cost lies within the drive train, and this is the area where HF Mixing has made huge technological advances – namely in energy-saving features for internal mixers.
34 AUGUST / SEPTEMBER 2015
Top test system – The Rapid Process Analyser (RPA) from MonTech is the centre of the process underway at Nuvo Rubber: it is being used to test the effect of changes in mixing cycles on the dynamic properties of compounds. In this way, the Maritzburg rubber compounder is translating development which was common in the tyre area to compounds for industrial rubber applications Top local presenter – Donal Ryan of Nuvo Rubber Compounders received the Best Local Presenter award from Ron Dunwoodie; his presentation looked at how enhanced lab analysis is enabling Nuvo to improve both control of the process and supply higher performance compound, particularly to the industrial rubber sector
Much more Munch – Dr Manfred Breining of Munch Chemie, who was on his first visit to South Africa, flanked by Rob Macnab and Grant Rosettenstein of West African Group, which represents Munch
Team Plastichem – Andrew Bannatyne, Diane Koen, Dean Delaporte and Helmut Oellermann of Plastichem with Raphael Smith (second from right), the Young Persons Lecture Competition winner
MATERIAL PERFORMANCE
AUGUST / SEPTEMBER 2015 35
ASSOCIATION NEWS
Less exothermic chloroprene rubber In his presentation, ‘Development of Less Exothermic Chloroprene Rubber,’ Nobuhiko Fujii of Denka of Japan looked at how low-heat-buildup polychloroprene rubber is achieving longer life of conveyor belts and improved performance Chloroprene rubber (CR) developed in 1931 has been widely used not only for industrial fields such as transmission and conveyor belts, electric cables, hoses and sponges, but also for adhesives, dipping goods and fibre treatments. Transmission belts occupy major application of CR because its processability and bonding properties are excellent. In this application, various efforts were made to extend CR product life, specifically of polymer development to achieve less exothermic properties under dynamic
service conditions as well as higher new CR showed longer shelf life. bonding strength. Sulfur modified CR with less dynamic CARBON BLACK heat generation has greater advantage in New grades meet elevated expectations the transmission belt application in terms Gerardo Sica of Birla Carbon outlined how of extension of belt life his company is working as well as energy saving. on the development of “With 17 plants Newly developed sulfur carbon blacks to meet in 15 countries and modified CR has less free the highly demanding an annual output chain-ends and higher specifications from the crosslinking density. automotive and other of over 2 million This enables decrease industries. tons, Birla Carbon of loss factor (tan δ) at With 17 plants in 15 is a world leader in high temperature. From countries and an annual dynamic viscoelasticity output of over 2 million carbon black.” test, compression fatigue tons, Birla Carbon is a test and bonding test between rubber world leader in carbon black. and polyester cord, the newly developed Its XT grades, for example, cover a wide CR showed less exothermic properties range of colloidal properties with the added and excellent bonding strength. Actual value of having extremely low levels of transmission belts manufactured from this residue. XT grades have been designed to
Bright Rwodzi (ContiTech), Coen Burger (Orchem Trading) and Ommesh Sutan (Dunlop Industrial Products) were looking debonair at the conference banquet
Dawie du Plooy of Orchem and Siya Rala of Tega Industries were in good spirits
Across Africa – Paul Lonsdale and Bernard Tennant of Protea Chemicals were able to show off the numerous countries across Africa where Protea and its parent company Omnia have offices, must be one of the largest networks in the industry
Machine suppliers – Ian Wilson of HF Mixing (Farrel) and Stewart Knight of REP International (France) flank Ron Dunwoodie; Ian and Stewart gave presentations about equipment advances. Both companies are represented by Carst & Walker
ASSOCIATION NEWS
Back stronger – Rosalie and Gareth Akerman of Envande; her presentation looked at how their company, a manufacturer of NR and SBR tread reclaim and rubber crumb in Maritzburg, not only survived a major plant fire but came back stronger The other Dunwoodie, getting the show on the road
provide A Class surface finish in extruded moulded products, provide fast mixing and extrusion, good screenlife, and compound flexibility. For the tyre sector, Birla has developed two grades, which offer reductions in hysteresis of rubber compounds without sacrificing in other important areas. These carbon grades are helping reduce the rolling resistance of tyres. 36 AUGUST / SEPTEMBER 2015
INJECTION MOULDING Energy-saving technology from REP In his presentation about ‘Green Technology in the rubber industry,’ Stewart Knight of REP International (France) looked at energy-saving technology for rubber injection moulding as well as how the REP machine can rework vulcanized rubber scrap. According to Knight, REP is not just
talking about what “should be done to save our planet”. REP has developed a number of solutions to reduce our footprint in the consumption of non-renewable resources and also make rubber a renewable resource.
www.iom3.co.za
www.iom3.org
Guests were treated to rousing traditional dancing and drumming
Dr Kathy Garde was able to marshal all the men in the Carst & Walker team along with the company’s principals at the conference, including Birla (carbon black), Denka (chloroprene), HF Mixing group and REP Int’l (injection moulding). C&W has been a main supplier to the rubber and tyre sector in Southern Africa for over 70 years
Accolades for Coen after 40yrs! Boy from Upington came good in rubber game COEN Burger received recognition for his consistent work for the industry over 40-plus years when he was presented with the John Tallant Medal for 2015 at the IOM³ Rubber Conference in the Drakensberg in June. The Tallant Medal is presented to an individual who has been deemed to have made a notable contribution to the industry as well as the Institute, and in Coen’s case that was not hard to justify: the man has been the epitome of a good industry player: always there, always calm and always ready to help. But it wasn’t that easy in the beginning for the boy from Upington. His career in the industry started in his last year at school when he was recruited by Sasol. He was employed by Oom Daan Malan at Karbochem and then joined Mike Jones to form the Orchem sales team. Coen knew nothing about accelerators, antioxidants, curing, mooneys and the rest. Fortunately, Mike was a qualified rubber technologist who had worked in a rubber processing factory who was able to impart some advice. Coen later worked at Longmile, where he got production experience in a mixing plant, and then he joined Protea. He joined the former PRI branch committee 38 AUGUST / SEPTEMBER 2015
The man’s got Tallant! – Coen Burger received the John Tallant Medal from IOM3 chairman Jaco Smith; Coen has been involved in the rubber game for over 40 years
when he was transferred to Durban and did the same when he moved to Port Elizabeth, where he has been since. He has been one of the most consistent members of the Institute throughout this time and helped at all the conferences and Foundation lecture events around the country.
Crighton du Preez of Anchor Chemicals (centre) was session chairman during the presentations by Etienne Gautier of Cabot Corporation and Gerardo Sica of Birla Carbon. Birla, an Indian conglomerate with its headquarters in the USA, was also a platinum sponsor of the conference Thank you – IOM national chairman Jaco Smith thanked Wendy Knott Craig for her exceptionally good organisation of the 2015 conference – everything ran smoothly, well done! It may have been one of the best IOM3 events to date, spanning back over more than four decades
KZN winner ASSOCIATION NEWS
The Iddon Trophy, presented by the IOM KZN branch each year to the best presentation at its member events, for 2014 was won by Ralf Baeuerlein of MonTech Germany for his lecture on ‘Advances in rubber testing technology’. The cup was accepted on Ralf’s behalf by Jaimie Targett, sales and applications manager for MonTech’s South African operation (handed over by Ron at the conference). The trophy was donated by Mike Iddon of Iddon Bros UK about 30 years ago and has been awarded annually by the Natal branch since
Top of the world – Helicopter trips are offered from the resort, and you get a marvelous view … as well as, if conditions are good, champagne on, you guessed it, the nearby Champagne Castle summit (3377m), the second highest point in South Africa
AUGUST / SEPTEMBER 2015 39
Locally manufactured, globally sought after synthetic rubbers since 1964 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
ASSOCIATION NEWS
National Clean-Up and Recycle Week
getting everyone involved Various clean-up projects will take place in cities, towns, FROM 14-19 September, South Africans from all walks of communities and schools as individuals are encouraged to pay life will once again be encouraged to clean-up and recycle in attention to the problem of waste around them, and get their their environment as part of National Clean-Up and Recycle friends, neighbours or colleagues involved with recycling. Week SA. “Plastics|SA and our partners in this project will be According to Douw Steyn, Director: Sustainability at sponsoring 250 000 bright yellow refuse bags which will be Plastics|SA and chairman of the National Recycling Forum donated for clean-up projects around South Africa,â€? Steyn (NRF), all packaging streams, as well as oil and e-waste said. Highlights of this week will once again recyclers, will use this week to spread the be National Recycling Day on 18 September message about the importance of looking after Plastics/SA and and the annual International Coastal Clean-Up the environment and ensuring that everybody Day on 19 September. takes responsibility for recycling where they partners will be This year Plastics|SA has also launched a work, live or play. sponsoring 250 &OHDQ 8S DQG 5HF\FOH Âľ6HOÂż H &RPSHWLWLRQÂś RQ “The only way forward, if we are going to its Facebook page to promote the initiative: improve the quality of the environment, is to get 000 bright yellow 7DNH D ÂľVHOÂż HÂś ZLWK \RX DQG \RXU IULHQGV everybody involved,â€? Steyn said. refuse bags cleaning up and recycling in your environment. For the past 20 years, Plastics|SA has 2. Upload or post the picture, a caption and been coordinating clean-up events around the #CleanUp #Recycle on the Plastics|SA Facebook page country. It has become an annual, countrywide event which is (www.facebook.com/plasticssa) and get your friends to like supported by the glass, cans, paper and board industries, as DQG VKDUH \RXU SKRWR :HHNO\ Âż QDOLVWV ZLOO EH DQQRXQFHG well as oil convertors, recyclers, brand owners, retailers, Brand LQ WKH UXQ XS WR WKH Âż QDO ZHHN RI 6HSWHPEHU ZKHQ WKH SA, KZN Wildlife, Tuffy Manufacturing, Pick ‘n Pay, Garbie winners of a Samsung Galaxy Core Prime Smartphone will be (East Rand Plastics) and the Department of Environmental announced. Affairs (DEA).
New-look website goes live for Plastics|SA 3/$67,&6_6$ÂśV QHZ ORRN ZHEVLWH KDV gone live! According to marketing & communications executive, Monya Vermaak, she and her team have been working behind the scenes for the past few months to update the
content, redesign the layout and make various improvements aimed at easier navigation. The revamped website sports a fresh new look and layout, whilst staying true WR 3ODVWLFV_6$ÂśV EUDQG and corporate identity. Information about events, developments and publications are FODVVLÂż HG XQGHU VL[ KHDGLQJV WKDW UHĂ€ HFW its focus areas (i.e. training, sustainability, advocacy, health and safety, education and industry news). Other features include a new, interactive calendar 40 AUGUST / SEPTEMBER 2015
function that allows events to be saved DQG OLQNHG WR XVHUVÂś 2XWORRN FDOHQGDU as well as a comprehensive library where all the Plastics|SA publications can be read or downloaded. The new site is also compatible with all browsers and gadgets, including Google Search, and allows users to link and share content to social media platforms such as LinkedIn, Facebook and Pinterest. “We are hoping that the new-look site will help us stay connected with all of our stakeholders. We would encourage our members in particular to visit the site and give us feedback and suggestions for further improvements,â€? Monya said.
www.plasticsinfo.co.za
Plastics|SA hosts talks on bio-plastics 9DOXH RI UHVRXUFHV WKH FRXQWU\ LV ORVLQJ WR ODQGÂż OOV LV DURXQG 5 ELOOLRQ D \HDU PLASTICS|SA hosted a free-to-attend VHPLQDU RQ ELR SODVWLFV DW LWV KHDG RIÂż FH in Midrand recently, during which experts shared their knowledge and raised some interesting food for thought! Prof Dr Christian Bonten from the Stuttgart University in Germany, who was visiting South Africa as a guest of Plastics|SA and was also one of the keynote speakers at the African Marine Debris Summit, explained that ‘bioplastics’ refers to a variety of materials, including biodegradable plastics and bio-based plastics made from renewable resources like sugar cane or starch. He noted, however, that not all biodegradable plastics are made from natural materials. “In the same way, not all bio-plastics are biodegradableâ€?, he explained. Prof Dr Linda Godfrey, a principal researcher of the CSIR, shared information on the possible impacts of bio-plastics on South Africa’s waste and secondary resources economy at the event. “About 90% of waste in South Africa is VWLOO JRLQJ WR ODQGÂż OO :H HVWLPDWH WKDW WKH value of resources the country is losing to ODQGÂż OOV LV DURXQG 5 ELOOLRQ SHU DQQXP ´ Godfrey explained. “These materials
could be recovered and reintroduced into the country’s manufacturing economy.â€? Godfrey went on to explain that various factors have created the perception that the country should be using more biodegradable products. “People look at the high percentage of PDWHULDOV DUH JRLQJ WR ORFDO ODQGÂż OOV DQG automatically assume that biodegradable packaging material will breakdown in the environment before they cause long-term impacts. Information received from Plastics Europe does indeed suggest that there are certain niche markets where biodegradable plastics make sense, such as in agriculture and horticulture where packaging and content is very similar,â€? Godfrey said. “The concept of a circular economy is one where we create products that we can recycle and return back into the manufacturing sector.â€? Commenting on the topic, Plastics|SA executive director Anton Hanekom said that a lot of confusion still existed in the marketplace
around some of the environmental claims made by the manufacturers of GHJUDGDEOH SODVWLFV :KLOVW LQGXVWU\ leaders agree that there are certain uses and applications that could potentially be ideally suited to degradable plastics, both Plastics|SA and SAPRO have warned that it introducing bio-plastics to the country’s burgeoning and well-developed recycling industry would contaminate the recycling streams with disastrous and costly consequences. Of special concern is the impact degradable materials will have once this plastic is recycled and used in second and successive applications. www.plasticsinfo.co.za
Bioplastics ‘fundi’ Prof Christian Bonten, Rejoice Mabudafhasi (Deputy Minister of Arts & Culture), Prof Linda Godfrey (CSIR), Anton Hanekom and Douw Steyn (Plastics|SA) AUGUST / SEPTEMBER 2015 41
ASSOCIATION NEWS
POLYCO
plans to invest R9 million in recycling projects
Recyclers invited to apply for interest free loans Rigorous selection process She warns, however, that applicants must prepare themselves for a rigorous selection process. “We do a thorough due diligence of each company we invest in, and require them to submit their business plan Mandy NaudĂŠ, detailing the support POLYCO CEO required to be able WR GLYHUW PRUH SRO\ROHÂż Q SDFNDJLQJ PDWHULDOV IURP ODQGÂż OO 7KH UDQG WRQ cost-effectiveness of the potential investment by POLYCO is an important consideration,â€? she said, “and all funding FRQWUDFWV DUH OLQNHG WR SURMHFWHG YROXPH JURZWK ZKLFK LV WKH NH\ REMHFWLYH ´ “We have set ourselves the goal of JURZLQJ SRO\ROHÂż Q UHF\FOLQJ LQ 6RXWK Africa by a further 300 000 tons over WKH QH[W Âż YH \HDUV :H EHOLHYH LW LV achievable and in line with the IWMP recycling rate target of 35% or 238 000 UHF\FOHG SRO\ROHÂż Q WRQV LQ WKH \HDU 2020. This is an ambitious target when considering that the 2014 recycling rate achieved was 31,8% or 171 000 tons,â€? said Mandy. Application guidelines can be downloaded from the POLYCO website at www.polyco.co.za. Applicants can also contact POLYCO business support manager, George %ODFNZRRG RQ WHO for more information.
SAPRO hosts 5th Recycled Product of the Year ENTRIES closed on 3 August for the South African Plastics Recyclers’ 2UJDQLVDWLRQÂśV 6$352 WK ‘Best Recycled Plastics Product of the Year Competition, hosted this year in collaboration with Plastics|SA and two of the world’s leaders in recycling machinery, Erema Engineering Recycling Machinery & Facilities 42
AUGUST / SEPTEMBER 2015
UHSUHVHQWHG LQ 6$ E\ 5HOOR\ 6$ and Starlinger Recycling Technology UHSUHVHQWHG LQ 6$ E\ 0DULWLPH 0DUNHWLQJ “The competition offers the ideal platform to honour recyclers and all the parties involved in the value chain for their commitment to diverting waste away IURP RXU FRXQWU\ÂśV ODQGÂż OOV ´ VDLG $QQDEp 3UHWRULXV RI 6$352 Âł,W DFNQRZOHGJHV
products that are made from recycled materials, and encourages brand owners and industrial designers to consider recycled plastics as a material of choice�. A winner will be selected in each of the categories, with the overall winner being awarded the SAPRO trophy for the Best Recycled Product of the Year during a gala dinner on 18 September at the Spier Wine Estate in Stellenbosch.
www.polyco.co.za
The companyâ&#x20AC;&#x2122;s third call for proposals SINCE POLYCO started operations in 2015 will begin on 17 of August and over two years ago, they have invested LV IRFXVHG VSHFLÂż FDOO\ RQ VXSSO\ FKDLQ R17 million into various separation, HIÂż FLHQF\ SURMHFWV IRU PHFKDQLFDO collection, sorting and recycling projects UHF\FOHUV 7KH Âż QDO VXEPLVVLRQ GDWH IRU around South Africa to increase the these proposals is 25 September. recycling rate. As SA Plastics was â&#x20AC;&#x153;We have budgeted approximately R9 going to print, the second round of million to invest in projects that would projects this year, aimed at collectors, ZDV LQ WKH Âż QDO VWDJHV RI HYDOXDWLRQ DQG grow recycling production volumes, resulting in the long-term sustainable ZDV WR EH DQQRXQFHG LQ WKH Âż UVW ZHHN JURZWK RI WKH SRO\ROHÂż Q of August. This will see plastics recycling an estimated R5 million Goal is to grow industryâ&#x20AC;?, Mandy said. being invested in the Common problems recycling industry. SRO\ROHÂż Q experienced by recyclers Three times a year, UHF\FOLQJ LQ 6RXWK include supply chain POLYCO issues a call $IULFD E\ D IXUWKHU ERWWOH QHFNV GXH WR for proposals from either WRQV material availability collectors or recyclers or logistic issues, and who need funding RYHU WKH QH[W Âż YH production constraints VXSSRUW WR WDNH WKHLU years GXH WR LQVXIÂż FLHQW FDSDFLW\ businesses to the next or unreliable ageing level. To enable this equipment at their plants. process POLYCO has developed a selfâ&#x20AC;&#x153;To improve the output and quality of sustaining funding model. their products, recyclers need to upgrade â&#x20AC;&#x153;We believe in giving the successful their wash plant facilities or invest in new candidates a â&#x20AC;&#x2DC;hand-upâ&#x20AC;&#x2122; not a â&#x20AC;&#x2DC;hand-outâ&#x20AC;&#x2122;,â&#x20AC;? shredding, granulation, extrusion and said POLYCO CEO, Mandy NaudĂŠ. testing equipment. These are often very Approximately 80% of the funding H[SHQVLYH LQYHVWPHQWV WR PDNH LQ DQ VXSSRUW 32/<&2 SURYLGHV WDNHV WKH LQGXVWU\ WKDW LV NQRZQ IRU LWV VPDOO PDUJLQV form of the interest free loans repayable and high operating costs. By partnering over three years. The loan repayment with POLYCO, however, these and many funds are then re-loaned to other other improvements can be implemented successful applicants. The remaining cost-effectively,â&#x20AC;? explained Mandy. 20% of funding support is in the form â&#x20AC;&#x153;Successful applicants also enjoy of grants, redeemed against growth WKH EHQHÂż W RI EHFRPLQJ SDUW RI WKH volumes. 32/<&2 QHWZRUN ZKHUHE\ WKH\ â&#x20AC;&#x153;The more funding POLYCO loans to are referred business opportunities, the recycling industry, the more funding FRQQHFWHG WR YDOXDEOH QHWZRUNV income we are able to generate for provided with media exposure and further project support, without having offered general business support and to increase the recycling levy from advice if required,â&#x20AC;? Mandy added. convertors,â&#x20AC;? Mandy explained.
Pretoria-based
entrepreneur
boosts polystyrene recycling
ASSOCIATION NEWS
Recycles 20 tons of polystyrene a month and will soon need 100 tons a month The value of partnerships KOREAN born and South African raised Jimi Son is busy transforming Jimi is quick to point out that his the face of South Africaâ&#x20AC;&#x2122;s recycling success is not the result of individual LQGXVWU\ E\ Âż QGLQJ QHZ ZD\V RI HIIRUWV EXW FUHGLWV WKH SRZHU RI recycling post-consumer polystyrene IRUPLQJ VWUDWHJLF SDUWQHUVKLSV and singlehandedly diverting Âł:H UHDOL]HG HDUO\ RQ WKDW ZH thousands of tons of polystyrene from FDQQRW GR WKLV DORQH 6LQFH ZH WKH FRXQWU\ÂśV ODQGÂż OOV VWDUWHG RXU RSHUDWLRQV ZH KDYH Jimiâ&#x20AC;&#x2122;s entry into the recycling WDNHQ JUHDW FDUH WR EXLOG DQG JURZ industry is thanks to his exposure WKH UHODWLRQVKLSV ZH KDYH IRUPHG and experience gained at his parentsâ&#x20AC;&#x2122; ZLWK ORFDO SRO\VW\UHQH PDQXIDFWXUHUV VXFFHVVIXO H[WUXVLRQ EXVLQHVV $V ZDVWH PDQDJHPHQW FRPSDQLHV manufacturers and suppliers of picture municipalities and associations such IUDPH PRXOGLQJV SURÂż OHV FRUQLFHV DV WKH 3RO\VW\UHQH 3DFNDJLQJ &RXQFLO and even embellishments used on :H DOVR EX\ IDFWRU\ VFUDS IURP RWKHU FRIÂż QV WKDW DUH VROG GLUHFWO\ WR WKH SRO\VW\UHQH IDFWRULHV DQG SHOOHWL]H WKH end market, Jimiâ&#x20AC;&#x2122;s father frequently PDWHULDO LQ KRXVH ´ KH VDLG KDG WR GHDO ZLWK VKLSSLQJ GHOD\V DQG Jimi currently recycles 20 tons H[FKDQJH UDWH Ă&#x20AC; XFWXDWLRQV ZKLFK KDG Jimi Son with a picture frame made from recycled polystyrene D GUDPDWLF LPSDFW RQ KLV EXVLQHVV of polystyrene a month that goes â&#x20AC;&#x153;This caused us to start looking into decorative picture frames and DURXQG IRU ORFDO UHDGLO\ DYDLODEOH PDWHULDO WKDW ZH FRXOG PRXOGLQJV VROG WKURXJKRXW 6RXWK $IULFD ZLWK IXWXUH JURZWK recycle and use in the products instead of the imported SURMHFWLRQV VKRZLQJ WKDW KH ZLOO VRRQ QHHG LQ H[FHVV RI YLUJLQ PDWHULDO ´ H[SODLQHG -LPL Âł$W WKDW WLPH SRO\VW\UHQH WRQV D PRQWK WR NHHS XS ZLWK WKH GHPDQG ZDV DYDLODEOH LQ DEXQGDQW VXSSO\ EXW ZDV FRQVLGHUHG WR Âł:H QHHG D ORW RI SRO\VW\UHQH LQ HYHU\ VKDSH DQG FRORXU EH GLIÂż FXOW WR UHF\FOH DQG KDG YHU\ OLPLWHG HQG PDUNHWV ´ WKDW ZH FDQ JHW 7R WKLV HQG ZH DUH DOVR YHU\ JUDWHIXO WKDW 2WKHU REVWDFOHV WKDW WKH\ KDG WR IDFH ZDV WUDQVSRUWLQJ WKH RXU SDWKV KDYH FURVVHG ZLWK WKRVH RI $GUL 6SDQJHQEHUJ YHU\ OLJKW EXW EXON\ PDWHULDO WR WKHLU SODQW ZRUNLQJ ZLWK DQG WKH 3RO\VW\UHQH &RXQFLO ZKR KDV EHHQ LQVWUXPHQWDO LQ often heavily contaminated and soiled products, and the SXWWLQJ XV LQWR FRQWDFW ZLWK VRXUFHV RI PDWHULDO DURXQG WKH GLIIHUHQW FRORXUV RI SRO\VW\UHQH WKDW WKH\ KDG WR XVH FRXQWU\ ´ -LPL VDLG Jimi refused to accept defeat, and started adapting their The company employs 30 people on a full time basis at H[LVWLQJ PDFKLQHV Âł:H VRRQ IRXQG WKDW ZH ZHUH DEOH WR its factory in Silverton, Pretoria, and has also expanded effectively use and recycle all kinds of polystyrene for our WKHLU RSHUDWLRQV LQWR &DSH 7RZQ 7KHLU QHZ UHF\FOLQJ SODQW VSHFLÂż F SXUSRVHV Âą HYHQ VOLJKWO\ GLUW\ SRVW FRQVXPHU LQ 'XUEDQ LV H[SHFWHG WR RSHQ ZLWKLQ WKH QH[W IHZ PRQWKV coloured and even high impact polystyrene,â&#x20AC;? he said, adding that they have been accepting and using every type &RQWDFW -LPL RQ HPDLO MLPLQV#\DKRR FRP RU FHOO RI SRO\VW\UHQH WKDW WKH\ JRW IURP ZDVWH FROOHFWRUV
Pipes IX Conference in September Will cover a myriad of topics and angles THE Southern African Plastic Pipe Manufacturersâ&#x20AC;&#x2122; Association 6$330$ ZLOO KRVW LWV DQQXDO 3LSHV &RQIHUHQFH RQ 8 September DW WKH %\WH &RQIHUHQFH &HQWUH LQ 0LGUDQG According to SAPPMA Chairman, Jan Venter, this annual FRQIHUHQFH VSHFLÂż FDOO\ IRU WKH SODVWLF SLSH LQGXVWU\ ZLOO RQFH DJDLQ FRYHU D P\ULDG RI WRSLFV DQG DQJOHV Âł:H DUH ORRNLQJ IRUZDUG WR KDYLQJ FXWWLQJ HGJH interesting and thought-provoking presentations by local and LQWHUQDWLRQDO H[SHUWV *LYHQ WKH ZLGH VSHFWUXP RI GHOHJDWHV that have been attending the Pipes Conferences over the 44 AUGUST / SEPTEMBER 2015
SDVW QLQH \HDUV ZH SUHIHU QRW WR UHVWULFW VSHDNHUV WRR PXFK LQ WHUPV RI WKHLU WRSLFV DV WKHUH LV VR PXFK QHZ UHVHDUFK EHLQJ GRQH QHZ PHWKRGV EHLQJ GHYHORSHG DQG QHZ DUHDV RI GLVFXVVLRQ WKDW QHHG WR EH JLYHQ D SODWIRUP ´ 9HQWHU VDLG 7KH FRQIHUHQFH ZLOO EH D IXOO GD\ HYHQW ZLWK NH\QRWH sessions taking place in the main auditorium and parallel VHVVLRQV UXQQLQJ FRQFXUUHQWO\ DIWHU WKH WHD EUHDN For more information or to register for the 2015 PIPES IX &RQIHUHQFH YLVLW ZZZ VDSSPD FR ]D RU FRQWDFW /RXLVH 0XOOHU RQ HPDLO DGPLQ#VDSSPD FR ]D www.sappma.co.za
ASSOCIATION NEWS
Belgotex is 1st Vinyl. product Empowering South African consumers to make responsible product choices BELGOTEX Floors has become the Southern $IULFDQ 9LQ\OV $VVRFLDWLRQÂśV 6$9$ Âż UVW RIÂż FLDO license holder of the Vinyl. product label â&#x20AC;&#x201C; a mark RI H[FHOOHQFH WKDW VLJQLÂż HV WKH SURGXFW FRPSOLHV with best practice as prescribed by SAVAâ&#x20AC;&#x2122;s Product Stewardship Programme (PSP). According to Delanie Bezuidenhout, CEO of Belgotex chairman, Stephan Colle said that Belgotex was SURXG RI WDNLQJ \HW DQRWKHU ¾¿ UVW VWHSÂś IRU RWKHUV WR IROORZ â&#x20AC;&#x153;Thanks to the work SAVA is doing, we are optimistic and excited about what the future holds for the vinyls industry LQ 6RXWK $IULFD ´
SAVA, the association only licenses the coveted Vinyl. accreditation to member companies which, on application, have demonstrated third party YHULÂż FDWLRQ RI FRPSOLDQFH WR WKH 6$9$ 363 â&#x20AC;&#x153;The SAVA Product Stewardship Programme is a stringent set of long-term, self-administered objectives created to promote the interests of vinyl business throughout the entire PVC supply chain. By voluntarily signing the PSP, our members have committed themselves to the responsible and sustainable use of additives, supporting a responsible and sustainable vinyl recycling
Another glorious day and all in Durban KZN guys show their sensitive side, raise large sum for charity ,7 :$6 D Âż QH GD\ LQ 'XUEDQ RQ )ULGD\ -XQH ZLWK D ZKRSSLQJ Âż HOG RI WHHLQJ RII LQ JORULRXV VXQVKLQH DW WKH 5R\DO 'XUEDQ *ROI &OXE IRU WKH 3,6$ .=1 JROI GD\ No rain was predicted and we were all very cheerful, and it did indeed not rain â&#x20AC;&#x201C; so the weatherman was right for a change. Our main sponsor this year was President Plastics and the Newcastle companyâ&#x20AC;&#x2122;s MD Peter Ho was there at the start, but â&#x20AC;&#x201C; as a non-golfer and dedicated production man â&#x20AC;&#x201C; he didnâ&#x20AC;&#x2122;t stay the whole day. But â&#x20AC;&#x201C; surprise surprise â&#x20AC;&#x201C; the President Plastics II team were victorious on the day: Suntosh Balchund, Dhivan Govender, Mishan Lilrithan and Dave *RYHQGHU VFRUHG DQ LPSUHVVLYH SRLQWV ZHOO GRQH JX\V Second was the Banbury Chemicals fourball of Craig 6FKHIĂ&#x20AC; HU 0DUN 'RXJODV 6ORJURYH DQG 'HDQ 6LQFODLU 7KH 6N\ODQG WHDP FRPSOHWHG WKH WURSK\ KDXO ZLWK .DYLVK 5XSQDUDLQ .XEDVKLQ *RYHQGHU $VKOH\ %HJJV DQG -RVK Brophy in good form on the day. The prizes Over the past six years the Happy Wanderers and White Mountain Inn resorts have kindly sponsored mid-week selfcatering stays at their venues. This year they surpassed WKHPVHOYHV DQG RIIHUHG IRXU QLJKW PLG ZHHN VWD\V DW WKH
KZN golf winners Âą 7KH 3UHVLGHQW 3ODVWLFV Âľ,,Âś IRXUEDOO FRPSULVLQJ Sunthosh Balchund, Mishan Lilrithan, Dave Govender and Dhivan *RYHQGHU VFRUHG D IRUPLGDEOH SRLQWV RQ WKH GD\ +HUH ZH VHH them with Ian McIntosh, PISA national chairman Garth Taylor and â&#x20AC;&#x2DC;The &RDFKÂś 3LOOD\
respective resorts. PISA KZN would like to thank Richard and -HQQ\ 2VERUQH IRU WKH YHU\ JHQHURXV SUL]HV 5LFKDUG MRLQHG the chairmanâ&#x20AC;&#x2122;s fourball for the day. The special guest for the day was Ian McIntosh, the former Springbok selector and past Sharks and Springbok coach, who played in the chairmanâ&#x20AC;&#x2122;s fourball. For a man of 78, Ian still hits a good ball and the banter was worth the outing on its own. Royal Durban is Ianâ&#x20AC;&#x2122;s home course and he was able to give his teammates plenty of tips (which was very necessary). :KDW D VFKRODU DQG D JHQWOHPDQ All in all the day was a huge success and the auction by Ian RI D VLJQHG 6KDUNV MHUVH\ UDLVHG 5 Âą WKDQNV WR Macâ&#x20AC;&#x2122;s persistent badgering. 10-team man â&#x20AC;&#x201C; Bobby Pillay received a special award for his assistance with the KZN golf day over many years 46 AUGUST / SEPTEMBER 2015
label license holder programme, ensuring an ongoing and effective communiquĂŠ between the industry, public and government, and ensuring a healthy, robust industry health through growing product development, markets and applications,â&#x20AC;? said Delanie. â&#x20AC;&#x153;Belgotex are forever looking to improve our products and services in our ongoing Green Journey,â&#x20AC;? said Belgotex chairman, Stephan Colle. â&#x20AC;&#x153;We have D SURXG KHULWDJH RI Âż UVWV DQG OHDG E\ innovation so this was the next logical VWHS WR EHFRPH WKH Âż UVW OLFHQVH KROGHU RI the Vinyl. product label in South Africa,â&#x20AC;?
As a license holder of the Vinyl.product ODEHO DOO YLQ\O Ă&#x20AC; RRULQJ VROG E\ %HOJRWH[ Floors will bear the mark of quality. This seal â&#x20AC;&#x201C; a mark of environmental excellence â&#x20AC;&#x201C; is proof that the company is committed to the SAVA Product Stewardship Programme and contributes to transforming and environmentally conscious industry. â&#x20AC;&#x153;Since launching the plans to introduce the Vinyl. mark of quality to the industry last year, we have received an overwhelming amount of support from our members. Retailers have also
FRPH WR UHFRJQL]H WKH EHQHÂż WV WKDW WKH Vinyl. product label will unlock for their businesses. However, the process to qualify as a licensee is no easy or fast journey as we have to ensure that each potential licensee meets the necessary criteria of excellence that we have set out for them to achieve. To this end, we are thrilled to have one of the biggest players LQ RXU FRXQWU\ÂśV Ă&#x20AC; RRULQJ LQGXVWU\ DV D pioneer and brand ambassador,â&#x20AC;? Delanie added. www.savinyls.co.za www.belgotex.co.za
A special award was made to Bobby Pillay for his dedication and support of the PISA KZN golf day. Bobby arranges for 10 teams to enter each year. Thank you Bobby â&#x20AC;&#x2DC;GUPTAâ&#x20AC;&#x2122; â&#x20AC;&#x201C; you are a star. A big thank you to all the sponsors for their generous donations this year. The proceeds will go to Golden Hours Mentally Challenged School in Durban North. The aim is to supply benches and tables from recycled plastics.
The auctioneer â&#x20AC;&#x201C; Besides playing a good round of golf, former Bok coach Ian McIntosh also badgered the KZN guys to cough up â&#x20AC;Ś but it was also for a good cause as the proceeds for the day went to a local charity AUGUST / SEPTEMBER 2015 47
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Grant Neser has been appointed MD of JoJo Tanks
Paul Rogers returns to composites sector at Jushi SA
Mark Hepburn has been appointed MD of Bodo Möller Chemie
John Lindsay-Smith started TechDesign consultancy
Lowell September started sheet supply company, Genikul Plastics
Jeff Weakley appointed as new Seecor service technician for Gauteng
APPOINTMENTS & people on the move
PEOPLE
New man at JoJo helm Grant Neser, a civil engineer who has spent most of his career to date in the cement and concrete industry, has been appointed managing director of JoJo Tanks, the roto moulded tank business. Grant (52), who is taking over from Rod Cairns, has until recently worked at AfriSam with exposure to the cement as well as the aggregate and readymix business. He has also worked at the Industrial Development Corporation (IDC). His first job was as an assistant engineer in the SATS maintenance department at Durban harbour, so he has quite a bit of experience. JoJo operates seven manufacturing operations around South Africa (Groblersdal, Camperdown, East London, Glencoe, Hopetown, Pretoria and Worcester), managed from the group’s head office in Groblersdal. Rod Cairns is to become chairman of JoJo.
Rogers returns Paul Rogers has been appointed group commercial manager/GM designate of Jushi Group (SA) Sinosia Composite Materials Co, based in Johannesburg. Paul was previously involved in the composites industry with Harveys Composites until 2013, when
he moved into the security industry, but his experience in the composites area has now drawn him back. Jushi Group manufactures both E-glass and C-glass fiberglass products and fabrics, with over 200 types and varieties available. It is currently the largest producer of fiberglass reinforcements in China. Paul also assumes the responsibility for two group companies, Johnson Taylor Forklifts (supply of forklifts and construction equipment) and Sinosia Utama (supply of machine tools).
New MD for Bodo Möller Chemie Mark Hepburn has been appointed MD of Bodo Möller Chemie SA. With more than 30 years’ experience in the chemical industry and having held executive positions at Darvesh group, IMCD South Africa and T&C Chemicals, Hepburn is tasked with strengthening the German group’s trading activity throughout sub-Saharan Africa. His primary tasks at Bodo Möller are to broaden the company’s product portfolio and expand the logistics on site. Bodo Chemie head office and production plant are in Port Elizabeth and it runs a sales office in Johannesburg. Bodo Möller Chemie SA was recently honoured with a Toyota Supplier Award.
The South African subsidiary company is an established partner for companies in the Southern Africa and Sub-Sahara region, including countries such as Nigeria, Kenya, Zambia and Namibia. With more than 40 years of experience in distribution of specialty chemicals and adhesives, Bodo Möller Chemie is a leading trading partner for well-known European companies such as DOW Automotive Systems, HB Fuller, BASF and Huntsman Advanced Materials. Its product portfolio includes powerful adhesives and adhesive systems, additives for plastics, coatings, rubber products, textiles, lubricants and other specialty chemicals. www.bm-chemie.com
Tech Design John Lindsay-Smith has set up on his own, having started TechDesign, a consultancy business in Johannesburg. John has been involved with a number of SA’s major packaging groups and particularly in the design of several big production plants. One of his areas of focus now is in making plants more energy efficient: he supplies energy efficient lighting, a new ‘intelligent soft-start’ system for granulators and other equipment
Polyflor SA takes part in CEO sleep-out
Polyflor SA’s Tandy Coleman-Spolander spends a night on the street to raise millions for charity 48 AUGUST / SEPTEMBER 2015
POLYFLOR SA was proud to participate in this year’s CEO Sleep-out hosted for the first time in South Africa by Talk Radio station 702 and Sun International in June. Tandy Coleman-Spolander joined 244 business leaders in braving the cold and uncomfortable conditions, to spend a night sleeping on the hard pavements of Johannesburg to help raise over R25 million for the charity organisation Girls & Boys Town. With little more than the clothes she was wearing, a sleeping bag, a cardboard box and a fire to protect her against the elements, Tandy said the evening left her feeling humbled. “We had security, food and ablutions which would not be available to true street dwellers. I’ve a new respect for how the homeless survive on the street and I’m also extremely grateful for the life of comfort
many of us take for granted on a daily basis” she added. The initiative was started in Australia 10 years ago, and takes a different approach to philanthropy by asking CEOs, board executives, influencers and heads of professional firms to lead by example. Apart from having to raise and donate at least R100 000 to the project, each participant was also required to spend a night on the streets. Polyflor SA thanked the following sponsors who made it possible for Tandy to participate in this year’s event: Combined Flooring JNB, Turner Pierson, Pretoria Flooring, Buildia, D&L Flooring, Mastec, Flor Pro, Kevin Bates Flooring, Polyflor UK, Gradus Ltd. www.polyflor.co.za
Mkhululi ‘Khusta’ Adams appointed sales manager at Orion
Shephard Muterere has joined PET Technologies
as well as a range of extremely energy efficient chillers from Italy. He also does 3D CAD product, component and machine design and is also active in project management. techdesign@global.co.za
New sheet supplier Lowell September has taken the plunge and gone out on his own. Genikul Plastics, operating out of Mitchells Plain in the Western Cape, supplies a range of plastic sheet. Lowell has been involved in the sheet market since 1991 when he joined Ampaglas in Cape Town. He first handled deliveries and slowly climbed the ladder to storeman, internal sales, external sales and then became sales manager for Ampa in Cape Town. In 2007 he joined Paisley Plastics, an independent sheet supply business in Cape Town. He recently decided to start his own business and registered Genikul. The company’s core business is the supply of slipsheet; it also supplies virtually all types of plastic sheet, including ABS, polystyrene, polyprop, polyethylene, PET-G, foamed PVC and polycarbonate sheet. “Now, after 24 years in the industry, I’m looking forward to what the future holds.
Mike Meyer … has gone touring
Despite a relatively slow start, I believe that, with the necessary commitment and hard work, anything is possible,” said Lowell.
• Phone 084 928 8849 www.genikulplastic.com
Susan Brand has been appointed general manager of Atlas Plastics in Klerksdorp. She takes over from Gary Bolt, who has been steering the North-West rotational moulding company for the past 10 years. According to Susan, these are “big shoes to fill”. Jeffrey Weakley has joined Seecor, the blow moulding machine manufacturer and supplier, where he now fills the role of field service technician for the Gauteng region. A qualified electrician, Jeff did his apprenticeship at Ultrapak, which was a film extrusion business in East London, and then joined Hestico in Johannesburg, where he first worked as a service technician. Following that he moved to Mattman, where he was involved in machine control systems and rebuilds. He’s an expert on Siemens PLC systems and will be supporting Seecor customers across Gauteng. Mkhululi ‘Khusta’ Adams has been appointed sales manager: business line rubber at Orion Engineered Carbons, based in Port Elizabeth. He takes over from Rod Lochhead, who has decided to get
more involved in ocean sports, and who can blame him? Shephard Muterere has been appointed as the regional marketing representative for PET Technologies for the Southern African region. PET Technologies is an Austrianowned company based in the Ukraine; it manufactures a range of blow moulding machines with varying production capacities, according to accredited European standards. The company also manufactures compressors, chillers, preform box loaders and moulds. Shephard’s goal is to expose PET Technolgies to southern African PET bottle moulders. A number of the PET Technologies’ machines are already in operation in SA. Shephard, who is based in Harare, is available to provide information and specs. shepmutee@yahoo.com
OBITUARIES We regret to advise that Peter Webb of Prac-Pak of Cape Town passed away recently. He established Prac-Pak, a manufacturer of bags and pouches for the retail industry, in 1985 and the business had truly come of age. Peter’s son Russell now runs the Ottery-based company. We also unfortunately have to record the passing away of Ed Searle. Ed spent most of his career in the polymer industry in Johannesburg: he was originally involved in rubber and silicone material supply, and then spent about a decade in film extrusion at Coextruded Film Technologies and PSA Plastics up until 2014, when he returned to AUGUST / SEPTEMBER 2015 49
Dave Moore: 083 675 8325 Email: mouldbasesa@gmail.com
STANDARD FEATURES • Energy saving servo system • Proportional back pressure adjustment • Mould water flow regulator • Mould clamp set • T slot platens • Hopper slide • 2 core pull circuits • 2 air jet circuits • Double cylinders for carriage movement • Liquid grease lube system for toggles • Taiwanese Mirle controller • Roller mounted rear covers for easy access
MOULD BASE SA Dave Moore: 083 675 8325 | www.mouldbasesa.co.za
Cheers Johnny – A very decent lunch was held in Maritzburg to say farewell to John Everitt. In fact, a series of lunches for FI and WAG customers were held around the country in June – and the only guarantee was that it wasn’t boring,
John Everitt the surfer!
John Everitt is going surfing … and this time it’s serious
PEOPLE
Career of four decades spans huge change in material supply sector JOHN EVERITT, a committed raw materials supplier to the rubber industry as well as the plastics, chemical, resin, paper and medical sectors throughout Southern Africa over the past four decades, has decided it’s time to take surfing a bit more seriously. After a good innings in the industry, the step was a virtual inevitability for the man (as it ultimately is for most surfers!) The Durban-based maverick Everitt had been self-employed for most of the past 40-plus years, but in 2013 he sold his company (along with its various principal/supplier agreements) to West African Group. John’s father (the late Ray Everitt, cofounder of Lewis & Everitt in 1948), was one of the pioneers of the raw material supply market in Africa. John duly joined L&E, tasked with supplying to the paint and resin sectors. But he had little enthusiasm for ‘watching paint dry’ and gravitated almost unwittingly towards L&E’s rubber interests, including Barwell, a UK-based manufacturer of rubber extruders and pre-formers, and Maclaine Watson, a
Singapore-based natural rubber and NR latex trading company – meaning that he got involved in the rubber business at an early stage. Ray retired in 1979, having sold L&E to Anglo Vaal the year before. Two years later, John was literally looking for new horizons. He resigned with the intention of emigrating along with his young family to Reunion, following some great surfing trips to the tropical island paradise. He invested in an ocean-going trimaran to establish a yacht chartering/brokerage company on the island. However, embarrassing as it was to a surfer, continued bouts of severe sea-sickness during sea-trials off Durban put paid to the plan. Safely back on terra firma, an unexpected telex was received from Maclaine Watson appointing John as its SA agent. A quick decision had to be made and it was on 1 April 1981 (no joke) that Everitt Agencies moved into a tiny, single-room office in Metal Industries House close to the Durban beachfront. Ray joined the company in 1986, having completed a
restraint of trade, and his ability to manage the time-consuming daily admin, document processing and customs clearing procedures proved a huge help for the fledgling company which, in similar pioneering mode, was then renamed Frontier Industries. The foundation of ‘FI’ was the supply of NR and NR latex (Maclaine Watson had in the interim being bought by Cargill, a USA-based international commodities trader). John never looked back and FI’s style of operation – relaxed but efficient – remained consistent for the next three decades. It came as no surprise when FI’s success attracted the interest of West African Group, a far larger and more specialised materials supply operation. Amongst others, the combined FI-WAG portfolio includes various synthetic rubbers and polymers, of which will now be handled by the WAG team, including Frederica Smith; Rob McQueen, Rob MacNab and Willie Esterhuizen. Farewell to John Everitt who’s … gone to catch the next wave of his career!
material supply with Keeneyes International. He was only in his 50s. We also say farewell to Leon van der Merwe, formerly of Ultra Polymers, the material supplier in Johannesburg, who passed away in May.
with the corporations. After studying accounting, he started at AECI in Durban and then completed an MBA, whereupon he was moved up to Johannesburg in an accounts/admin capacity; but he wanted to get into sales and got the opportunity when a post came up at what was by then the Polifin office in Durban, prompting his return to the coast. Mike’s thoroughly enjoyed the ensuing few decades, although things did change, the most notable of which was in the area of customer relations – in the earlier years customer lunches were standard, which was fun, and the convertors and
suppliers hence became friends, but that’s all history now. In fact, customer lunches more recently have virtually prompted an investigation. But Mike has a lot of good stories from that time and is excited about his new venture as a tourist guide in KZN. He specialises in wildlife and scenery tours, including 4x4 trips. And it’s also goodbye to Manjary Subiah, Plastics|SA’s training manager for Gauteng, who is to leave the organisation in September to pursue her academic interests: she is to complete her PhD thesis in business leadership.
FAREWELLS It’s farewell to Mike Meyer, the popular Sasol Polymers’ senior account manager in Durban, who has taken the ‘golden handshake’ and gone into the tourism business. Mike followed the logical progression from AECI to Polifin and then Sasol and spent a total of 34 years 50 AUGUST / SEPTEMBER 2015
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Lifting of sanctions will give boost to Iranian polymers industry
More than 5 million tons of polyolefin capacity in Iran The UN sanctions have not directly restricted the oil and petrochemical industries (unless they are owned by the THE recent signing of the Joint Iranian Government or the Revolutionary Comprehensive Plan of Action Agreement Guard) or other international trade. between the permanent members of the Sanctions applied by the EU, which UN Security Council and Germany (the P5+1 group) and Iran opens a new chapter initially also targeted products and companies related to the nuclear for the Middle East polymer industry: programme, were extended in 2010 to a new source of polymers without the also include oil and polymers. While the complications of complying with a complex EU market was effectively closed to Iran, collection of sanctions. The signing of the elsewhere, countries complying with the agreement, which has not been universally UN sanctions were still able to buy oil welcomed, will lead to the progressive and petrochemicals from Iran. lifting of sanctions in return for limitations In 2012 the EU instructed the Belgiumon the Iranian nuclear programme. based SWIFT to exclude all Iranian Iran has been subject to multiple banks (and not just previously blacklisted sanctions dating back to the Iranian banks) from using the Revolution in 1979. The SWIFT system. SWIFT is a strictest sanctions are Expected that secure messaging service those imposed by the used globally by banks USA which bars US polymer volumes to transfer money across citizens and companies available for export borders and the exclusion from doing any business of Iranian banks from using with Iran without a waiver will increase by the system effectively from the US Treasury. 30-40% prevented non-EU and nonForeign companies are USA banks from handling prevented from doing payments to or from Iran. Certain countries transactions with Iran in US dollars, and continued buying oil and polymers from those that do business with Iran can be Iran (as allowed by the UN) but it effectively restricted from doing business in the USA became on a barter-basis. The result of DQG PD\ EH ¿ QHG IRU FHUWDLQ EUHDFKHV RI these concerted sanctions resulted in a US law. The French bank BNP Paribas rapid devaluation of the Rial, widespread DJUHHG WR SD\ D ELOOLRQ ¿ QH ODVW \HDU VKRUWDJHV DQG KLJK LQÀ DWLRQ for violating US sanctions on Iran (and The election of President Rouhani in Sudan and Cuba). While some of the US 2013 opened the door for negotiations sanctions are in response to the Iranian between Iran and the P5+1 group on nuclear programme, there are other the nuclear enrichment issue. After sanctions related to alleged sponsorship more than one-and-a-half years of of terrorism and human rights abuses QHJRWLDWLRQV DQ DJUHHPHQW ZDV ¿ QDOO\ and those are not likely to be lifted as a signed in July 2015 which will lead to result of this agreement. a partial lifting of sanctions. Although The United Nations imposed sanctions details have not been released it is on Iran in 2006 when Iran refused to expected that banking restrictions will be suspend all uranium enrichment and eased and oil and petrochemical exports reprocessing activities. Initially the UN will be allowed to Europe. sanctions targeted companies and There is a great deal of excitement individuals tied to the nuclear programme, that the lifting of sanctions will open but they have been extended to include the Iranian petrochemical market to banks and shipping lines and freezing Iranian state assets worth billions of dollars. international companies. Iran has the third
52 AUGUST / SEPTEMBER 2015
FEATURE
BY DR NIALL MARSHALL
largest proven oil reserves in the world as well as the second largest natural gas reserves, and while it already has a large petrochemical industry there is a lot of potential for growth which means business IRU HQJLQHHULQJ ¿ UPV DQG LQYHVWPHQW opportunities for oil companies. Iran has announced that it plans to spend $100 billion on oil and gas projects in the next four years and European companies, including Total, Eni and OMW, have already started discussions for when the sanctions are lifted. The lifting of sanctions will give a boost to the polymers industry too. There is more WKDQ PLOOLRQ WRQV RI SRO\ROH¿ Q FDSDFLW\ LQ Iran and while production volumes are down for various operational reasons (including the availability of spares and process materials such as catalysts), Iran remains a major exporter to Asia. Once sanctions are lifted many of these issues will fall away and it is expected that polymer volumes available for export will increase by 30-40% within a relatively short period of time and new markets, especially Europe, will open to Iranian producers. Further investments are planned to add another 3 million tons RI SRO\ROH¿ Q FDSDFLW\ LQ WKH QH[W WHQ \HDUV It may have seemed that the signing of the JCPA agreement was just about restricting Iran’s capability to produce a nuclear bomb, but really it has allowed another low-cost oil and petrochemical producer into the global economy. And this can only make the Middle East polymer market more interesting! NIALL CAN BE REACHED AT: NIALL.MARSHALL@EVERSPRINGME.COM
PRODUCTS
Innovative hose handle can help prevent injuries DALE Greggâ&#x20AC;&#x2122;s unique pipe grip was developed as a way to avoid injuries caused while moving large hoses and pipes in industries like oil and frac sand mining. Gregg, owner of Handle-Tech in the USA, used innovative compounds from RTP Company and plastic mouldings from Gemma Plastic Products to create an independent, removable handle that could lock onto a hose or pipe, allowing workers to move hoses while standing in a natural, upright position, like holding a suitcase. Gregg got the idea for the product when a friend explained how his son had crushed his hand while moving VHFWLRQV RI KHDY\ KRVH LQ WKH RLO Âż HOGV RI &DQDGD +H XVHG a 3D printer to create a device that could help avoid these injuries, and â&#x20AC;&#x201C; after seven prototypes â&#x20AC;&#x201C; brought the device to an international oil and gas show. Fueled by the interest of the industry, Gregg shifted his attention to manufacturing. He met with Tom Vermeeren from Gemma Plastic Products. Tom advised Gregg to use ORQJ JODVVÂż EUH UHLQIRUFHG Q\ORQ www.handle-tech.com from RTP Company.
The unique pipe grip from Handle-Tech of the USA helps reduce the number of industrial accidents by allowing workers to move hose RU SLSH VDIHO\ DQG HIÂż FLHQWO\
Âł, VWLOO FDQÂśW EHOLHYH KRZ ZHOO WKLV PDWHULDO Âż WV P\ YLVLRQ ,WÂśV extremely strong, has great electrical insulation characteristics and is practically impervious to heat and cold.â&#x20AC;? Using long JODVVÂż EUH UHLQIRUFHG Q\ORQ IURP 573 &RPSDQ\ *UHJJ partnered with Gemma Plastic Products to mould the plastic. www.gemmaplastics.com
www.husqvarna.com
www.greiner-gpi.com
Easy to handle,
WZLFH WKH EHQHĂ&#x20AC; W GREINER Packaging of Austria put its expertise to the test in implementing the new Husqvarna â&#x20AC;&#x2DC;Combiâ&#x20AC;&#x2122; can design. The result: an innovative oil/gasoline FRQWDLQHU WKDW \LHOGV QXPHURXV EHQHÂż WV both in production and in use. Husqvarna is one of the most successful providers of agricultural and gardening machinery and tools in the world and is a market leader in the forestry and landscaping equipment sector. The new Combi can holds oil in one container and gasoline in another and was specially designed for chainsaw users who, thanks to the refueling tanks, can now keep working without major interruptions.
Until now, the oil and gasoline containers had to be produced separately and then assembled. Intensive collaboration led to the GHVLJQ RI D VLJQLÂż FDQWO\ PRUH HIÂż FLHQW production process: A container consisting of two chambers can now be manufactured in one production step and with only one tool. The timeconsuming assembly step is gone, helping to save costs. And users also EHQHÂż W IURP WKH QHZ FRQWDLQHU $ VSDFH was added between the two containers to provide room for tools and spare parts and, thus, facilitating uninterrupted work. Transparent windows in both
www.rtpcompany.com
The newly redesigned Husqvarna Combi can is an innovative oil/gasoline container which can carry 2.5 litres of oil and 5 litres of fuel. It is extrusion blow moulded in HDPE and MB
chambers also allow the user to check the oil and gasoline level at any time.
Lightweight chains DSM Dyneema and Norway-based Load Solutions AS, a global provider of lashing and loading systems for the transport industry, have launched their innovative lightweight synthetic TycanÂŽ chain. The chain has been hailed for its outstanding
performance by users across a wide range of industries, from shipping, mining DQG RLO DQG JDV WR FRPPHUFLDO Âż VKLQJ Tycan chain is a non-metallic link chain made with Dyneema and developed to replace the steel chains that are traditionally used to lash and secure project cargo during transportation. Dyneema is a patent-protected ultra-high 54 AUGUST / SEPTEMBER 2015
molecular weight polyethylene (UHMWPE) Âż EUH PDGH E\ '60 '\QHHPD ZKLFK LV times stronger than steel on a weight-toweight basis and up to 40% stronger than aramid materials. Tycan chain weighs up to 8 times less than its conventional metal FRXQWHUSDUWV DQG LV PRUH WKDQ WLPHV less noisy in use. www.dyneema.com
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New EVM rubber
1 Lanxess has launched a new family of precrosslinked EVM rubbers. With the ethylene-vinyl acetate copolymers of Levapren PXLSeries it is possible to reduce the mixing times in the production process, for example in 1) the manufacture of KLJK TXDOLW\ FDEOH VKHDWKV LQ Ă&#x20AC; DPH UHWDUGDQW Ă&#x20AC; RRU FRYHULQJV EHWZHHQ WUDLQ carriages, and 4) in the manufacture of cylinder head cover seals for the VW Tuareg (Photos: Lanxess AG)
for reduced mixing times
56 AUGUST / SEPTEMBER 2015
MATERIALS
Ideal for continuous mixing processes LANXESS is launching a new family of pre-crosslinked EVM rubbers, in the form of the ethylene-vinyl acetate copolymers of the Levapren PXL series. These have been developed VSHFLÂż FDOO\ IRU UDSLG SURFHVVLQJ LQ particularly cost-effective, continuous mixing processes â&#x20AC;&#x201C; using Buss cokneaders, for instance, or twin-screw extruders. Among other things, the freeĂ&#x20AC; RZLQJ JUDQXOHV DUH LGHDO IRU UHGXFLQJ mixing times when producing particularly high-quality hoses or cable sheathings. Samples of the new ethylene vinyl acetate rubbers have already been PDGH DYDLODEOH WR WKH Âż UVW FXVWRPHUV 7KH Âż UVW JUDGHV WR EH DYDLODEOH DUH 3;/ 3;/ 3;/ DQG 3;/ ZLWK YLQ\O DFHWDWH FRQWHQWV RI EHWZHHQ DQG 7KH SURSHUWLHV RI YXOFDQL]DWHV produced using Levapren PXL are similar to those made using conventional EVM rubbers from Lanxess.
several advantages â&#x20AC;&#x201C; for instance, IHZHU SODVWLFL]HUV RU HYHQ QRQH DW all are needed for EVM processing. However, some users require EVM rubbers with somewhat higher viscosity. For some time now, we have been able to offer these customers our precrosslinked Levapren XL grades.â&#x20AC;? However, the technical conditions of the radiation crosslinking process used in the production of these grades mean they have to be mixed very well if the surface of the extrudates has to meet particularly high quality standards. â&#x20AC;&#x153;We have therefore long been looking for an alternative crosslinking technology, and have now found the solution in reactive extrusion,â&#x20AC;? said Stumbaum. In this process, the polymer is precrosslinked with very small amounts of peroxide â&#x20AC;&#x201C; although it is ensured that the product does not contain any traces of the crosslinking agent at a later stage. The process ensures that all Levapren PXL granules have the same crosslinking density. The result is freeĂ&#x20AC; RZLQJ (90 JUDQXOHV WKDW DUH TXLFN DQG easy to process in an internal mixer or in continuous mixing processes and deliver H[FHSWLRQDO Ă&#x20AC; RZ SURSHUWLHV Âą WKLV LV UHĂ&#x20AC; HFWHG IRU H[DPSOH LQ WKH SDUWLFXODUO\
Processing advantages â&#x20AC;&#x153;Standard Levapren grades have a much lower Mooney viscosity than many other synthetic rubbers,â&#x20AC;? said EVM specialist JĂśrg Stumbaum from the High Performance Elastomers business unit at Lanxess. â&#x20AC;&#x153;This brings
high surface quality of the extrudates. The rubbers in the Levapren PXL series also provide much higher green strength than standard and XL grades. â&#x20AC;&#x153;This can increase process reliability in the production of feeding strips for the extruder, for instance,â&#x20AC;? said Stumbaum. â&#x20AC;&#x153;And the increased creeping strength FDQ DOVR KDYH EHQHÂż WV IRU KRVH DQG SURÂż OH H[WUXVLRQ ´ :KDWÂśV PRUH WKH QHZ Levapren PXL grades from Lanxess are much less susceptible to blocking even after long-term storage, which keeps WKH PDWHULDO IUHH Ă&#x20AC; RZLQJ â&#x20AC;&#x153;Levapren PXL is a pre-crosslinked EVM grade that we have developed VSHFLÂż FDOO\ IRU TXLFN DQG FRVW HIIHFWLYH processing in continuous production. This technology is set to become increasingly important â&#x20AC;&#x201C; and not just for SMEs in the rubber processing industry,â&#x20AC;? said Stumbaum. â&#x20AC;&#x153;We are also aiming to extend the user group to processors of rubber and plastics who have not been able to work with Levapren until now. Thanks to Levapren PXL, versatile EVM rubber has now EHFRPH HYHQ PRUH Ă&#x20AC; H[LEOH ´ Plastichem are the Lanxess partners in Southern Africa for the new Levapren PXL series
www.plastichem.co.za 2
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MATERIALS
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Mold In Graphicsâ&#x20AC;&#x2122; new MIG 5 Supplier addresses all challenges MOLD In Graphic Systems of the USA, a world leader in the SHUPDQHQW GHFRUDWLRQ RI URWR PRXOGHG SRO\ROHÂż Q SODVWLFV KDV been busy: its new generation of in-mould Mold In GraphicsÂŽ â&#x20AC;&#x201C; the MIGÂŽ5 series â&#x20AC;&#x201C; was launched recently. While Mold In Graphics have always delivered an outstanding result, under FHUWDLQ PRXOGLQJ FRQGLWLRQV WKH\ FRXOG EH GLIÂż FXOW WR DSSO\ 7KLV DOO FKDQJHG ZLWK WKH ODXQFK RI WKH Âż IWK JHQHUDWLRQ 0,*ÂŽ5 series. Âł7KH QHZ 0,*ÂŽ5 Graphic addresses all the concerns that roto moulders had, when working with Mold In GraphicsÂŽ in WKH SDVW VSHFLÂż FDOO\ WKH WLJKW DSSOLFDWLRQ SDUDPHWHUV ´ VDLG Nick Moldan of MIGS. Moldan, originally from South Africa but now based in France, recently visited roto moulders around Southern $IULFD FRQGXFWLQJ WULDOV DQG GHPRQVWUDWLQJ WKH EHQHÂż WV RI the new system.
7KLV QHZ 0,*ÂŽ5 graphic system is now incredibly easy to work with. For a start, they can be applied to the mould at any temperature â&#x20AC;&#x201C; no matter how hot or cold. No need now to cool down the mould to apply the graphic, a major concern for moulders in the past. It is now â&#x20AC;&#x153;possible to decorate what you QHYHU WKRXJKW ZDV SRVVLEOH ´ VDLG 0ROGDQ A further major step forward is that aerosol adhesive is no longer required, simplifying the application process and reducing the opportunity for operator error. Lastly, a new pigment package has been developed, resulting in bolder, stronger colours and excellent opacity. /RJRV DQG EUDQGV WUXO\ ÂłMXPS RXW´ QRZ Âł7KHUH UHDOO\ LV QR EHWWHU ZD\ WR EUDQG DQG GHFRUDWH SRO\ROHÂż Q SODVWLFV +LJKO\ HIÂż FLHQW WR XVH LQ D EXV\ SURGXFWLRQ HQYLURQPHQW and truly permanent, he added. www.moldingraphics.com Dump Ezy â&#x20AC;&#x201C; An easily LGHQWLÂż DEOH DQG UXJJHG solution for waste disposal from Gough Plastics of Australia, the â&#x20AC;&#x2DC;Dump-Ezyâ&#x20AC;&#x2122; system is designed for the disposal of portable waste from mobile vehicles and boats. With effective, self-evident operational signage, the various models have a lockable lid and moulded-in handle and rubber seal
58 AUGUST / SEPTEMBER 2015
Keep out! â&#x20AC;&#x201C; Marwood Group of the UK makes use of permanent graphics from MIGSÂŽ for its roto moulded rental road barriers. Mold In Graphic logos have resulted in permanent, high visibility road side branding and are proving effective with stock management and loss prevention
graphics far easier to use Max out on colour – Bright and intensely coloured Mold On Graphics® were chosen by Warrior Tanks of Papua New Guinea to UDLVH WKHLU SUR¿ OH LQ WKH highly competitive water storage market
*RLQJ ZLWK WKH À RZ – Mold In Graphics’ products have proved extremely popular in the kayak and water sports market. Here branding and durability of the graphic are very important. Fluid Kayaks of Parys (on the Vaal in South Africa) has used the MIGS® products for several years
Four’N Twenty – The roto moulded vendor systems from Four-‘N Twenty of Australia, for the sale of the iconic Australian meat pie. A football match would not be the same without a Four’N Twenty Pie! MIG graphics are used for permanent point of sale branding
Lifesaver – The range of Lifesaver® M1 water bowsers in Malaysia, in bright colours ZLWK UHDGLO\ LGHQWL¿ DEOH graphics from MIGS, have been effective in situations ZKHUH WKH VXSSO\ RI FOHDQ GULQNLQJ ZDWHU LV QHFHVVDU\ 1DQR ¿ OWUDWLRQ technology delivers safe, sterile drinking water
Back in Mozambique – Plastex of Mozambique has made wide use of graphics from MIGS for nearly ten years. Their black water tanks with bold, bright branding have as a result become the standard for water storage and distribution in that country; the company recently celebrated its 20th year in operation – well done! AUGUST / SEPTEMBER 2015
Colour Compounding of Roto and Speciality Polymers Pulverising of Roto and Speciality Powders Agents for MIGS® Clive Robertson Michael Böltau Chanda Mukuka Address:
cliverobertson@iburst.co.za tech@rotoflo.co.za sales@rotoflo.co.za
28 Hilston Road Kya Sands Randburg, Johannesburg
082 880 4976 084 540 2896 011 708 3361 / Fax: 011 708 1919
59
MATERIALS
Security and ID card market benefits from Bayer PC films Materials portfolio addresses evolving needs of this highly innovative sector FORGERY is a major challenge for ID card manufacturers. Bayer MaterialScience, one of the world’s leading suppliers of polycarbonate films for security and ID cards, offers a portfolio of polycarbonate films that makes it possible for card manufacturers to incorporate a wide range of security features into their products. “With 20-plus years of polycarbonate film expertise and application-specific know-how, we are able to collaborate with our customers on specific solutions designed to address the evolving challenges in the market,” said Georgios Tziovaras, Specialty Films business development manager at Bayer MaterialScience. With its ability to fuse multiple layers into a monolithic structure, Makrofol® ID polycarbonate film is an ideal material for manufacturing secure cards and documents. And, because it is manufactured with extremely narrowly defined tolerances, it can meet even very tough requirements. Makrofol ID 332 Superlaser film is
Cards using the Makrofol® ID Superlaser film from Bayer MaterialScience can be personalized significantly faster than other cards with comparable construction and contrast levels, which saves considerable time and money
laser-engravable and able to boost laser personalisation speeds while maintaining excellent high contract and image quality. Other Bayer polycarbonate films specially designed for card applications include a transparent scratch- and chemical-resistant grade (Makrofol® ID 320 polycarbonate film), a D2T2 printable
grade (Makrofol® ID 285 Dyefusion film) and a very thin, white film (Makrofol® ID 4-4 polycarbonate film) designed to cover chip modules integrated into the core of polycarbonate cards.
www.materialscience.bayer.com
Heat exchangers with fluoroplastics tubes prove resistant to corrosion THANKS to the use of Teflon® PTFE based AlWaFlon® fluoroplastic tubes and fluoroplastic linings, heat exchangers supplied by Wallstein Ingenieur GmbH of Recklinghausen/Germany withstand the attack of highly corrosive media released when flue gas is cooled down to well below the acid dew point temperature. One current application example are the gas-gas heat exchangers (GGH) serving in the flue gas desulphurisation system of the waste-to-energy (incineration) plant at the Chinese town of Laogang, Nanhui near Shanghai, which ranks among the
world’s largest plants of its kind. At this site, four such heat exchangers have been in trouble-free continuous operation since June 2012 under very demanding conditions. Designed for all-round corrosion resistance capability, each of these four lines consists of two modules with 8-metre-long AlWaFlon tubes measuring 52mm in diameter. The use of AlWaFlon fluoroplastic tubes offers benefits in many respects. Thanks to their outstanding corrosion resistance they ensure a longterm trouble-free availability of the plant. In addition, they provide high thermal shock resistance and good heat transfer properties. Another advantage
is the reduced time required for cleaning cycles, which are rarely required given the anti-stick properties of Teflon. The AlWaFlon system was jointly developed in partnership between Wallstein Ingenieur GmbH, DuPont, and Fluortubing B.V. of the Netherlands. The product is characterised by an exceptionally high maximum usage temperature of 260°C and a similarly high Vicat softening point of 130°C to 140°C, combined with both a high flexural fatigue strength and stress cracking resistance. Certain applications are made possible only by the system’s exceptionally high long-term resistance to the combined effects of internal pressure and high temperatures. www.dupont.com
Four large-size gas-gas heat exchanger modules equipped with Teflon PTFE based AlWaFlon fluoroplastics tubes form part of the flue gas cleaning system at the giant waste incineration plant operating in the Chinese town of Laogang near Shanghai
60 AUGUST / SEPTEMBER 2015
MATERIALS
World’s first rear axle transmission crossbeam made of plastic in the S-Class from Mercedes-Benz
World’s 1st
rear axle transmission crossbeam
made of plastic
62 AUGUST / SEPTEMBER 2015
Engineering plastic Ultramid® A3WG10 CR saves 25% weight compared to die-cast aluminum design THE world’s first plastic transmission crossbeam in the rear axle subframe has been developed by ContiTech Vibration Control and BASF for the S-Class from MercedesBenz. It is made from the engineering plastic Ultramid® A3WG10 CR, a specialty polyamide from BASF which is particularly reinforced and optimized to withstand high mechanical loads. Compared to the previous beam made from die-cast aluminium, this highly durable component offers a weight saving of 25%, better acoustics as well as excellent mechanical properties even at high temperatures and conforms
to the latest crash requirements. The design expertise of BASF’s simulation tool Ultrasim® also made a major contribution to these properties. The plastic load-bearing structural component meets all the requirements for the static and dynamic loads which act on a transmission beam: As a central component of the rear axle it supports part of the torque which is transferred from the engine to the transmission, and bears a constant share of the load of the differential. This is why the Ultramid crossbeam is used in all the vehicle designs from Mercedes-Benz with all-wheel drive, with
the exception of the AMG cars. In order to replace the aluminium in this demanding, crash-relevant application, the plastic has to meet high mechanical requirements: The plastic Ultramid A3WG10 CR (CR = crash-resistant), which is 50% glass fibre reinforced, shows optimum strength and rigidity and displays a low tendency to creep under constant loading. In addition, the material has to withstand high bending torques. The component shows good NVH performance (NVH= noise, vibration, harshness). www.ultramid.de
Solvay PPSU improves lifetime, performance of ergonomic tattoo grips Reduced weight of grips by over 60%, lowered manufacturing costs MORPHIX Inc, an innovative designer and manufacturer of tattoo equipment, has chosen Solvay’s Radel® PPSU resin to pioneer lighter, longer lasting designs for its innovative Humbolt® and Flatiron® tattoo needle grips. Morphix designed its grips to help relieve the pain and discomfort associated with repetitive-use stress injuries that tattoo artists often experience. As an alternative to conventional metals, Solvay’s tough, injection-mouldable Radel PPSU resin enabled the company to affordably develop light-weight grips with more ergonomic contours and surface textures and to offer grips in a wider selection of colours. “Tattoo artists’ hands take a beating,” said Todd Myers, Morphix president and chief executive officer. “Between the heavy
equipment, constant vibration and repetitive motion, many artists battle with wrist and digital pain throughout their career. Our redesigned grips are a lot lighter and more comfortable than standard metal grips, and they give artists better control.” “We’ve never seen a thermoplastic material perform as well in stress testing as Radel PPSU,” said Myers. “Each grip design integrates two sets of metal threads to which we simultaneously applied 101.7 N-m of torque without observing any cracking or breakage. The tensile strength for Radel PPSU is off the charts for our product. No other material came close. Equally important, we reached a milestone of 1,000 sterilization cycles under load.” Myers added that Radel PPSU will not only allow Morphix’s redesigned grips to
Radel® PPSU resin enabled Morphix to mould longer lasting ergonomic tattoo grips. (PHOTO COURTESY SOLVAY SA)
last four times longer than earlier designs, it will also help them maintain their aesthetics longer in the tattoo parlour’s unforgiving environment of dried ink, blood, harsh surface disinfectants and the daily rigors of steam-heat sterilization. www.solvayspecialtypolymers.com
Styrolution is the exclusive supplier for mirror and pillar coverings on the new 2016 Jeep® Renegade (PHOTO, FCA BRAZIL)
Styrolution equips the new
Jeep Renegade 2016 MATERIALS
Mirrors and pillars will use specially formulated version of Luran® S 778T AS THE leading styrenic material solution provider to the automotive industry, Styrolution is the exclusive supplier for mirror and pillar coverings on the new 2016 Jeep® Renegade. The new SUV was introduced to the Brazilian market in April and is manufactured at Jeep’s factory in in Pernambuco, Northeast Brazilian state. Luran® S 778T is an ideal material for automotive exterior applications: The Renegade’s rearview mirror and coverings for its B & C pillars use Luran S 778T, a customized formulation of acrylonitrile styrene acrylate (ASA) from Styrolution. This specialty styrenic material boasts superior weathering, impact and chemi-
cal resistance when compared with other polymers. Luran S also offers excellent design flexibility due to its colourability and dimensional stability. The material also provides good surface adhesion, making it possible for car manufacturers to overlay the Luran S substrate with a hot-stamped foil for decorative features on exterior parts, such as front grilles. Styrolution’s Novodur® HH, high-heat acrylonitrile butadiene styrene (ABS), is also a proven solution for automobile interior and exterior decorative parts. “Automotive customers require styrenic polymers that offer greater design flex-
ibility, enhanced material performance and premium aesthetics. The Jeep brand is known for its rugged and sporty look, making it staple for outdoor and off-road enthusiasts,” said Paulo Motta, business director, South America, Styrolution. “This raises the bar for material performance, making Luran S an ideal polymer for these exterior applications,” she added. • Plastichem represent Styrolution in South Africa
www.styrolution.com www.plastichem.co.za
Solvay materials fuel breakthrough innovation of
‘Polimotor 2’ all-plastic car engine
64 AUGUST / SEPTEMBER 2015
Solvay will replace up to 10 metal engine components SOLVAY is taking a leadership role in the development of the Polimotor 2 all-plastic automotive engine to be tested in a race car next year. The collaborative project will ultimately set the stage for innovative breakthroughs in future commercial automobiles. Automotive engines typically are made entirely of metal and are the single heaviest part in a car. Polimotor 2 aims to develop an engine weighing 63-67kg, or about 41kg less than today’s standard production engine. Solvay is the industry leader in specialty polymers materials for the automotive industry, which is increasingly relying on the company’s ultra-resilient materials solutions to replace metal parts in exterior, interior
and underhood applications to enable the industry to comply with tougher fuel and emission regulations. In Polimotor 2, Solvay will replace up to 10 metal engine components – including the water pump, oil pump, water inlet/outlet, throttle body, fuel rail, cam sprockets and others – with parts made from seven of its high-performing thermoplastic materials. The Polimotor 2 four-cylinder, doubleoverhead CAM engine will ultimately be installed in a Norma M-20 concept car in 2016 for competitive racing at Lime Rock Park, Conn. Solvay contributed a major role toward the success of the first Polimotor engine, conceived by U.S. engineer Matti Holtzberg in the early 1980s.
www.solvay.com
In Polimotor 2, Solvay will replace up to 10 metal engine components – including the water pump, oil pump, water inlet/outlet, throttle body, fuel rail, cam sprockets and others – with parts made from seven of its high-performing thermoplastic materials
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MATERIALS
Clariant launches Licocene toolbox for sustainable hot melts Provide perfect balance between adhesion and cohesion CLARIANT has created the complete toolbox for formulators to design hot melts with superior performance for any need, using sustainable processing. It features Clariant’s acclaimed Licocene® metallocenebased systems and formulating guidelines, and was unveiled at the European Coatings Show 2015. Unique Licocene Performance solutions have low molecular weight yet high mechanical strength. For hot melt adhesives, they are valued for providing a perfect balance between adhesion and cohesion. The optimized Licocene viscosity profile in particular achieves desired properties even at low processing temperatures. Excellent thermal stability means less charring, no gelling, and enables higher productivity, generated by reduced cleaning downtime and increased mileage due to its low density. Further improved Licocene solutions offer possibilities for an adhesion boost to support formulators’ switch to using less tackifying resin in PE and PP based hot melt adhesives. To meet the steady growth for Licocene Performance Polymers since their launch in 2006, Clariant is increasing production capacity by 50% at its facility in the FrankfurtHöchst Industrial Park in Germany. The additional capacity is scheduled to come on stream during the first quarter of 2016. www.clariant.com Licocene® waxes provide a perfect balance of adhesion and cohesion for hot melts
Transparent noise protection for humans & animals BAYER’S Makrolon® Silent Sound solid polycarbonate sheets are more and more becoming the material of choice for noise protection barriers along highly frequented highways, expressways and railways. They reduce the noise level and resist weathering, falling rock and collision impact as well as vandalism. To ensure the well-being not only of the residents but also of birds, the sheets also feature highly effective protection against bird collisions. Makrolon Silent Sound solid sheets with a thickness from 8 to 20mm reduce the noise level by up to 34dB. The sheets are certified according to DIN EN 1793-2 and provide sustainable noise protection even in places where high-speed trains rush by at 250 km/h. With a maximum weight of only 24kg/m2, the polycarbonate sheets from Bayer MaterialScience are lightweight compared to conventional building materials while fulfilling the highest possible safety standards. www.materialscience.bayer.com 66 AUGUST / SEPTEMBER 2015
>>To set the right tone we invent 80,000 new colours every year.<< WHAT IS PRECIOUS TO YOU?
Clariant Southern Africa (Pty) Ltd, 329 Tungsten Road, Strydom Park, Randburg. RSA Tel: +27 11 (0) 796 3400 www.clariant.com
EQUIPMENT
TMC and NTIP
SDUWQHUVKLS EHQHÀ WV apprentices PLASTIC injection moulding forms part of the National Tooling Initiative Programme curriculum for South African toolmaker apprentices participating in the TDM Powered Programme. Here students are required to produce and sample injection moulds, all made possible with TMC plastic injection moulding machines provided by Maritime Marketing at a discounted price. Maritime Marketing does this in support of the training of future toolmakers, a resource currently scarce in South Africa. Most recently, the Cape Town Tooling Centre of Excellence and NECSA Tooling Centre of Excellence took ownership
Maritime Marketing’s Jan Delport (senior technician) and Martin Botha, project manager at the Western Cape Tooling Centre of Excellence with one of the TMC machines
of new TMC injection moulding machines from Maritime Marketing to ensure that the programme is able to carry out its mandate of rehabilitating the tool, die and mouldmaking sector for the manufacturing industry in SA. www.marimark.co.za
www.ntipweb.co.za
Load cells increase accuracy of vacuum dryer (QKDQFHV HI¿ FLHQF\ DQG YHUVDWLOLW\ RI SODVWLFV SURFHVVLQJ MAGUIRE Products has incorporated load cell technology into its patented VBD™ vacuum resin dryer, increasing its accuracy and reliability and providing plastics processors with new capabilities for controlling and documenting their use of material. The VBD dryer now uses load cells for continuous control of the resin level in
two of the three vessels in the system-the vacuum chamber and the retention hopper. The load cells operate on a lossin-weight basis, providing real-time data on material throughput that is unaffected by variations in bulk density. They achieve accuracy of +/- 0.5%, according to Mike Gera, senior dryer product manager. “The use of load cells in the vacuum and retention vessels provides 100% reliability and is superior to alternatives such as capacitive proximity sensors and paddle wheel sensors,” said Gera. “Because of their accuracy, they provide molders and extrusion processors with QHZ WRROV IRU LQFUHDVLQJ WKH HI¿ FLHQF\ DQG versatility of their operations.” The cost savings achieved with vacuum drying in comparison with standard desiccant dryers result from a reduction in Shown with Maguire VBD vacuum dryer are president and chief designer Steve Maguire (left) and senior dryer product manager Mike Gera. Load cells are located beneath the vacuum vessel (middle vessel in photo) and the retention vessel (at bottom) 68 AUGUST / SEPTEMBER 2015
energy consumption of more than 60%; elimination of the need to regenerate desiccant; and reduction in startup time as a result of a drying cycle that is only onesixth as long. In addition, resin is exposed to elevated temperature for as much as 80% less time than with the desiccant dryer, which means less processed-in stress. The VBD system eliminates most moving parts, using gravity to move material through vertically arranged stages of the drying process. It is typically a continuous batching operation carried out in three heavily insulated, stainless steel-lined vessels arranged vertically. High-speed slide-gate valves for dispensing material from one vessel to another have an accuracy per dispense of +/- 4 grams and are of the same design widely employed in other Maguire equipment. The system uses ambient air that is circulated by a blower whose variable-frequency drive saves energy. Maguire is represented in SA by Hestico
www.maguire.com
www.hestico.co.za
Injection Moulding Machines
30 years of partnership in South Africa Excellent local back-up & support
Precision Reliability
Tried and tested globally since 1977 Over 450 machines in South Africa
Turnkey solutions High Performance
Stock available in South Africa
Low Maintenance Cost
m m
maritimemarketing plastics machinery
Tel: Email: Web:
+27 (0)11 466 1717 sales@marimark.co.za www.marimark.co.za
EQUIPMENT
Optimized temperature pelletizing â&#x20AC;&#x201C; With OTP, pellets will shine like diamonds, no voids, no dents, no other defects
Revolutionary process to cut
www.joesten.co.za
www.maag.com
WKHUPRSODVWLFV XQGHU ZDWHU MAAG Automatik has developed a revolutionary process for pelletizing special engineering polymers. Optimized Temperature Pelletizing (OTP) opens the way to pelletize technical thermoplastics in Maagâ&#x20AC;&#x2122;s SpheroÂŽ underwater pelletizing system. It can cover the entire process from plastic PHOW WR Âż QLVKHG KLJK TXDOLW\ SHOOHWV Spherical pellets have less wear during any transportation SURFHVV FRPSDUHG WR RWKHU JHRPHWULHV /HVV ZHDU HTXDOV less dust formation, which results in less effort for dust removal or cleaning. The improved process gives a better SHOOHW TXDOLW\ DQG WKHUHIRUH LQFUHDVHG SURÂż WV In the presence of pressurized over-heated water (> 100°C) SHOOHWV DUH FXW DQG VXEMHFWHG WR WKH Âż UVW FRROLQJ VWHS ,Q WKH transfer unit, the pellets are separated from overheated water and handed over to the second cooling circuit (< 95°C). $IWHU VXEVHTXHQW FRROLQJ WKH SUHVVXUH LV UHOHDVHG DQG WKH
pellets are separated by the Centro dryer from the process water. Leaving the drying process, the pellets are ready for VXEVHTXHQW SURFHVVLQJ RU SDFNLQJ The closed loops result in operating conditions without any emission to the air and without contamination of the product. %DVHG RQ WKH KLJKHU WHPSHUDWXUH OHYHO LQ WKH LVRODWHG Âż UVW cooling process, that energy could easily be used for heating purposes or transformed e.g. into electrical power, suitable for the involved consumption elements like pumps, motors, etc. OTP pellets meet the high standards of plastics used in medical applications. Even optical applications like glasses or screens can now be handled with polycarbonate, pelletized with OTP. There is also a large scope for use in the automotive industry: MAAG-Automatik is represented in SA by Joesten International
5HLIHQKlXVHU VHOOV (XURSH¡V ZLGHVW FDVW Ă&#x20AC; OP OLQH PP ZLGH 0LGH[ FDVW Âż OP OLQH LQ RSHUDWLRQ DW 3RUWXJXHVH Âż OP SURGXFHU REIFENHĂ&#x201E;USER Cast Sheet Coating has installed a PP ZLGH 0LGH[ FDVW Âż OP OLQH LQWR RSHUDWLRQ DW D 3RUWXJXHVH Âż OP SURGXFHU ,W LV WKH ZLGHVW FDVW Âż OP OLQH LQ (XURSH HQDEOLQJ WKH SURGXFWLRQ RI Âż OPV ZLWK D Âż QLVKHG ZLGWK RI XS WR PP $QG HYHQ larger widths will be possible in the future: 5HLIHQKlXVHUÂśV SRUWIROLR LQFOXGHV FDVW Âż OP lines with up to 6,700mm wide rolls. Casting section of a 5,300mm ZLGH 0LGH[ FDVW Âż OP OLQH
The greatest challenge in the production of such large systems is the design and manufacture of the dies. Reifenhäuser Cast Sheet Coating has its own Ă&#x20AC; DW GLHV DYDLODEOH DQG FDQ GUDZ RQ WKH NQRZ KRZ RI WKH 5HLIHQKlXVHU *URXS 6LVWHU FRPSDQ\ 5HLFRÂż O D manufacturer of nonwoven systems, has been using dies of these larger widths for many years. The uniform melt GLVWULEXWLRQ RYHU WKH HQWLUH Âż OP ZLGWK LV HQVXUHG E\ D rheologically optimised coathanger channel design. )RU ZLQGLQJ WKH Âż OP 5HLIHQKlXVHU &DVW 6KHHW &RDWLQJ has found in BrĂźckner, a partner with great expertise in large widths: For BrĂźckner, the design and manufacture of turret winders with widths of up to 6,700mm has been the standard for many years. The winders are used for producing jumbo UROOV RI PD[ PP GLDPHWHU RQ VWHHO FRUHV IRU VXEVHTXHQW FRQYHUVLRQ WR WKH UHTXHVWHG Âż OP GLPHQVLRQV Reifenhauser is represented in SA by Ferrostaal Equipment Solutions
70 AUGUST / SEPTEMBER 2015
www.ferrostaal.com
www.reifenhauser.com
INSTRUMENTAL IN SUPPLYING ALL YOUR BLACK, WHITE AND FILLER MASTERBATCH REQUIREMENTS HEAD OFFICE - GAUTENG Telephone: +27 (0) 11 746 4000 KWA-ZULU NATAL - New Germany Telephone: +27 (0) 31 713 0636 EASTERN CAPE - Port Elizabeth Telephone: +27 (0) 41 451 2571 WESTERN CAPE - CAPE TOWN Telephone: +27 (0) 21 935 1788
www.ferro-sa.co.za
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Engel HL Awards 2015 Optimal use of tiebarless technology â&#x20AC;&#x201C; The outstanding use of the tiebarless mould area IRU WKH PDQXIDFWXUH RI RLO Âż OWHU PRGXOHV as shown in the application by Hengst of *HUPDQ\ KHOSV PDNH WKH DSSOLFDWLRQ YHU\ HIÂż FLHQW RYHUDOO WKH VLQJOH FDYLW\ PRXOG KDV HLJKW FRUH SXOOV ZKLFK DFFRXQWV IRU LWV considerable size
Award for innovative applications on tiebarless machines ENGELâ&#x20AC;&#x2122;S HL Awards, which recognize convertors who make outstanding use of its tiebarless technology, for 2015 were recently presented to the top European convertors Gardena, Hengst Automotive and Schneegans. The tiebarless system promotes design freedom, HIÂż FLHQW SURFHVVLQJ PHWKRGV FRPSDFW production cells and creative process ideas. Engel periodically honours outstanding applications with its Engel HL Awards. This yearâ&#x20AC;&#x2122;s recipients received their accolades at the design centre in Linz, Austria, on the evening of 16 June during the 2015 Engel Symposium. )RU WKH Âż UVW WLPH WKH SUL]HV ZHUH DZDUGHG LQ WKUHH FDWHJRULHV (IÂż FLHQW use of the mould area; Innovative process integration and Economical automation concept. Twenty-seven plastics processing Âż UPV IURP FRXQWULHV DSSOLHG IRU WKH internationally coveted distinction. All the applications submitted were scrutinised closely by the jury, who looked at the respective advantages and compared them to the use of conventional machines with tiebars. The jury included Prof Dr Frank Ehrig, director of the Institute for Material Engineering and Plastics Processing (IWK) at the University of Applied Sciences Rapperswil in Switzerland; Gunnar Hack, managing director of Hack Formenbau in Kirchheim unter Teck, Germany; and Harald Wollstadt, editor-in-chief of the trade magazine Plastverarbeiter, which is published by HĂźthig in Heidelberg. +HQJVW RSWLPDO XVH RI WKH WLHEDU OHVV PRXOG DUHD The replacement of metals with plastics is progressing rapidly, and this also includes components under car bonnets. Hengst SE & Co KG, based in MĂźnster, Germany, has developed a thermoplastic solution made from polyamide UHLQIRUFHG ZLWK JODVVÂż EUH IRU IDEULFDWLQJ RLO Âż OWHU PRGXOH EDVHV that are used in various Audi and Volkswagen four-cylinder 72 AUGUST / SEPTEMBER 2015
7KH RLO Âż OWHU PRGXOH EDVHV DUH PDQXIDFWXUHG LQ D JODVVÂż EUH reinforced polyamide by +HQJVW .* LQ 0Â QVWHU Germany
GLHVHO HQJLQHV 7KH Âż OWHU bases are among the most sophisticated components that the automotive supplier manufactures at its production plant in Nordwalde, Germany. The bases are PDGH RQ DQ (QJHO YLFWRU\ WHFK injection moulding machine with a clamping force RI N1 Before the tiebarless solution was chosen, alternative offers based on injection moulding machines with tiebars were requested. These began at a clamping force of 8000kN. A machine of this size would have been needed so that the bulky mould could be mounted and set up through the tiebars, even though the injection moulding process itself UHTXLUHV VLJQLÂż FDQWO\ OHVV FODPSLQJ IRUFH 7KH WLHEDUOHVV N1 PDFKLQH HQDEOHG +HQJVW WR UHGXFH WKH LQYHVWPHQW and operating costs for the application considerably, keep the production cell compact and also drastically shorten the time spent for mounting and setting up the mould. 7KH LQWHJUDWHG (QJHO 9LSHU URERW FDQ UHDFK IURP WKH side directly into the mould area without having to circumvent any obstacles. This lowers the working height and ensures that the robot remains well clear of the heavy-duty crane in the relatively low-ceilinged production hall.
Innovative process integration â&#x20AC;&#x201C; The tiebarless clamping unit makes it possible for Gardena to combine maximum precision with very short cycle times for the newly developed two-component process
Gardena: innovative process integration with very high process consistency levels At 20 million units per year, connectors for garden hoses are the components with the highest production volume at Gardena Manufacturing GmbH in the southern German municipality of Gerstetten, a company of the Husqvarna group. Since January of this year, an Engel victory 740H/310W/400 WP combi injection moulding machine has been used for them. Only the tiebarless clamping unit makes it possible to combine maximum precision with very short cycle times in the newly developed two-component process. The integrated Engel Easix multi-axis robot removes 16 hose connectors from the machine every 16 seconds. In order to be able to process the thermoplastic housing material and the elastomer for the grip surfaces simultaneously, the rotary mould has two sets of 16 cavities and four sets of 16 cores. The process has an ingenious twist: after the thermoplastic components have been injection moulded, the mould then turns the cores so that they are in a cooling position before overmoulding the soft components in a third step. This prevents the cooling from extending the cycle time. When turned to the fourth position, WKH FRQQHFWRUV FDQ Âż QDOO\ EH UHPRYHG IURP WKH PRXOG The four sets of 16 cores are each arranged in linear fashion. The heart of the tiebar-less clamping unit, the force divider, plays an especially important role in ensuring the connectors produced in the cavities at the top and the bottom have exactly the same wall thickness as those SURGXFHG LQ WKH PLGGOH FDYLWLHV 7ZR RI WKHVH FHQWUDO Ă&#x20AC; H[LEOH elements are located behind the moving mould mounting platen and distribute the clamping force evenly across the entire mould cross section. In so doing, they guarantee very high reproducibility levels and excellent mould protection and have thus made a crucial contribution to the fact
Up to 20 million of the Gardena hose connectors are produced a year, with 16 hose connectors emerging from the machine every 16 seconds
that the production cell hasnâ&#x20AC;&#x2122;t produced any quality-related rejects since it was commissioned. $OWKRXJK WKH PRXOG FRPSOHWHO\ Âż OOV RXW WKH N1 machineâ&#x20AC;&#x2122;s mould area with its many cooling connections, there is still enough room for movement. If the mould were to be used on an injection moulding machine with tiebars, the machine would have to be considerably larger. That would also make the cycle time longer, because bigger machines need more time than smaller ones to open and close the mould. /DVW EXW QRW OHDVW WKH HIÂż FLHQW DXWRPDWLRQ RI WKLV application is only made possible by the tiebarless technology. Despite its very long gripper, the robot arm can reach the mould cores directly from the side. The jury was won over by the high precision and process consistency levels, which were achieved despite the unconventional arrangement of the cavities only due to the even distribution of the clamping force through the force divider. AUGUST / SEPTEMBER 2015 73
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Schneegans: space-saving automation concept increases cost-effectiveness Space is very limited under a car bonnet. Like a big 3D puzzle, the various components needed to make the car UXQ DOO KDYH WR Âż W WRJHWKHU QHDWO\ 7KH EHVW H[DPSOH RI WKLV LV WKH RLO OHYHO PHDVXUHPHQW PRGXOHV 6R WKDW WKH\ Âż W LQWR the space provided in the best possible way, they are no ORQJHU PDGH RI VWHHO EXW FRPSOHWHO\ RI SODVWLF ,Q DGGLWLRQ WR PRUH GHVLJQ IUHHGRP WKH SODVWLF UHGXFHV WKH ZHLJKW RI WKH modules and also means they can be produced using a very HFRQRPLFDO PDQXIDFWXULQJ SURFHVV Schneegans Freudenberg Silicon GmbH uses projectile LQMHFWLRQ WHFKQRORJ\ 3,7 WR SURGXFH PRUH WKDQ PLOOLRQ PRGXOHV HYHU\ \HDU IRU %0: 'DLPOHU 9RONVZDJHQ 6HDW Audi and Skoda in Losenstein, Austria. Every 45 to 50 seconds, two completely assembled units are ejected IURP D IXOO\ DXWRPDWHG SURGXFWLRQ FHOO WKH FRUH RI ZKLFK is a tiebarless Engel victory 400 tech injection moulding PDFKLQH )RXU LQWHJUDWHG PXOWL D[LV URERWV VKDUH WKH WDVNV RI LQVHUWLQJ WKH SURMHFWLOHV UHPRYLQJ WKH PRXOGHG SDUWV IURP WKH PRXOG GHWDFKLQJ WKH RYHUĂ&#x20AC; RZ FDYLWLHV SULQWLQJ RQ WKH IURQW RI WKH IXQQHOV Âż WWLQJ 2 ULQJV DVVHPEOLQJ RLO VOHHYHV
The oil level measurement devices produced E\ 6FKQHHJDQV DUH GHVLJQHG WR Âż W LQWR WKH space provided in the vehicle engine in the best possible way, they are no longer made of steel but completely of plastic. In addition to more design freedom, the plastic reduces the weight of the modules and also means they can be produced using a very economical manufacturing process
74 AUGUST / SEPTEMBER 2015
DQG GLSVWLFNV OHDN WHVWLQJ DQG SDFNDJLQJ WKH Âż QLVKHG modules. $V VSDFH LV QRW MXVW RI SDUWLFXODU LPSRUWDQFH XQGHU the bonnet, but also in Schneegansâ&#x20AC;&#x2122;s production hall, a tiebarless solution was always going to have to be used IRU SURGXFLQJ WKH PRGXOHV ,W DOORZV WKH PXOWL D[LV URERW supporting the injection moulding process to work especially close to the clamping unit and access the cavities without losing any time. Using a machine with tiebars would have PHDQW KDYLQJ WR HPSOR\ VLJQLÂż FDQWO\ PRUH FRPSOH[ UHPRYDO processes, and a larger machine with at least 6000kN RI FODPSLQJ IRUFH ZRXOG DOVR KDYH EHHQ QHFHVVDU\ 7KLV ZRXOG KDYH LQFUHDVHG WKH SURGXFWLRQ FHOOÂśV IRRWSULQW DQG lengthened the cycle time. (1*(/ LV UHSUHVHQWHG E\ 0DULWLPH 0DUNHWLQJ tel: 011 466 1717 www.engelglobal.com
www.marimark.co.za
Economical automation â&#x20AC;&#x201C; Four multi-axis robots are integrated on a very small footprint in the production cell at Schneegans. An injection moulding machine with tiebars would have had to be considerably larger
A BOLD AND BALANCED VISION. At SABIC, we have a bold and balanced vision of the future. Everywhere, everyday we partner with our customers, suppliers and the world at large to deliver ingenious and sustainable solutions that make a difference for good. To learn more, visit ZZZ VDELF FRP PH HQ RXUFRPSDQ\ VDOHV RIĆ&#x201A;FHV
EQUIPMENT The GN800, a highspeed form/cut/stack thermoformer, is the Âż UVW *1 PRGHO WKDW offers movable top and bottom platens
GN
Thermoforming enters form/cut/stack market
www.bre-innovations.co.za
www.gncanada.com
First GN model that offers movable top and bottom platens GN Thermoforming Equipment of Canada has introduced a highVSHHG IRUP FXW VWDFN WKHUPRIRUPHU LWV Âż UVW PRGHO ZLWK PRYDEOH top and bottom platens. The launch marks GNâ&#x20AC;&#x2122;s entrance into the form/cut/stack market and expands the companyâ&#x20AC;&#x2122;s plug-assist PDFKLQH RIIHULQJ 7KH Âż UVW XQLW RI WKH *1 V\VWHP ZDV VROG WR a European processor for production of PET sealed containers. 7KH *1 ZDV GHYHORSHG LQ SDUWQHUVKLS ZLWK $JULSDN of Milan, Italy, which manufactured and sold form/cut/stack WKHUPRIRUPLQJ PDFKLQHV XQWLO %DVHG RQ D PDUNHW DQDO\VLV *1 FRQÂż UPHG WKH JURZLQJ XVH RI IRUP FXW VWDFN technology by packaging manufacturers and concluded that a partnership offered the fastest entrance into the market. GN bought the rights to Agripakâ&#x20AC;&#x2122;s original machine design and has added new features and technologies to make it a â&#x20AC;&#x2DC;GN machineâ&#x20AC;&#x2122;. The enhancements offered in this new thermoformer came in response to input from customers and tool makers to ensure GNâ&#x20AC;&#x2122;s new machine would meet todayâ&#x20AC;&#x2122;s changing market conditions. 7KH *1 KDV D IRUPLQJ DUHD RI PP [ PP LV FDSDEOH RI IRUPLQJ PP DERYH DQG EHORZ WKH VKHHW OLQH and the cutting force of the forming and cutting stations is WRQV 7KH *1 DOVR KDV DGGLWLRQDO VSDFH EHWZHHQ WKH forming and cutting stations, providing extra cooling time when running heavier gauge materials or PP.
7KH *1 IHDWXUHV D VWDQGDUG RYHQ ZKLFK LV IRXU times the index length of the forming area. The machine LQFRUSRUDWHV KLJK HIÂż FLHQF\ VRODU KHDWHUV DQG LV HTXLSSHG with cut-in-place capabilities as a standard feature. The unit also features independent top and bottom servo-plug drives for better material distribution. 7KH *1 KDQGOHV VKHHW ZLGWKV XS WR PP 7KH PDFKLQH FDQ UXQ VKHHW WKLFNQHVVHV UDQJLQJ IURP PP WR PP 7KH unit comes fully equipped and handles all thermoformable grades of PET, OPS, HIPS, PLA, PP, and PVC. The company is currently targeting food, medical, and industrial packaging. 7KH *1 WKHUPRIRUPHU LV FRPSHWLWLYHO\ SULFHG ZLWK PDQ\ options and features listed above included as standard. According to Tim Forshaw of BRE, the local agent for GN, the top and bottom clamp frames are no longer included as standard and are now being offered as options. â&#x20AC;&#x153;We have found that generally, customers prefer to order or manufacture those with their tooling as the up charge is minimal. The price of the roll lift assembly with material unwind system has been lowered, again as a result of our cost saving exercise,â&#x20AC;? he added. GN Thermoforming is represented by Tim Forshaw of BRE 3DFNDJLQJ ,QQRYDWLRQ S
Modular system for medical extrusion Cuts job-change time from 2 hours to 3 minutes, preserves clean room integrity A NEW modular extrusion system enables processors of tubing and other smalldiameter medical products to be up and running with a new job just three minutes after the previous run, leaving the tasks involved in die and barrel cleanout to take place outside the clean room environment. American Kuhneâ&#x20AC;&#x2122;s Modular QuickChangeâ&#x201E;˘ system has four components: an extruder drive module for the clean room; a purge module for the tool room or other maintenance area; and two barrel modules, one used on-line while the alternate is purged and cleaned. At the end of a job, the â&#x20AC;&#x2DC;dirtyâ&#x20AC;&#x2122; barrel module, 76 AUGUST / SEPTEMBER 2015
including die head, is rolled away to the tool room for cleanout â&#x20AC;&#x201C; a procedure that typically takes two hours. The alternate barrel module, preheated and with the new job recipe pre-loaded, can be installed on-line in about three minutes. Based on Single-Minute Exchange of Die (SMED) concepts, the new system is especially suited for medical and other contamination-sensitive applications. The Modular Quick-Change system is available for extruders up to 51mm, though custom-engineered systems are available for larger units. American Kuhneâ&#x20AC;&#x2122;s Modular QuickChangeâ&#x201E;˘ system
www.grahamengineering.com www.americankuhne.com www.welex.com
HEAD OFFICE merSETA House, 95 7th Avenue, Cnr Rustenburg Road Melville Johannesburg, 2092 Tel: 010 219 3000 Fax: 086 673 0017 EASTERN CAPE 3LFNHULQJ 3DUN 2IÂż FH 6XLWHV 14-20 Pickering Street Newton Park, Port Elizabeth, 6045 Tel: 0861 637 734 Fax: 041 363 0144
The merSETA is one of 21 SETAs established through the Skills Development Act of 1998. The merSETA is also part of the manufacturing and engineering cluster. In the merSETA domain, there are ďŹ ve economic sub-sectors, Metal and Engineering, Auto Manufacturing, Motor Retail and Component Manufacturing, New Tyre Manufacturing and Plastics Manufacturing. The merSETA facilitates implementation of provisions of the Skills Development Act through our levy-paying companies: these companies sign learnership agreements and apprenticeship contracts and offer workplace experience to learners or internship opportunities to graduates. The merSETA incentivises and supports the companies that recruit learners in the afore-mentioned chambers.
GAUTENG SOUTH merSETA House, 95 7th Avenue, Cnr Rustenburg Road Melville Johannesburg, 2092 Tel: 010 219 3000 Fax: 086 673 0017 GAUTENG NORTH & NORTH WEST Automotive Supplier Park, 30 Helium Road Rosslyn Ext. 2 Pretoria, 0200 Tel: 0861 637 731 Fax: 0866 700299 FREE STATE & NORTHERN CAPE 46 Second Avenue Westdene Bloemfontein, 9300 1RUWKHUQ &DSH 6DWHOOLWH 2IÂż FH 9b Roper Street Kimberley, 8301 Tel: 0861 637 733 Fax: 051 447 8873
VISION Leaders in closing the skills gap
KWAZULU-NATAL 149 Essenwood, Stephen Dlamini Road Musgrave Durban, 4001
MISSION To increase access to high quality and relevant skills development and training opportunities to support economic growth in order to reduce inequalities and unemployment and to promote employability and participation in the economy.
Tel: 086 163 7736 Fax: 031 201 8732 LIMPOPO & MPUMALANGA 1st Floor, No.8 Corridor Crescent Route N4 Business Park Ben Fleur Ext 11, Witbank, 1040 Tel: 0861 637 735 Fax: 013 656 4629
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WESTERN CAPE WK Ă&#x20AC; RRU &DWQLD %XLOGLQJ %HOOD 5RVD 2IÂż FH 3DUN Bella Rosa Road, Bellville, 7530 Tel: 0861 637 732 Fax: 021 914 8131
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Technologically
complex plastic parts for the automobile industry Process is a key technology for fast and sustainable success Absolute top quality and reliability in the production of technologically sophisticated parts tailored to customersâ&#x20AC;&#x2122; demands â&#x20AC;&#x201C; this is the challenge Denk Kunststoff Technik, based in Gevelsberg/Germany, has set out to meet, since last year with the help of an EcoPower from Wittmann Battenfeld. Denk Kunststoff Technik was established 20 years ago. In 2009 the company, managed by the two brothers Falk and Lars Denk, moved to its present location in Gevelsberg. It now has a workforce of 80 and realized â&#x201A;Ź15.5 million in sales in 2014. Since the beginning of 2015, Denk Kunststoff Technik has also been operating a IDFLOLW\ LQ 1DQMLQJ &KLQD ZKHUH Âż YH associates produce parts on three injection moulding machines. The companyâ&#x20AC;&#x2122;s customer base consists almost exclusively of wellknown automotive suppliers in Germany, North America, China, Spain, the Czech Republic and Romania. An in-house mould making shop and an in-house mechanical engineering department ensure complete internal system integration
within the company. In addition, automation is also designed in-house. The companyâ&#x20AC;&#x2122;s technologically complex products include twocomponent parts such as door check housings, plastic parts with metal inserts, plastic hinges, parts for the engine compartment and much more. The two brothers are enthusiastic about the EcoPower 300/1330 delivered by Wittmann Battenfeld at the beginning of March 2014. Important features from Falk and Lars Denkâ&#x20AC;&#x2122;s point of view in DGGLWLRQ WR WKH HQHUJ\ HIÂż FLHQF\ DQG precision of their machinery are above all reliability and a long service life.
Retainer ring containing the ball bearing for the front suspension struts: TPU on polyamide with a sheet metal insert
www.wittmann-group.com Polyamide door check housing with TPU buffers and inserts (left), and supporting arm for door check, insert-moulded with polyamide (right)
Connector for charging air pipe: the part itself is injection-moulded, the O-ring, the retainer ring and the silver-coloured spring circlip are subsequently fastened to it Resonator made of highly reinforced aromatic polyamide, infrared-welded 78 AUGUST / SEPTEMBER 2015
- passionate about the plastic industry. Supplier of:
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Injection Moulding Machine
Servo Klockner
Rebuild
JIANGSU 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
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Scrap reduced to tyres crumb rubber with help of
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30 million (13%) scrap tyres are recycled into ground rubber in US ACCORDING to the US Environmental Protection Agency, approximately 290 million scrap tyres are generated in the United States each year. As recently as 1990, most of these VFUDS W\UHV WRRN XS VSDFH LQ ODQGÂż OOV RU ZHUH GXPSHG LOOHJDOO\ Today, many of them are recycled by companies such as Edge 5XEEHU LQWR YDULRXV JUDGHV RI JURXQG UXEEHU DOVR NQRZQ DV Âż QH PHVK FUXPE UXEEHU 0DUNHWV QRZ H[LVW IRU PLOOLRQ RI DOO VFUDS W\UHV 6RPH PLOOLRQ RI WKHVH VFUDS W\UHV DUH EXUQHG DV IXHO $QRWKHU PLOOLRQ DUH XVHG LQ FLYLO HQJLQHHULQJ SURMHFWV VXFK DV DUWLÂż FLDO UHHIV ZKLOH PLOOLRQ DUH UHF\FOHG LQWR JURXQG UXEEHU $QRWKHU PLOOLRQ VFUDS W\UHV DUH UHWUHDGHG 2I WKH PLOOLRQ VFUDS W\UHV LQ WKH 8QLWHG 6WDWHV UHF\FOHG LQWR JURXQG UXEEHU VRPH PLOOLRQ Âż QG WKHLU ZD\ WR WKH (GJH Rubber plant in Chambersburg, Pennsylvania, the oldest and PRVW VXFFHVVIXO IDFLOLW\ SURGXFLQJ Âż QH PHVK FUXPE UXEEHU LQ WKH 8QLWHG 6WDWHV 2QH RI WKH PRVW HIÂż FLHQW VFUDS UXEEHU SODQWV LQ WKH FRXQWU\ PXFK RI LWV HIÂż FLHQF\ LV DWWULEXWDEOH WR LWV EXON UDZ PDWHULDO handling system using six Flexicon bulk bag dischargers. Âł:KHQ ZH UHFHLYH WKH VFUDS W\UHV ZH Âż UVW VKUHG WKHP LQWR DSSUR[LPDWHO\ FP SDUWLFOHV ZKLFK DUH JUDYLW\ IHG LQWR NJ EXON EDJV ´ VDLG 6DP .DXIIPDQ YLFH SUHVLGHQW DQG FKLHI RSHUDWLQJ RIÂż FHU RI (GJH 5XEEHU Âł7KHVH URXJK JURXQG SDUWLFOHV PDNH XS RI WKH UDZ PDWHULDO WKDW ZH SURFHVV LQWR Âż QH PHVK FUXPE UXEEHU ´ 7KH RWKHU DUULYHV LQ VPDOO EDJV IURP W\UH UHWUHDGHUV WKDW grind a portion of the tread from used tyres prior to applying QHZ WUHDG WR WKH FDUFDVVHV JHQHUDWLQJ ÂľEXIÂż QJVÂś WKDW PHDVXUH DSSUR[LPDWHO\ FP %XON EDJ GLVFKDUJHUV LPSURYH SURFHVV Ă&#x20AC; RZ Because Edge Rubber has eliminated manual dumping of VPDOO EDJV IURP LWV SURGXFWLRQ SURFHVV LW Âż UVW WUDQVIHUV WKH
FRQWHQWV RI VPDOO EDJV LQWR EXON EDJV ZKLFK DUH VWRUHG RU GLVFKDUJHG WR IHHG JURXQG UXEEHU SDUWLFOHV DORQJ ZLWK URXJK shredded particles, to a cracker milling process to further reduce particle size. Moving the rubber particles from the bulk bags to the cracker mills are six automated Bulk-Outâ&#x201E;˘ BFC Bulk Bag discharger V\VWHPV ZLWK LQWHJUDO Ă&#x20AC; H[LEOH VFUHZ FRQYH\RUV IURP )OH[LFRQ 'XH WR WKH QDWXUH RI WKH UXEEHU SDUWLFOHV PDWHULDO Ă&#x20AC; RZ IURP WKH EDJ FDQ EH LQFRQVLVWHQW 7R HQVXUH FRQWLQXRXV DQG HIÂż FLHQW RSHUDWLRQ )ORZ )OH[HUÂ&#x152; EDJ DFWLYDWLRQ GHYLFHV SRVLWLRQHG RQ the frame continually compress and release opposite sides of WKH EXON EDJ WR SURPRWH Ă&#x20AC; RZ WKURXJK WKH EDJ VSRXW LQWR WKH Ă&#x20AC; RRU KRSSHU 7KH UXEEHU SDUWLFOHV Ă&#x20AC; RZ IURP WKH GLVFKDUJH SRUW RI WKH Ă&#x20AC; RRU KRSSHU DQG FKDUJLQJ DGDSWHU LQWR WKH P ORQJ PRGHO Ă&#x20AC; H[LEOH VFUHZ FRQYH\RU GHVLJQHG WR KDQGOH GLIÂż FXOW PDWHULDOV DQG FRQVLVWLQJ RI D Ă&#x20AC; H[LEOH VWHHO VFUHZ URWDWLQJ LQVLGH D FP diameter carbon steel outer WXEH 7KH VFUHZ LV GULYHQ by an electric motor located at the discharge end of the FRQYH\RU ZKLFK IHHGV WKH rubber particles through a transition adapter into the cracker mill. +LJK DQG ORZ OHYHO VHQVRUV LQ WKH Ă&#x20AC; RRU KRSSHU VLJQDO D PLC to activate the conveyor on reaching high level, and $W WKH GLVFKDUJH HQG RI WKH turn off the conveyor on Ă&#x20AC; H[LEOH VFUHZ FRQYH\RU UHDFKLQJ ORZ OHYHO IRUZDUG RI WKH HOHFWULF PRWRU JURXQG SDUWLFOHV JUDYLW\ IHHG Âł%HIRUH ZH DFTXLUHG through a transition adapter and the bulk bag dischargers, GRZQVSRXWLQJ LQWR WKH PLFUR PLOO
80 AUGUST / SEPTEMBER 2015
)URP WKH ODUJH KRSSHU WZR Ă&#x20AC; H[LEOH VFUHZ FRQYH\RUV WUDQVSRUW JURXQG UXEEHU SDUWLFOHV IURP WKH FUDFNHU PLOOV WR ZHW JULQG PLOOV IRU WKH Âż QHVW VL]H UHGXFWLRQ 'LVFKDUJH FKXWH EODFN GHSRVLWV WKH cracker mill grindings into the hopper
bulk bag dischargers we manually emptied the small bags of material from tyre retreaders into the cracker mills. If our tyre shredder was down IRU PDLQWHQDQFH RU UHSDLU WKH YROXPH RI UHWUHDG EXIÂż QJV ZH were feeding the cracker mills was not enough to maintain full production speed, which slowed the entire ambient grinding process. Manually emptying the bags was also a very slow operation,â&#x20AC;? Kauffman said. Ambient grinding produces high quality powder A typical tyre shredded by Edge Rubber contains, by weight, DSSUR[LPDWHO\ UHFRYHUDEOH UXEEHU VWHHO Âż EUH DQG H[WUDQHRXV PDWHULDO VXFK DV LQHUW Âż OOHUV 2Q DYHUDJH RQH passenger tyre yields 4.5 to 5.4kg of crumb rubber. 7KH URXJK VKUHGGHG SDUWLFOHV DQG UHWUHDG EXIÂż QJV DUH Âż UVW JURXQG LQ WKH FUDFNHU PLOOV DPELHQW JULQGLQJ Âą WKH Âż UVW of two size reduction processes that produce nine particle VL]HV UDQJLQJ IURP PHVK PP WR DV Âż QH DV PHVK PP 7KH FUDFNHU PLOOV SURGXFH SDUWLFOHV IURP PHVK PP WR PHVK PP
Micro-milled particles are packaged in pre-measured batch inclusion bags to be placed directly into the customerâ&#x20AC;&#x2122;s process
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www.edgerubber.com
AUGUST / SEPTEMBER 2015 81
Edge Rubberâ&#x20AC;&#x2122;s micro-milled, cleanest and Âż QHVW SDUWLFOHV KDYH D XQLTXH VKDSH IRU PD[LPXP VXUIDFH DUHD \LHOGLQJ SHUIRUPDQFH DGYDQWDJHV LQ DSSOLFDWLRQV UHTXLULQJ VWURQJ bonding or high tensile strength
Micro milling produces the smallest, cleanest particles :HW JULQGLQJ RU PLFUR PLOOLQJ SURGXFHV FOHDQHU Âż QHU PHVK particles. â&#x20AC;&#x153;While it produces particles as coarse as 40 mesh PP WKH PDMRULW\ RI WKH SDUWLFOHV DUH PHVK PP DQG Âż QHU $ SHUFHQWDJH RI WKH RYHUDOO WKURXJKSXW LQ IDFW LV Âż QHU WKDQ PHVK PP ´ VDLG .DXIIPDQ Most of Edge Rubberâ&#x20AC;&#x2122;s wet milled particles are packaged in pre-measured batch-inclusion bags that are placed directly into the customerâ&#x20AC;&#x2122;s moulding process and then disintegrate by melting at a low temperature. The rest of the wet milled particles, along with the larger particles produced by the cracker mills, are shipped in various size bags to customers in the United States and internationally. â&#x20AC;&#x153;Thanks in large part to our bulk bag discharging equipment, ZH DUH RQH RI WKH PRVW HIÂż FLHQW VFUDS UXEEHU UHF\FOLQJ SODQWV LQ the United States,â&#x20AC;? added Kauffman. Flexicon Africa is based in Port Elizabeth. Tel: 041 453 1871
Finished powder is shipped to customers
WEB NEWS
'X3RQW 3HUIRUPDQFH SRO\PHU DGYLVRU WRRO VDYHV WLPH UHGXFHV ULVN Simplify selection of high-performance plastic $ 1(: RQOLQH SRO\PHU DGYLVRU WRRO GHYHORSHG E\ 'X3RQW 3HUIRUPDQFH 3RO\PHUV FDQ KHOS SODVWLFV SURIHVVLRQDOV QDUURZ WKH FKRLFH RI ZKLFK KLJK SHUIRUPDQFH WKHUPRSODVWLF IDPLO\ WR FRQVLGHU ZKHQ GHVLJQLQJ D QHZ FRPSRQHQW RU V\VWHP 7KH WRRO DOORZV XVHUV WR VHOHFW IURP XS WR FULWLFDO SHUIRUPDQFH SURSHUWLHV LQFOXGLQJ WHPSHUDWXUH SHUIRUPDQFH VWLIIQHVV Ã&#x20AC; H[LELOLW\ FRQGXFWLYLW\ K\GURO\VLV UHVLVWDQFH ZHDU DQG IULFWLRQ %DVHG RQ SHUIRUPDQFH UHTXLUHPHQWV WKH WRRO HYDOXDWHV DQG UDQNV 'X3RQW WKHUPRSODVWLF IDPLOLHV IURP ZKLFK WR FKRRVH 'XULQJ XVHU WHVWLQJ FXVWRPHUV VDLG WKDW WKH\ FRXOG VHH KRZ WKLV WRRO ZRXOG EH XVHIXO LQ SRLQWLQJ VSHFL¿ HUV LQ WKH ULJKW GLUHFWLRQ HDUO\ LQ WKH GHVLJQ SURFHVV WKXV VDYLQJ WLPH RU PLVVWHSV 7KH 3RO\PHU $GYLVRU KHOSV PDWHULDO VSHFL¿ HUV JHW FORVHU WR D JRRG VWDUWLQJ SRLQW SULRU WR GLVFXVVLRQV ZLWK 'X3RQW WHFKQLFDO DQG GHYHORSPHQW H[SHUWV RU UHYLHZLQJ WHFKQLFDO GDWD LQ WKH 'X3RQW 3URGXFW 3UR¿ OHU ,Q DGGLWLRQ WR WKH RQOLQH WRROV 'X3RQW 3HUIRUPDQFH 3RO\PHUV SURYLGHV H[SHUW VXSSRUW WKURXJKRXW WKH DSSOLFDWLRQ GHYHORSPHQW F\FOH ZKLFK LQFOXGHV PDWHULDOV VHOHFWLRQ VLPXODWHG GHVLJQ SUHGLFWLYH HQJLQHHULQJ SURFHVVLQJ VXSSRUW SURWRW\SLQJ DQG WHVWLQJ
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The DuPont Polymer Advisor can be used on smart phones, tablets or laptops to help users select thermoplastic materials
www.dupont.com
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3XVK QRWL¿ FDWLRQV ZLOO VRRQ EH DYDLODEOH RQ 5HF\FOH1HW :KDW GRHV WKLV PHDQ" :KHQ VXSSOLHUV OLVW PDWHULDO WKDW WKH\ KDYH DYDLODEOH DQ\ EX\HUV UHJLVWHUHG IRU WKDW PDWHULDO ZLOO LPPHGLDWHO\ JHW D QRWL¿ FDWLRQ RQ WKHLU SKRQH ZLWK EULHI GHWDLOV RI WKH VWRFN %X\HUV ZLOO QR ORQJHU KDYH WR HQWHU WKH DSS WR VHDUFK IRU ZKDW LV DYDLODEOH ,Q -XQH WKH QHWZRUN VDZ LWV ¿ UVW WRQV RI PDWHULDO OLVWHG XVLQJ WKLV QHZ IHDWXUH ZKLFK PHDQV WKDW ZKHQ VXSSOLHUV OLVWHG WKHLU PDWHULDO EX\HUV UHFHLYHG QRWL¿ FDWLRQV RI WKLV GLUHFWO\ WR WKHLU SKRQHV 7KH QHWZRUN LV VWLOO VPDOO EXW LW LV JURZLQJ GDLO\ DQG ZLOO JURZ PXFK TXLFNHU ZLWK \RXU SDUWLFLSDWLRQ ,I \RX DUH QRW DOUHDG\ XVLQJ WKH ODWHVW YHUVLRQ RI WKH DSS PDNH VXUH WR XSGDWH LW VR WKDW \RX FDQ DOVR VHQG UHFHLYH QRWL¿ FDWLRQV 'RZQORDG WKH ODWHVW YHUVLRQ RI 5HF\FOH1HW IURP WKH $SSOH $SS VWRUH RU *RRJOH 3OD\ VWRUH www.recyclenet.co.za
TEL: +27 (0) 11 462 2990
SOLUTION
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Groundbreaking carbon core passenger cell
in new BMW 7 series
WORLD NEWS
86kg weight reduction in comparison to its predecessor BMW has unveiled the all-new BMW 7 Series sets a new benchmark in lightweight design. The extensive use of carbon-fibre-reinforced plastic in the structure of the passenger cell and the strategic application of lightweight design reduce weight and increase both the overall torsion strength and bending stiffness of the passenger cell. The advances achieved with the latest generation of the BMW 7 Series succeed in resolving a number of traditionally conflicting paradigms: the car comes with an array of new innovations but weighs less, performance is more dynamic but fuel efficiency has been improved, and while it is more luxurious than ever, emissions are lower. The BMW ‘EfficientLightweight’ concept allows the new BMW 7 Series line-up an 86kg weight reduction in comparison to its
predecessor. The intelligent body design succeeds in increasing the strength and rigidity of the passenger cell while also bringing about a substantial reduction in vehicle weight. The carbon core body is based on technology transferred from BMW i car development. The all-new BMW 7 Series is the first ever vehicle in which mass produced CFRP is used in combination with steel and aluminium. The BMW Group’s expertise in producing carbon fibre in the manufacturing of high-volume vehicles is unrivalled in the automotive sector, with the new BMW flagship model pioneering the creation of new possible applications for this high-tech material. www.bmwgroup.com
84 AUGUST / SEPTEMBER 2015
Office furniture made from EPP EMBRACING workplace trends of flexibility and collaboration, American office furniture manufacturer, Herman Miller Inc, has launched reconfigurable office furnishings made of ‘plastic foam’. According to Plastics News, the Metaform Portfolio is a system of lightweight expanded polypropylene blocks and corresponding accessories that can be rearranged and reconfigured to suit an
(PHOTOS COURTESY HERMAN MILLER INC)
office’s changing needs. Designed by Berlin-based firm Studio 7.5, Metaform Portfolio includes work surfaces and a series of add-on accessories that can be used to hold work tools or personal items. EPP is commonly used in
automotive applications and in impactabsorbing products like bike helmets. Studio 7.5 chose the material to create configurable office spaces because of its durability and lightweight nature. Metaform Portfolio components are made with 36 to 47% recycled material, a portion of that post-consumer. “When developing Metaform Portfolio, we knew that the core properties of EPP were compelling: It’s lightweight with an exceptionally high strength to weight ratio. It withstands severe impacts without significant damage. It is highly durable and resistant to water, chemicals, and most oils. It’s resistant to temperature extremes and is recyclable. We thought that EPP could be used in a solid and architectural way to create generous frameless surfaces,”
AROUND THE WORLD BASF to sell stake in SolVin to Solvay BASF has sold its 25% share in the joint venture SolVin to Solvay. The transaction took place on 1 July. Financial details were not disclosed. In addition, BASF has reached agreements with Solvay and Inovyn to continue to supply BASF’s site in Antwerp with basic chemicals. SolVin was established in 1999 as a 75-25 joint venture between Solvay and BASF in the area of polyvinyl chloride (PVC). www.basf.com
Big cartel fines for European packaging firms
BMW’s 2016 7 series sedan will use carbon fibre along with steel and aluminium in a mixed-material process in the passenger cell (PHOTO, BMW AG)
the calm visual quality of a pure material said designer, Studio 7.5: without any covering or veneered surface. “While we have been absolutely convinced by the properties of the • Herman Miller is a global material, the challenges were huge. company with operations, sales So we started to learn all about the offices, dealers, and licensees in more material in order to tackle them. The first than 100 countries challenge was learning in North America, how to mould EPP. To “It’s lightweight with Asia Pacific, create EPP shapes, an exceptionally high Europe, Middle pellets are extruded, East, Africa, and and then popped into strength to weight Latin America. Its beads. Those beads ratio, withstands world headquarters are then pressurized severe impacts, is are in Zeeland, and filled into a mould. Michigan, USA and The mould is then filled highly durable and its manufacturing with steam to fuse the resistant to water, facilities are located beads, thus creating chemicals, and most in the USA, China, a solid compound. Italy and the United This sounds like a oils. It’s resistant to Kingdom. simple recipe, but even temperature extremes developing a consistent and is recyclable.” colour was tough.” Studio 7.5 tested multiple techniques and forms to get www.hermanmiller.com to the final solution - forming the entire Metaform block as one moulded part. The www.plasticsnews.com resulting homogenous structures offer (FIRST PUBLISHED ON WWW.PLASTICSNEWS.COM, BY KERRI JANSEN)
THE European Commission (EC) has fined a group of European packaging manufacturers and distributors a total of €115.9-million (R1,5bn) for having participated in cartels across the continent. Linpac of the UK; Huhtamäki of Finland; Nespak and Vitembal of France; Coopbox, Magic Pack and Sirap-Gema of Italy, and Silver Plastics of Germany are alleged to have been involved in separate cartels. The distributors involved are Propack of the UK and Portugal’s Ovarpack. The EC’s antitrust commission said that between March 2000 and February 2008 the companies “fixed prices and allocated customers of polystyrene foam or polypropylene rigid trays, in breach of EU antitrust rules”. It went on: “From the early 2000s and for periods ranging from just over a year to almost eight years, and with some differences between the cartels, the 10 companies fixed prices, allocated customers and markets, engaged in bid-rigging and exchanged commerciallysensitive information”.
Braskem chairman in jail after corruption allegation BRASKEM SA of Brazil was to hold an extraordinary general meeting on 4 August to appoint a new chairman for its board of directors, following the 20 July indictment of current Marcelo Odebrecht for alleged involvement in a corruption scheme in state-run oil company Petroleo Brasileiro SA, or Petrobras. It was expected that Newton de Souza, who is serving as interim CEO in construction company Odebrecht SA, will become chairman of Braskem’s board. He is also on the board Odebrecht SA and has previously held seats on the boards of all Odebrecht companies, including Braskem. Odebrecht SA is Braskem’s largest stakeholder, with a 38.3 percent stake in the company, along with Petrobras, which owns 36.1% of Braskem, the largest petrochemical company in the Americas. Marcelo Odebrecht was indicted, along with seven other people, by the Brazilian Federal Police in July for involvement in fraud and corruption in some Petrobras bidding processes, according to local media. He has been in prison since 19 June. AUGUST / SEPTEMBER 2015 85
Milestone in manufacture of plastics from CO2 BAYER MaterialScience has taken another major step toward using CO2 for plastic production from 2016. A production line is currently under construction for this purpose at the Dormagen site in Germany. A chemical reactor weighing 25 tons has now been put in place at the heart of this line. The last major part – a CO2 tank – is due to be installed later this year. This will take the construction of the €15 million plant into the homestretch. Bayer MaterialScience intends to use the new production line as part of the ‘Dream Production’ project and for the first time integrate carbon dioxide as a raw material for polyols on a commercial scale. Polyols are crucial precursors for manufacturing foam. The line is designed for an annual production capacity of 5,000 tons. The idea is for the innovative polyol, which contains approximately 20% CO2, to initially be used in the manufacture of polyurethane foam mattresses. www.materialscience.bayer.com
AROUND THE WORLD
Six dies in PVC plant explosion AN explosion at a PVC plant in South Korea on in July killed six workers and injured a security guard at a factory owned by Hanwha Chemical, the country’s largest petrochemical manufacturer. According to local reports, the blast happened as welding work was being done to expand a storage tank at the factory’s wastewater disposal facility. The Ulsan, South Korea, facility, is in a large industrial area and is Hanwha Chemical’s second largest factory. Local media said the cause was still being investigated but that officials suspect a welding spark ignited methane, biochemical gas or another heat source. Hanwha chief executive Kim Chang-bum made a public apology for the deaths and explosion.
Borealis, Nexeo Solutions extend partnership
86 AUGUST / SEPTEMBER 2015
to boost search for sustainable materials Step towards achieving 2030 ambition on sustainable materials LEGO will invest 1 billion Danish krone dedicated to research, development and implementation of new, sustainable, raw materials to manufacture Lego® elements as well as packaging materials. “This is a major step for the Lego Group on our way towards achieving our 2030 ambition on sustainable materials. We have already taken important steps to reduce our carbon footprint and leave a positive impact on the planet by reducing the packaging size, by introducing FSC certified packaging and through our investment in an offshore wind farm. Now we are accelerating our focus on materials,” said Jørgen Vig Knudstorp, CEO and President of the LEGO Group. The Lego Sustainable Materials Centre will be based at the Lego Group’s headquarters in Billund,
Denmark, and include all current functions and employees working to find alternative materials. The Lego Group expects to recruit more than 100 specialists within the materials field during the coming years to work on this challenging ambition. In 2014 more than 60 billion Lego elements were made – finding alternatives to the materials used to make these bricks would significantly reduce the Lego Group’s impact on the planet. Lego has been using ABS since the early 1960s to make its bricks. Lego operates more than 5000 moulds on more than 1000 injection moulding machines in Denmark, Mexico and Hungary.
www.lego.com/en-us/
WORLD NEWS
BOREALIS, the manufacturer of polyolefins, base chemicals and fertilizers, and Nexeo Solutions, a worldwide leader in plastics distribution, have agreed to extend and develop their existing partnership. The agreement reaffirms their shared commitment to the European polymers market and to Borealis’ new distribution strategy. This new strategy targets the rigid and flexible packaging and fibre market as well as the automotive, healthcare and infrastructure industries and the strategy factors in the increasingly competitive nature of the polymers market. Borealis and Nexeo Solutions (formerly a part of Ashland, up until 2011) entered into Europe’s first pan-European polyolefin distribution partnership in 1996 with the distribution of Borealis PE and PP materials to small and medium-sized customers. After ten years of growth, they were distributing over 500 Borealis products to more than 3,000 customers across Europe. In 2012, a major milestone was achieved when Borealis and Nexeo joined forces to distribute products in North America.
Lego invests 1 billion krone
Perstorp inaugurates major new Oxo plant in Sweden
Perstorp’s new Oxo plant in Stenungsund, Sweden, the result of the company’s largest-ever investment, is now producing key feedstocks for PVC plasticizers, lubricants, adhesives and surfactants
WORLD NEWS
Will strengthen position in PVC plasticizers and chemical intermediates PERSTORP has opened a major extension to its capacity to produce PVC plasticizers and key chemical intermediates. The new state-of-the-art Oxo plant in Stenungsund, Sweden, began producing material soon after its start-up in January, and is now running at full regime and delivering high quality material according to plan. “The new production platform is the single largest investment in Perstorp’s history and clearly demonstrates Perstorp’s commitment to the PVC
industry,” said Perstorp CEO Jan Secher. “It significantly boosts our output of valeraldehyde and 2-propyl heptanol (2-PH), two key raw materials for Perstorp’s innovative general purpose PVC plasticizers, Emoltene™ 100 and Pevalen™. It is a testimony to our commitment to the PVC industry, and puts us in a very strong competitive position.” The Oxo plant is also a source of products for other key markets: 2-propyl heptanol is used in production of lubricants, adhesives and surfactants,
for example. N-valeric acid, which is also made in the plant directly from valeraldehyde, is an important raw material for lubricants, pharmaceuticals and fragrances. The upstream integration into essential raw materials greatly strengthens Perstorp’s position as a reliable supplier of innovative plasticizers to the PVC market. The total Oxo capacity has been increased by 150,000 tons per year. www.perstorp.com
88 AUGUST / SEPTEMBER 2015
P&G change laundry packaging to keep kids safe Proctor & Gamble (NYSE:PG) will add a bitter taste to the outer layers of its Tide, Gain and Ariel laundry packets in North America in an ongoing effort to help safeguard children from accidents with laundry packaging. Previous changes to P&G packaging includes containers with more secure closures, and opaque containers, so the contents are not visible. Because children are still accessing the product - often be-
cause the package is left open, packets are left outside of the container, or within reach of children. “We are seeing a 28% decline in the rate of incidents relative to the number of our laundry packets in the market, but we want to see more progress which is why we’re taking these important additional steps,” said Shailesh Jejurikar, President of P&G Fabric Care, North America. “Accidents happen regardless
of a laundry packet’s colour or design, so we are focused on reducing access to the packet and its contents.” In June, the European Commission enacted new standards for laundry packets, and P&G is bringing those standards to North America later this year. In addition to the bitter-tasting substance, the packet is designed to delay release of the liquid in the laundry packets, which will help give a child the chance to spit the packet out. The packets must also withstand the average squeezing pressure of a small child. This is the latest in a series of interventions in Europe, where incident rates have also dropped in countries like Italy, the United Kingdom, and Ireland. www.pg.com
Accidents happen regardless of a laundry packet’s colour or design, but Proctor & Gamble are focused on reducing access to the packet and its contents
BOOKS
Practical techniques of tyre retreading THIS book provides details of the different elastomers â&#x20AC;&#x201C; including reclaim rubber and crumb rubbers â&#x20AC;&#x201C; used in the manufacture of different types of tyre retreading. There are GLVFXVVLRQV DERXW UHLQIRUFLQJ Âż OOHUV DQG RWKHU FRPSRXQGLQJ LQJUHGLHQWV WKHLU HIÂż FDF\ WKH XVH RI ERQGLQJ DJHQWV DQG WKHLU relevance to the tyre retreading process. Precise guidelines for the practical compounding of different categories of rubber compounds used to make retread can be drawn from the book. A practical approach is also taken to describe the manufacturing technology used in tyre retreading. The book then moves on to describe the innovations LQ JUHHQ UHWUHDGLQJ WHFKQRORJ\ DEUDVLRQ DQG Ă&#x20AC; H[ IDWLJXH deterioration of tyre tread.
State-of-the-art methods for the inspection and testing of old tyres before rubberisation DQG DIWHU UHWUHDGLQJ DUH H[DPLQHG LQ GHWDLO as well as techniques for the testing of basic raw materials and process testing of prepared rubber compounds. Nanotechnology (potentially the bringer of a revolution in the Âż HOG RI W\UH UHWUHDGLQJ DQG WKH GHYHORSPHQW RI WKH UXQ Ă&#x20AC; DW W\UH are described in some depth in this book. This concise book is intended to be a practical guide to tyre retreading manufacture and a ready reference for students, researchers and academics. Tyre Retreading is available from www.polymer-books.com
All you ever wanted to know about label dispensing & application LABEL Dispensing and Application Technology by Michael )DLUOH\ DLPV WR H[SODLQ DQG GH P\VWLI\ ODEHO GLVSHQVLQJ DQG application technology, which is crucial to the pressuresensitive label industry.
How is it possible to separate pressure-sensitive face material from the silicone backing? How is label application controlled? How can labels be placed around corners or into recesses? All of these questions are answered in the book. Learn about: The basics of label application Manual and electric label dispensers Automating the labeling line Integrated and intelligent product handling Overprinting, coding and marking on label applicators Application of linerless labels Troubleshooting tips and guidelines 7KH ERRN LV DYDLODEOH H[FOXVLYHO\ RQ $PD]RQ FRP
The Indian sub-continent: The worldâ&#x20AC;&#x2122;s fastest growing regional polymer market THE Indian sub-continent has established itself as WKH PRVW H[FLWLQJ DQG dynamic emerging market in the world and is full of potential and investment opportunities. With a population greater than China but with a polymer demand less than oneÂż IWK WKH VL]H WKH UHJLRQ LV H[SHFWHG WR HQMR\ WKH IDVWHVW JURZWK LQ SRO\PHU GHPDQG DQ\ZKHUH LQ WKH ZRUOG RYHU WKH QH[W Âż YH \HDUV RXWVWULSSLQJ China and other emerging economies. According to a recently published study â&#x20AC;&#x2DC;Polymer Demand in the Indian sub-continentâ&#x20AC;&#x2122; by industry consultants, Applied 0DUNHW ,QIRUPDWLRQ /WG $0, &RQVXOWLQJ WKHUH LV QRZ PDVVLYH investment occurring in the regionâ&#x20AC;&#x2122;s petrochemical, polymer production and downstream plastic processing industries, driving strong growth in polymer demand - AMI forecasts that at the regionâ&#x20AC;&#x2122;s current rate of growth its thermoplastics market will surpass 20 million tons by 2020. The market in the region is dominated by India on account of its huge population and high GDP. However, growth in the region on the whole is driven by its increasingly globally90 AUGUST / SEPTEMBER 2015
minded governments that are introducing policies to encourage foreign direct investment and facilitate closer integration with the worldwide economy, helping to drive investment in petrochemicals, polymer production and downstream plastic processing. Although rapidly developing, the region does face substantial FKDOOHQJHV )RU H[DPSOH ODFN RI VXIÂż FLHQW ORFDO SRO\PHU SURGXFWLRQ LV D PDMRU REVWDFOH IDFHG E\ PDQ\ SODVWLFV SURFHVVRUV in the region with each country besides India being heavily or even entirely reliant on resin imports depending on the country in question; these imports are mainly sourced from India, the Middle East and South East Asia. It is clear that plastics will be called on to play a vital role in this changing region and the plastics industry will EHQHÂż W IURP QDWLRQDO HIIRUWV WR HQFRXUDJH DQG LPSURYH manufacturing. In its report, AMI forecasts 8% per year DYHUDJH LQFUHDVHV LQ WKH ,QGLDQ VXE FRQWLQHQW RYHU WKH QH[W Âż YH \HDUV ZLWK OHYHOV RI DQQXDO JURZWK YDU\LQJ IURP LQ Sri Lanka to up to over 8% in India. Polymer Demand in the Indian sub-continent is an AMI consulting data report. It provides detailed statistical data on WKH GHPDQG DQG HQG XVH IRU DOO PDMRU WKHUPRSODVWLF PDWHULDOV on a country by country basis. For further information please contact Thomas Longley-Hurcom at: tlh@amiplastics.com or ID[ WR +44 (0) 117 311 1534.
COMING UP DIARY SECOND INDUTEC SHOWED JUMP IN VISITOR NUMBERS WITH a 16% jump in visitors from 28 countries, the second SA Industry and Technology Fair (INDUTEC) held at Gallagher Convention Centre in May produced excellent results for exhibitors and visitors. The three-day, 12-shows-inone industrial expo proved to be the ideal platform for product exposure, business networking and deal-making. â&#x20AC;&#x153;INDUTEC 2015 was truly an international event, with 260 exhibitors from 15 countries including China, the Czech Republic, Germany, India, Iran, Italy, the Netherlands, Portugal, Saudi Arabia, South Africa, Taiwan, Thailand, Turkey and the United Kingdom,â&#x20AC;? said show organiser John Thomson of Exhibition Management Services. â&#x20AC;&#x153;Visitors arrived from 28 countries â&#x20AC;&#x201C; 10 of these from Africa â&#x20AC;&#x201C; to do business at INDUTEC.â&#x20AC;? www.exhibitionsafrica.com
NEW INKJET SOLUTIONS AT LABELEXPO EUROPE MIMAKI, a leading manufacturer of wide-format inkjet printers, will be participating in Labelexpo Europe from 29 September-2 October in Brussels, Belgium. Highlighted at the show will be eye-catching labels embellished with Mimakiâ&#x20AC;&#x2122;s Eco-Solvent Silver Ink. Its CJV150 series printers feature printing and integrated cutting solutions at print speeds up to 56m²/hr with automatic switching from printing to cutting. Continuous crop mark detection delivers accurate contour cutting to support even the most complex label layouts. New eco-solvent silver ink opens the door to new and profitable product offerings for label converters. www.mimakieurope.com
Rapid 3D â&#x20AC;&#x201C; Sean van Niekerk and Gavin Leggott on the Rapid 3D stand at the Manufacturing Indaba show at Emperorsâ&#x20AC;&#x2122; Palace in June; Rapid 3D specialises in supplying the most suitable 3D printers and 3D scanners for businessesâ&#x20AC;&#x2122; needs. They supply 3D printing and scanning technologies from 3D Systems, Envisiontec, MCor Technologies, Blueprinter, Zortrax, Ultimaker, Artec, Vialux and Geomagic
Rapid progress at
Manufacturing Indaba â&#x20AC;&#x2DC;Success depends on innovative manufacturingâ&#x20AC;&#x2122; THE second Manufacturing Indaba, at Emperors Palace in Johannesburg on 29/30 June, was aimed at bringing together business owners, industry OHDGHUV JRYHUQPHQW RIÂż FLDOV FDSLWDO providers and professional experts to discuss challenges faced by the South African economy â&#x20AC;Ś and to brainstorm solutions. â&#x20AC;&#x153;The success of our nation depends on a strong and innovative manufacturing base. We must
continue to work together to promote prosperity through manufacturing, science and innovation,â&#x20AC;? said the organisers of the event, Siyenza Management. The event attracted support from several big organisations, including the DTI, the Department of Science & Technology, Denel, Deloittes and a number of prominent professional associations.
www.manufacturingindaba.co.za
www.rapid3d.co.za
Propak West Africa in September! Samples of labels printed on one of the Mimaki inkjet printers; the CJV150 machine incorporates printing and cutting
COMPOSITES CONFERENCE IN DURBAN The Second International Conference on Composites, Biocomposites and Nanocomposites (ICCBN-2), organised and hosted by the Durban University of Technology, is to take place in Durban from 28-30 October. The event is being organised by the Composite Research Group (CRG) of the universityâ&#x20AC;&#x2122;s Department of Mechanical Engineering department. www.dut.ac.za/iccbnm 92 AUGUST / SEPTEMBER 2014
WEST Africaâ&#x20AC;&#x2122;s largest packaging, food processing, plastics, labelling and print expo â&#x20AC;&#x201C; Propak West Africa 2015 â&#x20AC;&#x201C; will take place at the Landmark Convention Centre, Lagos, Nigeria from 1-3 September. Since Nigeria took the crest as Africaâ&#x20AC;&#x2122;s largest economy in 2014, Nigeriaâ&#x20AC;&#x2122;s global business attractiveness has taken a positive direction and has brought a subsequent boom in numerous industries. With the countryâ&#x20AC;&#x2122;s favourable population and demand for packaged goods, Nigeria is forecasted to yield a 12% growth rate
in its packaging industries for the next couple of years. Propak West Africa 2015 offers its exhibitors and attendees the platform to explore the possibility of expanding business in the West African region, and the opportunity to source solutions from the largest regional and global range of suppliers. If you are involved in the packaging, printing, labelling purchasing decisions of your organisation, then you donâ&#x20AC;&#x2122;t want to miss this pivotal and premier event. www.propakwestafrica.com
Putting all your eggs in one basket?
SPREAD YOUR RISK Rely on us! For all your Polymer Raw Material Requirements HDPE LDPE LLDPE PVC PET PS ABS PP
MBT South Africa Distributors of Plastic Raw Materials Cape Town Office 4 College House, Village Walk, Parklands Tel: +27-21-5567787
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082 901 0477 082 456 6659 082 775 5344
Carlotta Stafford Helga Ferreira Ivan Horowitz
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082 600 7403 072 573 4221 072 896 6636
DIARY
Engel e-victory produces housings PROCESS integration is a key factor when it comes to being more competitive, and for this reason Engel is presenting a twocomponent application at the T-Plas 2015 from 26-29 August in Bangkok, Thailand. An Engel e-victory 200H/80W/120 combi injection moulding machine with an Engel viper 20 linear robot will produce VHQVRU KRXVLQJV IRU Ă&#x20AC; RZ PHWHULQJ ZLWK DQ LQWHJUDWHG VHDO 7KH Âż UVW VWDJH LQYROYHV WZR housings being moulded simultaneously from a thermoplastic material. The robot then transfers the parts of the housing to a second set of cavities, where the seal made from liquid silicone (LSR) is moulded on directly. While the soft components of one set of housings are being processed, the next housings are already in progress in the lower half of the mould. Having the seals moulded directly onto the housings QRW RQO\ LQFUHDVHV SURGXFWLRQ HIÂż FLHQF\ EXW also product safety. The thermoplastic and elastomer form an inseparable unit. The multi-component process is not
4th International Polyurethane Industry Exhibition
2nd Composites Industry and Production Technologies Exhibition
Eurasiaâ&#x20AC;&#x2122;s Leading Polyurethane & Composites Industry Platform
the only challenge presented by the manufacture of the housing parts here; handling the liquid silicone safely is also GLIÂż FXOW SDUWLFXODUO\ EHFDXVH LWV ORZ viscosity makes it hard to work with. The demands placed on the processing of liquid silicone (LSR) are that it must be fully automatic, waste-free, low in burrs and require no post-processing. Various factors contribute to ensuring that these demands DUH IXOÂż OOHG UHOLDEO\ 6HUYR HOHFWULF LQMHFWLRQ units guarantee a very high degree of precision, for example. The shot weight of the LSR components is just 0.04g per part, and a special individualised solution would normally be required for processing LSR when such a small injection volume is involved. Engel is able to use a standard unit, however. To measure out the liquid silicone, mini pumps with one-litre tanks are XVHG WKDW DOO Âż W ZLWKLQ WKH VDIHW\ KRXVLQJ of the injection moulding machine, saving both space and costs. www.engelglobal.com
World of cups at Illig open house Launch of the new large IC-RDM 76K
Istanbul Expo Center
Media Partner
In Cooperation with &KHPŕś&#x2C6;VWU\ 6HFWRU 3ODWIRUP DQG 0HPEHUV
Organiser
Phone : +90 212 324 00 00 F ax : +90 212 324 37 57 sales@artk com.tr www.artk com.tr
THIS FAIR IS ORGANIZED WITH THE PERMISSION OF TOBB (THE UNION OF CHAMBERS AND COMMODITY EXCHANGES OF TURKEY) IN ACCORDANCE WITH THE LAW NO.5174
94 AUGUST / SEPTEMBER 2014
www.putecheurasia.com www.eurasiancomposites.com
ILLIG, the manufacturer of thermoforming lines, welcomed almost 200 participants from the thermoforming sector internationally at its open house show Heilbronn, Germany, in April. Presentations on state-of-the-art automatic pressure forming machines of the RDM-K series for combined forming and punching were supplemented by different practical machine demonstrations. Serial production of samples of different shapes and sizes was demonstrated on a total of six state-of-the-art highperformance thermoforming lines. Guests show particular interest in two exhibits: the new large IC-RDM 76K which was SUHVHQWHG WR WKH SXEOLF IRU WKH Âż UVW WLPH as well as an IC-RDM 70K, interlinked with a newly developed RDML 70b IML-T unit. Cups with sealed rims were produced on the new, large IC-RDM 76K out of PP using a 60-up mould, cup diameter 75mm and height 100mm Illig introduced its new large RDM 76K thermoforming machine at an open house show in Germany in April
with an hourly output of about 126,000 cups. The higher productivity of the ICRDM 76K can be attributed to its even larger forming area (760mm x 530mm) compared to the forming area of the wellknown IC-RDM 75K (700mm x 450mm) which is already considered â&#x20AC;&#x2DC;largeâ&#x20AC;&#x2122;. The lower table in lightweight design is also a new feature which still allows high movement speeds in spite of the enlarged forming area, such as achieved by the IC-RDM 75K. Very precise movement sequencing is achieved together with very high running smoothness and in conjunction with an innovative gear for the main drive this last but not least also results in an extended service life of the mould. Illig is represented by Hestico. www.illig.de/en/illigmaschinenbau
with integrated seal
The multi-component process is not the only challenge presented by the manufacture of the housing parts here; handling the liquid silicone safely is also GLIÂż FXOW
Taking the heat!
DUPONTâ&#x20AC;&#x2122;s new VamacÂŽ VMX5000 AEM pre-compounds extend the upper temperature limit for AEM applications by 15-20°C, enhancing their use in air intake manifold gasket applications, and for seals, gaskets and hightemperature coolant hose covers. DuPont showed these new compounds at the International Rubber Conference in Germany in June.
www.dupont.com
4th Annual Environmental Crimes Conference Future developments, progress in favour of SAâ&#x20AC;&#x2122;s environment THE 2015 edition of the Annual Environmental Crimes Conference, on 9-10 September at the Indaba Hotel, Fourways, Johannesburg, aims to gather regulators and industry to meet on an objective platform to exchange ideas and collaborate on future developments and progress in favour of the environment of South Africa. &RQÂż UPHG VSHDNHUV LQFOXGH 'U 7KXOL 0GOXOL &KLHI 'LUHFWRU $LU 4XDOLW\ 0DQDJHPHQW 'HSDUWPHQW RI (QYLURQPHQWDO $IIDLUV 1LJHO $GDPV $FWLQJ &KLHI 'LUHFWRU (QIRUFHPHQW 'HSDUWPHQW RI :DWHU DQG 6DQLWDWLRQ 5DLQ\ 'LVHER 0DVKLWLVKR &KLHI 'LUHFWRU &RPSOLDQFH (QIRUFHPHQW *DXWHQJ 'HSDUWPHQW RI $JULFXOWXUH 5XUDO 'HYHORSPHQW
Key strategies to be discussed include =HUR SODVWLFV WR ODQGÂż OO 5HSRUWLQJ 5HTXLUHPHQWV LQ 7HUPV RI WKH 1DWLRQDO (QYLURQPHQWDO 0DQDJHPHQW $LU 4XDOLW\ $FW RI (QIRUFHPHQW ZLWKLQ WKH 5HJXODWRU\ )UDPHZRUN Âą WKURXJK change management Escalating environmental enforcement through VWUHQJWKHQLQJ FROODERUDWLRQ EHWZHHQ NH\ JRYHUQPHQW departments (YDOXDWLQJ WKH TXDOLW\ RI VHOHFWHG (QYLURQPHQWDO ,PSDFW $VVHVVPHQWV IRU HIIHFWLYH GHFLVLRQ PDNLQJ SURFHVVHV Emerging legal trends in inclusive green economy 'LVFXVVLQJ ,17(532/ÂśV WRROV DQG VHUYLFHV PDQLIHVWHG both regionally and globally Safeguarding the environment through strong monitoring and prosecution )RU UHJLVWUDWLRQV HPDLO bookings@intelligencetransferc.co.za RU FDOO =DNKHOH www.intelligencetransferc.co.za
AUGUST / SEPTEMBER 2014 95
DIARY
Higher output, stronger performance, faster line speed DURING this yearâ&#x20AC;&#x2122;s Chinaplas, battenfeld-cincinnati China organized two demonstrations where it presented two lines in production: a high-output (1,200kg/h) line for 400mm gas pipe extrusion and a LeanEX high-speed line for 20mm PE-RT pipe that ran with a line speed of 40m/min. Then during May, battenfeld-cincinnati welcomed 210 visitors at its Shunde plant for presentations and extrusion line demonstrations. At the Open House, the 400mm line for gas pipe extrusion delivered high outputs and top performance. The solEX 75 single screw extruder has an AC motor that saves 20% energy compared with a DC motor and achieved outputs of 1,200kg/h with a low noise level of below 80db. The proven helix 96, 7 SLSH KHDG ZLWK LQQHU SLSH FRROLQJ ($& HIÂż FLHQW DLU cooling) ensured excellent melt homogeneity and pipe quality, with minimized sagging. This is why the combination of solEX and helix VSI-T is also ideal for large diameter solid wall PO pipe extrusion â&#x20AC;&#x201C; diameters up to 2.6m are currently possible. The inner cooling in the pipe head also enabled an impressive 45% reduction in line length from 85m to 47m. The PE material BorSafe 3490LS was sponsored by Borouge and the dehumidifying and conveying system came from Piovan. This energy reclaim system was used for pre-heating of the material, saving 30% energy, bringing the lineâ&#x20AC;&#x2122;s combined energy consumption per ton of PE processed down to only 268 kWh. The second line on display was a LeanEX line, available LQ Âż YH VL]HV DQG PP 7KH /HDQ(; concept stands for â&#x20AC;&#x2DC;lean extrusionâ&#x20AC;&#x2122;, i.e. simple, turnkey lines for standard PO pipe applications built with European technology and locally sourced screws, barrels, motors and drives. The line shown was a LeanEX 63mm line with a LeanEX C1-60-30 single screw extruder producing a PE-RT pipe with dimensions of 20*2.3 mm at the high line speed of 4m/ min and an output of 320kg/h.
On the LeanEX line a 20 mm PE-RT pipe was produced with the high line speed of 40 m/min
On the high-performance solEX line with outputs of 1,200 kg/h, a 400 mm gas pipe was produced with a helix 400 VSI-T pipe head with inner pipe cooling
www.battenfeld-cincinnati.com/china
Packaging Indaba at Forum Labelling and packaging trends
Also at the Packaging & Beyond seminar were Alessandro Corticelli and Fabrice Digonnet from DOW, with Jolanda van de Spreng, MD of VDS Media
VDS Mediaâ&#x20AC;&#x2122;s Packaging and Beyond event in May was yet another huge success for organiser Jolanda van de Spreng and sponsors. The event brought the South African packaging industry together to reveal new innovations, stimulate and motivate developments and encourage new approaches. The latest thinking was highlighted in a range RI SUHVHQWDWLRQV RQ Ă&#x20AC; H[LEOH ULJLG SODVWLFV glass, corrugated, metal, labelling, directto-package digital printing and other
96 AUGUST / SEPTEMBER 2014
jolanda@vdsmedia.co.za
AFRICAN LABEL & PACKAGING INDABA THE FORUM BRYANSTON - JOHANNESBURG SOUTH AFRICA
packaging related technologies. The next event organised by VDS Media is the African Label & Packaging Indaba on 9 September. This event is primarily geared at education and innovation and will focus on the main label and packaging segments of PSA, IML, VKULQN ZUDS DURXQG Ă&#x20AC; H[LEOH SDFNDJLQJ glass, carton, metal, rigid plastics, etc. To register or for further information contact Jolanda van de Spreng at tel: +27 76 424 0831 email: www.vdsmedia.co.za
08-09 SEPT 2015 REGISTER
www.vdsmedia.co.za
Book ance n ainte nt m r you uireme e req befor , Y L EAR mber e c e D down shut
candice@relloy.co.za
New EVM rubber for reduced mixing times DIARY
Ideal for continuous mixing processes LANXESS launched a new family of pre-crosslinked EVM rubbers, in the form of the ethylene-vinyl acetate copolymers of the Levapren PXL series, at the International Rubber Conference in Germany in June. 7KHVH KDYH EHHQ GHYHORSHG VSHFLÂż FDOO\ IRU UDSLG processing in particularly cost-effective, continuous mixing processes â&#x20AC;&#x201C; using Buss co-kneaders, for instance, or twin-screw extruders. Among other things, the freeĂ&#x20AC; RZLQJ JUDQXOHV DUH LGHDO IRU UHGXFLQJ PL[LQJ WLPHV when producing particularly high-quality hoses or cable sheathings. Samples of the new ethylene vinyl acetate rubbers have DOUHDG\ EHHQ PDGH DYDLODEOH WR WKH Âż UVW FXVWRPHUV 7KH Âż UVW JUDGHV WR EH DYDLODEOH DUH 3;/ 3;/ PXL and 800 PXL, with vinyl acetate contents of between 50 and 80%. The properties of vulcanizates produced using Levapren PXL are similar to those made using conventional EVM rubbers from Lanxess. â&#x20AC;&#x153;Standard Levapren grades have a much lower Mooney
Lanxessâ&#x20AC;&#x2122; ethylenevinyl acetate copolymers of the Levapren PXL series have been GHYHORSHG VSHFLÂż FDOO\ for rapid processing in particularly costeffective, continuous PL[LQJ 7KH IUHH Ă&#x20AC; RZLQJ granules are ideal for reducing mixing times ZKHQ SURGXFLQJ SDUWLFXODUO\ high-quality hoses or cable sheathings
viscosity than many other synthetic rubbers,â&#x20AC;? explained EVM specialist JĂśrg Stumbaum from the High Performance Elastomers business unit at Lanxess. â&#x20AC;&#x153;This brings several advantages â&#x20AC;&#x201C; for instance, fewer plasticizers or even none at all are needed for EVM processing. However, some users require EVM rubbers with somewhat higher viscosity. For some time now, we have been able to offer these customers our precrosslinked Levapren XL grades.â&#x20AC;? ZZZ ODQ[HVV FRP
COMING UP ExtruAfrica: 3-7 August Potchefstroom, North West www.extruafrica.org.za
Euromold: 22-25 September Messe DĂźsseldorf, Germany www.Euromold.com
PETnology Conference: 9-10 November Nuremberg, Germany www.petnology.com
T-Plas 2015: 26-29 August Bangkok, Thailand www.engelglobal.com/de/at/news-presse
Labelexpo Europe 2015: 29 Sept-2 Oct Brussels, Belgium www.labelexpo-europe.com
PET Passion Week: 9-12 November Nuremberg, Germany www.petpassionweek.com
Infrastructure Africa: 1-2 September Sandton Convention Centre, Johannesburg www.infrastructure-africa.com
IIMC 2015: 30 Sept-1 Oct Aachen, Germany www.iimc-aachen.com
PUtech Eurasia/Eurasian Composites: 12-14 November Istanbul Expo Centre www.putecheurasia.com
Propak West Africa: 1-3 September Lagos, Nigeria www.propakwestafrica.com
TCT Show (UK): 30 Sept-1 Oct EC, Birmingham, UK www.tctshow.com
African Waste Week: 1-4 September CTICC, Cape Town www.africawaste.co.za
Polyurethanes Technical Conference: 5-7 Oct Orlando, Florida, USA ww.americanchemistry.com
SAPPMA Pipes Conference: 8 September Bytes Conference Centre, Midrand www.sappma.co.za
Compounding World Asia: 6-8 October Grand Copthorne Waterfront Hotel, Singapore www.amiplastics.com/events
African Label & Packaging Indaba: 9-10 Sept The Forum, Bryanston, Johannesburg www.vdsmedia.co.za
3RO\ROHÂż Q $GGLWLYHV 2FWREHU Maritim Hotel, Cologne, Germany www.amiplastics.com/events
Propak Africa: 15-18 March 2016 Expo Centre Nasrec, Johannesburg www.propakafrica.co.za
4th Environmental Crimes Conference: 9-10 Sept Indaba Hotel, Fourways, Johannesburg www.intelligencetransferc.co.za
CAMX: 27-29 October Dallas, Texas, USA www.thecamx.org
Drupa 2016: 31 May-10 June 2016 DĂźsseldorf, Germany www.drupa.com
ARMO 2015: 13-15 September Nottingham Conference Centre, UK www.armo-global.org
ICCBN: 28-30 October Durban University of Technology, Durban www.dut.ac.za/iccbnm
OLEDs 2015: 16-18 September Claremont Hotel Club & Spa in Berkeley, CA www.smithersapex.com
Polymer Foam: 2-4 November Maritim Hotel, Cologne, Germany www.amiplastics.com/events
1st Intâ&#x20AC;&#x2122;l Composites Cong (ICC): 22-24 Sept ICS Intâ&#x20AC;&#x2122;l Congress Centre, Stuttgart, Germany www.composites-germany.org
Airtec: 3-5 November Munich, Germany www.airtec.aero
98 AUGUST / SEPTEMBER 2014
Industrial Nanocomposites Conf 2015: 24-25 November SpOrt Stuttgart, Germany www.industrialnanocomposites.com 3/$67 (XUDVLD øVWDQEXO 'HFHPEHU øVWDQEXO 7XUNH\ www.plasteurasia.com 2016
K2016: 19-26 October DĂźsseldorf, Germany www.k-online.de
CLASSIFIED ADVERTS Advertisers: August / September 2015 ACD RotoFlo 59 Advanced Polymers 19 Air & Vacuum Technologies 24 Associated Additives 58 Banbury Chemicals 17 Carst & Walker 37 Clariant SA 67 DemaPlastech 83 DH Polymers 95 Engen Petroleum 91 Envande 38 Ferro Industrial Products 71 George Ferreira Plastics OBC Hosaf 63 Inkulu Plastic Pipes 23 Jenowill 03 Karbochem 39 Maritime Marketing 15, 69 Masterbatch SA 01 MBT 93 MCG Industries 09 MERSETA 77 MGMW Trading 57 Miracle Mould 26,27 MJH Machine Tools 20 MonTech Africa Rubber 35 Mould Base 41, 49 Nissei ASB 53 Nuvo Rubber Compounders 31 Orion Engineered Carbons 13 Performance Colour Systems 51 Plastichem IFC Plastics|SA 43 Plastomark 89 Polysaf Chemical 65 Protea Chemicals IBC Putech 94 Rawmac 47 Relloy 22, 97 Roediger Agencies 25 SABIC 75 Safripol 05 SAPY Colours 87 SES 79 Sun Ace 45 Ultra Polymers 61 VDS Media 96 W R Grace Africa 21 Welltec 55
SUBSCRIBE TO SA PLASTICS, COMPOSITES & RUBBER SA Plastics, Composites & Rubber is published six times a year and is available to people involved in the plastics and polymer industry in South Africa on a subscription basis at a cost of R285 a year. It is available in other countries in Southern Africa at a subscription cost of ZAR500 per year. International subscription, supplied by airmail, is ZAR700. If you’d like to subscribe, email your details to saplastics@iafrica.com or visit our website at www.saplastics.co.za
FOR SALE • 20 Ton grey pelletized polypropylene
•
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available, (ex correx) a once off, single source. Price R12/kg excl VAT, price includes delivery. 30 Ton black pelletized HDPE inj grade, a once off, single source, R11.50/kg excl VAT, price includes delivery. 4 ton PPGF30, black granulate, single source, pre-consumer stock. Price R6.50/kg excl VAT, price includes delivery. 14 ton clear, pre-consumer, granulated PET, any offers Granulated PMMA 20 ton plus, pre-consumer stock, open for offers. 6 ton/mnth Panlite PC clear granulate, pre-consumer stock R18/kg excl VAT. &RQWDFW Wouter de Lange 072 705 8597 wouterbagman@gmail.com
THERMOFORMING TECHNOLOGY SAVE 90% of your electricity use with GN! GN (Canada): machines for reduced waste and reduced energy; Thermoforming Moulds for GN and other thermoformers EXTRUSION TECHNOLOGY FROM AGRIPAK OF ITALY Mono & multi-layer extrusion lines for the production of: µ&DUWRQSODVW¶ WZLQZDOO KROORZ SUR¿ OH VKHHW Multilayer sheet for packaging; Semi-foamed sheet for thermoforming MATERIALS FOR THERMOFORMED PACKAGING 6HDOLQJ ¿ OPV IRU WUD\V DQG WRS ZHE IRU ))6 PDFKLQHV 3(7 3( ODPLQDWHG VKHHW IRU ))6 SDFNDJLQJ OLQHV OPS, PP, PET sheet for general packaging; 33 (92+ 33 IRU KLJK EDUULHU FRQWDLQHUV
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CONTACT: 015 293 0513
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:H %X\ DQG 6HOO 3ODVWLF 3DOOHWV 083 756 6897 ZZZ SUHPLHUSDOOHWV FR ]D 7R SODFH D FODVVLÀ HG DGYHUW SOHDVH
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Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com ZZZ VDSODVWLFV FR ]D AUGUST / SEPTEMVER 2015
99
SPORTS
Marinedegradable polymers in fishing equipment One possible way of tackling plastic litter in bodies of water
100 AUGUST / SEPTEMBER 2015
plastic. The company says its PHA biodeAMERICAN company Meredian Holdings grades completely in fresh water, similar Group Inc says its polyhydroxyalkanoate to the biodegradability polymer could reduce ‘When you think of all the it achieves in soil and litter generated by recfishermen out there and how industrial composting. reational fishing. The “As an avid firm claims to have many lures get lost each fisherman, I’ve developed the first season, it is hard to think of seen first-hand the certified biodegradable all that plastic that will sit in plastic pollution in plastic freshwater fishthe ocean for hundreds of the ocean,” said ing lure based on its years to come.’ CEO and Chairman Nodax PHA. Paul Pereira. “When you think of all the According to Plastics News, Meridian fishermen out there and how many lures says the new lure performs as well as its get lost each season, it is hard to think of counterpart moulded from conventional
all that plastic that will sit in the ocean for hundreds of years to come. The same thing applies to fresh water fishing but in a larger scale.” “Meridian has been driving towards this for a long time,” added Scott Tuten, Meridian chief marketing officer. “Producing a lure that is biodegradable makes an outdoor sport I enjoy, better for everyone and the environment.” www.mhgbio.com www.plasticsnews.com
Inside a golf ball! HAVE you ever wondered what a golf ball consists of? What ensures its resilience and accuracy? The core of a golf ball is made of polybutadiene rubbers (Nd-BR) such as Lanxess’ Buna CB and Taktene, both supplied by Plastichem in South Africa. These materials ensure the right dynamic properties and a positive impact on performance, for instance, flying distance, stability of the ball, and flight characteristics. The COR index (Coefficient of Restitution) is an indicator of the energy lost in golf balls. Golf balls with Nd-BR have the highest COR value and therefore the lowest energy lost, thus achieving the larger distance with the same driver energy. Lanxess offers linear polybutadiene rubbers such Co-BR and Nd-BR which fulfill the high requirements of the golf ball industry.
www.lanxess.com
www.plastichem.co.za
The Protea Chemicals Team offers offers innovative The Polymers Team innovative solutions to to the the plastics plastics industry industry with withthe thebacking backing solutions of products and andindustry industry ofworld world class products professionals. professionals.
Touching lives everyday
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