SA Plastics, Composites & Rubber

S A PLAS TI CS COMP OSITES + RU B BE R

www.saplastics.co.za

VOL 14 ISSUE 3 – JUNE / JULY 2016

y V OL 1 4 NR 3

Alpha Plast hits the jackpot

J UNE / JU LY 20 16

Polymers closing

the loop

Multimillion investment for Ferro

first local 90 MFR resin for injection moulding Plastics|SA latest recycling figures

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Industry concerned about Govt’s proposed packaging charge or tax

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Plastics for Life global parts competition

One litre of light 44

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

Give you a reach that stretches far beyond other materials.

3VUNLY ÅV^ WH[OZ c ,MÄJPLU[ LULYN` \ZHNL 3VUNLY ÅV^ WH[OZ c ,MÄJPLU[ LULYN` \ZHNL ࠮ -SV^ WH[OZ ILJVTL SVUNLY [OHU L]LY PTHNPULK ^OPSL [OL WYVK\J[ WYVWLY[PLZ YLTHPU ]PY[\HSS` \UJOHUNLK ࠮ 6W[PVU VM YLK\JPUN ^HSS [OPJRULZZ ^P[O [OL PTWYV]LK ÅV^ WYVWLY[PLZ ࠮ -SV^ WH[OZ ILJVTL SVUNLY [OHU L]LY PTHNPULK ^OPSL [OL WYVK\J[ WYVWLY[PLZ YLTHPU ]PY[\HSS` \UJOHUNLK ࠮ *`JSL [PTLZ JHU HSTVZ[ IL J\[ I` [V PUJYLHZPUN V\[W\[ HUK ZH]PUN [PTL HUK LULYN` ࠮ 6W[PVU VM YLK\JPUN ^HSS [OPJRULZZ ^P[O [OL PTWYV]LK ÅV^ WYVWLY[PLZ ࠮ <ZL VM ZTHSSLY THJOPULZ ^OPJO \ZL SLZZ LULYN` ࠮ *`JSL [PTLZ JHU HSTVZ[ IL J\[ I` [V PUJYLHZPUN V\[W\[ HUK ZH]PUN [PTL HUK LULYN` ࠮ 3HYNLY WYVJLZZPUN ^PUKV^ PU [LYTZ VM [LTWLYH[\YL HUK TV\SK ÄSSPUN WYLZZ\YL ࠮ <ZL VM ZTHSSLY THJOPULZ ^OPJO \ZL SLZZ LULYN` ࠮ :PNUPÄJHU[S` LUOHUJLK Z[PMMULZZ HUK Z[YLUN[O ࠮ 3HYNLY WYVJLZZPUN ^PUKV^ PU [LYTZ VM [LTWLYH[\YL HUK TV\SK ÄSSPUN WYLZZ\YL ࠮ :PNUPÄJHU[S` LUOHUJLK Z[PMMULZZ HUK Z[YLUN[O

Durethan® and Pocan® are registered trademarks of LANXESS

For more info call 0800 006 772 or go to www.plastichem.co.za

THE MORE WE COLLABORATE THE MORE WE INNOVATE Innovation never happens in isolation.

Our ten thousand-plus registered patents are the product of collaborations with customers. These have resulted in smarter fertilizers, stronger plastics and lighter transportation. That’s why ambitious global companies choose to work with us.

They know that collaborating with experts creates ‘Chemistry that Matters™’ for them.

SABIC.com

© 2016 Copyright by SABIC. All rights reserved.

BY THE WAY

Publisher: Martin Wells (martin@summitpub.co.za) Editor: Tessa Oâ&#x20AC;&#x2122;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 Unit 8, Bergvliet Village Centre, Cnr Hiddingh & Childrenâ&#x20AC;&#x2122;s Way Roads, Bergvliet 7945

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

PVC was used in an unusual application at the Two Oceans Aquarium in Table Bay recently when a cone produced out of Ă&#x20AC; H[LEOH 39& ZDV XVHG to capture the female ragged tooth shark here and lift her out of the tank; after which she was transferred to a holding tank and transported to East London, where she was released into the big blue.The cone is made of a soft PVC which has the advantages of being both strong and transparent. The VKDUN KDV EHHQ Âż WWHG ZLWK D WUDQVPLWWHU WKDW FRXOG ODVW DV ORQJ DV 10 years. The soft PVC cone was produced by Brianâ&#x20AC;&#x2122;s Canvas in what looks like a fairly rare application.

Dow convenes Africa media indaba DOW Packaging & Specialty Plastics convened an unusual event in South Africa recently when it brought together trade journalists from across Africa LQ ZKDW PXVW VXUHO\ EH WKH Âż UVW HYHU PHHWLQJ RI $IULFDÂśV SDFNDJLQJ DQG plastics writers. Two dozen journalists from across the continent â&#x20AC;&#x201C; from as IDU DÂż HOG DV 0RURFFR $OJHULD 1LJHULD *KDQD .HQ\D DQG 6RXWK $IULFD Âą met for the two-day event at a hotel in Johannesburg in April.

With the recent enthusiasm for trading into Africa having come off its highs of late, Africa certainly needs help where it can get it. Dowâ&#x20AC;&#x2122;s range of packaging products and polymers could go some way towards helping turn the tide. Many hurdles lie in wait, not least the challenge of actually getting the products to the people. Among the obstacles are the fact that intra-Africa trade has been declining, as has manufacturingâ&#x20AC;&#x2122;s contribution to GDP, which has fallen from 3% to just 2% â&#x20AC;&#x201C; which is extremely worrying (if you consider that manufacturingâ&#x20AC;&#x2122;s share of GDP in Thailand, for example, is 28%).

We wish Dow well in the quest and many in South Africa will share that sentiment.

Study predicts â&#x20AC;&#x2DC;Plastic Ageâ&#x20AC;&#x2122; to last millennia 6&,(17,676 KDYH EHHQ DEOH WR GHGXFH D JUHDW GHDO DERXW (DUWKÂśV SDVW through examining fossils. But in the future the story of our present may be yet gleaned from an alternate source â&#x20AC;&#x201C; plastics. Published in the journal Anthropocene, scientists from the University of Leicester have sought to examine the long-term impact of polymers on our planet. It is a study which claims we may be on the brink of a â&#x20AC;&#x2DC;Plastic Ageâ&#x20AC;&#x2122;.

According to the research, human activity will bury the lands and oceans under a layer of plastic waste by the mid-century. In addition, the planetâ&#x20AC;&#x2122;s surface itself will be altered by these polymers.

Jan Zalasiewicz, Professor of Palaeobiology from the University of Leicesterâ&#x20AC;&#x2122;s Department of Geology, explained: â&#x20AC;&#x153;Plastics are pretty well HYHU\ZKHUH RQ (DUWK IURP PRXQWDLQ WRSV WR WKH GHHS RFHDQ Ă&#x20AC; RRU Âą DQG can be fossilised into the far future. Once buried, being so hard-wearing, plastics have a good chance of becoming fossilised â&#x20AC;&#x201C; and leave a signal of the ultimate convenience material for many million years into the future.â&#x20AC;?

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Association of Rotational Plastics Institute

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Plastics Federation

South Africa

of SA

2-3.indd 2

Institute of Materials

THE article in our April/May issue SDJH 3ODVWLFV WUDGH TXDOLÂż FDWLRQ DSSURDFKHV FHUWLÂż FDWLRQ ZDV LQFRUUHFW 7KH IDFW LV WKDW WKH 7HFKQLFDO Working Group (Plastics Manufacturing Setter Trade Test) and parties involved in the trade test process are still in discussion about entrance requirements for the Plastics Manufacturing Machine 6HWWHU WUDGH TXDOLÂż FDWLRQ 7KH 0HUVHWD 3ODVWLFV HAVE â&#x20AC;Ś IF YOU TO SAY Chamber is also still in discussion about the Part SOMETHING if you side: ht ig br e to 4XDOLÂż FDWLRQV WKDW QHHG WR EH GHYHORSHG Look at th of wisdom e gem have som e to us at ease writ impart, pl ica.com fr ia s@ saplastic

2016/06/08 11:18

VOLUME 14 NR 3

REGLOPLAS

JUNE / JULY 2016

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

6 8 10 12 14

24

16 18 20 24 28 30

32 34 36

38

44

44

64 70

Temperature control units for oil up to 150°C

52

88

• Simultaneous readout of temperature set-point and actual value

48

MATERIALS & EQUIPMENT Bühler changes the dynamics of polymer sorting Latest version of Gapa machine from Technimac

NEW

• Controller RT61 PID • Outlet temperature max 150°C • Heating capacity at 400V 6 kW • Cooling capacity 28kW @ 140°C • Pump capacity 60 litres/min, 3.8 bar

COMPOSITES NEWS Formo )LEUHJODVV FHOHEUDWHV \HDUV

direction (clockwise) • Alarm buzzer • Heating capacity 9 kW

Type 150 Smart

40

DESIGN Plastics making our lives better!

• RT 70 control system • Solid-state relay (SSR)instead of

• Cooling capacity 24-90 kW • Pump capacity 60 litres/min, 3.8 bar

PEOPLE Sun Ace 6RXWK $IULFD WK DQQLYHUVDU\

Temperature control units for water up to 90°C

heating contactor • Automatic phasechanger for pump

ASSOCIATION NEWS POLYCO focuses on building strong recycling value chain Plastics|SA: Userve donates machine for training SAVA: 9LQ\O 9HUL¿ HG PRYHV VRXWK

… for large injection moulds, extruders, rollers, autoclaves and other processing equipment

New, more efficient Type 90 Smart

INDUSTRY NEWS Mpact Polymers closing the loop in bottle-grade recycling Recycling stats: Lack of quality material MCG installs major injection plant in Malvern Alpha Group signs distribution agreement with Ampacet Continental Compounders unveil state-of-the-art polymer testing facility Greenacres LQWURGXFHV LWV ¿ UVW IRDP FXWWLQJ V\VWHP Ferro’s multi-million investment in black, white masterbatch lines Safripol SURGXFH ¿ UVW ORFDO 0)5 UHVLQ IRU injection moulding Maverick Engineering is a leader in pouch bag machines Industry concerned about Govt’s proposed packaging charge or tax

High-performance temperature control units

• Clear arrangement of operating and indicating elements • Solid state relay (SSR) instead of heating contactor

ON THE COVER MPACT Polymers’ unveiled its new 20 000m² bottle-tobottle ‘Savuka’ rPET factory in Wadeville on 10 May and immediately announced that 6000 tons of the expected 21,000 tons of rPET it will produce annually has been contracted to Coca-Cola bottler ABI. Read more on page 6-7 www.mpact.co.za

• All components exposed to water are made of non-rusting materials, hence long service-life • Achieves estimated 24% reduction in rejects and 20% increase in productivity

JENOWILL SERVICES Contact – Willy Tschopp Tel: 021 551 7241 Fax: 021 551 7243 28C Lilly Park, Railway Rd Montague Gardens, Cape Town jenowill@iafrica.com www.regloplas.com

2-3.indd 3

2016/06/08 11:18

COMMENT New rPET line – Mpact Polymers unveiled its new 20 000m² bottle-tobottle rPET factory in Wadeville in May. It is expected to manufacture about 21,000 tons of ‘Savuka’ rPET annually. The main polymerization unit in the R350-million project plant includes the Krones processing unit and Piovan decontamination system seen here

Material, machinery makers progress

THIS ISSUE

SA companies invest to boost supply and quality

M

OST companies around the country and even across the UHJLRQ DUH ¿ QGLQJ WKH JRLQJ WRXJK at the moment but it’s not as if one can switch the lights off and walk out … although some people have been known to do that – and leave the lights on.

So we may as well make the best of it and, as you will see in the following pages, quite a lot of companies are doing just that.

We publish reports about plant improvements by the material manufacturers Alpha Plast/Elco Plastics, Continental Compounders, Ferro Plastics, Mpact Polymers and Safripol, all of who have made substantial investments to improve quality and supply, plus in some cases get into exports (and some instances not only into Africa).

Then we also look at developments in the machinery manufacturing area where Technimac has continued its virtually ceaseless evolution of the ‘Gapa’ bag-making machine, Maverick Engineering has succeeded where few would have expected by becoming a world leader in the manufacture of stand-up pouch machines (it recently supplied a system to the USA to produce 1000-litre pouches, a beast of machine which is 33m long). and then, in a nice little surprise, Greenacres – based in 0DOPHVEXU\ RQ WKH :HVW &RDVW ± KDV LQWURGXFHG LWV ¿ UVW foam-cutting machine, an ‘entry level yet world class system’ it says.

Now it’s quite easy to say these developments are incidental, but the fact is that these achievements are the result of extensive teamwork and planning on the part of all those mentioned, starting with the owners and management of these businesses – the people with the vision to progress with their enterprises – and all the individuals involved in the teams.

The weakening of the rand exchange rate is obviously also a factor, especially for equipment manufacturers, but it appears – ironically – that most of the components are imported. That’s the case at least partly because

4 JUNE / JULY 2016

South African engineering companies are seen as over-priced and lead times are too long, in other words uncompetitive. However, it appears a slight shift is underway and that some local manufacturers are becoming more competitive.

On the converting side, there are also some impressive achievements, not least by MCG, which has installed a world-class injection moulding plant at its site in Malvern, Johannesburg – with a price tag estimated at about R60-million; and then Jannock Tool & Die and Jannock Plastics on the West Rand are celebrating 30 years. Their operation has succeeded partly due to their ability to manufacture their own tools and, using that advantage, to partner effectively with customers, particularly during the product development phase.

One of the most important aspects behind the success of these Achievements companies is their ability to support are the result their customers on an on-going basis that leads to lasting working of extensive relationships.

teamwork

and planning Packaging ‘tax’ We also report about Packaging SA’s drive to engage with government on the proposed tax on packaging.

Given the history of the failed Buyisa-e-Bag project and the disappearing funds from the plastic bag levy, plastic packaging companies are nervous about the prospect. If the bag levy had been used to boost recycling and litter collection and recycling, there would probably have been at least some enthusiasm, but that’s not the case.

One of the interesting things that’s come out of the process is the situation of plastics within the broader packaging sector: of the four main materials in use, plastic is the only one which KDV VKRZQ VWHDG\ JURZWK RYHU WKH ODVW ¿ YH Martin Wells , Publisher years for consumption and recycling, whereas consumption of glass, metal and paper have all declined … which is not a good sign.

3137_Safripol_Generic_Ad_PRINT.indd 1

2014/07/24 3:02 PM

NEWS

MCG installs major injection plant in Malvern 4x KM machines plus one on order complete cooling and materials handling systems in R60m-plus project for the 2015/16 year

6 JUNE / JULY 2016

ONE could quite easily drive by MCGâ&#x20AC;&#x2122;s plant in Johannesburg without even noticing that a factory operates from the spot. About the only thing that gives the place away is the steady stream of trucks emerging out of the tight little side street in Malvern, transporting mainly crates to beverage manufacturers around the country.

The site in fact houses one of the largest injection moulding installations in the country, and there has been plenty of activity of late: in what was one of the major capex projects in the industry last year, MCG installed four KraussMaffei injection moulding machines together with a major Frigel cooling plant plus a complete new materials KDQGOLQJ V\VWHP IURP 0RUHWWR $ Âż IWK .0 machine is on order, due to arrive in August, together with new chillers and material handling equipment.

The project is estimated to have come in KU SURFHVVLQJ VSHHGV ZKLFK DUH GHÂż QLQJ at over R60-million. And the high perforcriteria for convertors. mance capability of the plant is expected to The KM units replace a number of older shake up the plastic crate market in South machines, some of which have been Africa. moved to the new MCG plant in Windhoek In what was effectively a standard while the other excess machines have replacement of older equipment, MCG apparently been cut up or earmarked for installed the four fast-cycling Krauss Maffei further expansion. machines, starting late To back up the injecin 2015, including three tion cell, and with the goal â&#x20AC;&#x2DC;Capability of plant 1000-ton clamp force MX of doubling the output systems plus a single 650t of crates on the same expected to shake GX machine and a 1300-ton footprint, MCG installed a up plastic crate MX to be installed in August. high-volume water chiller market.â&#x20AC;&#x2122; The hydraulic Krauss system from Frigel of Italy Maffei systems, reputed to plus a materials handling be among the most expensive available, system from Moretto (also Italian). were chosen by the MCG team for their The 1200kW Frigel â&#x20AC;&#x2DC;Ecodryâ&#x20AC;&#x2122; cooling syshigh reliability, high output and low maintetem, one of the largest chilling plants in the nance requirement. industry in SA, was a prerequisite for the Supplied by Plastic & Chemical Tradproject: fast-cycling large injection systems ing, the KM machines exhibit optimum require highly dependable supply of chilled power-to-performance criteria, achieving ZDWHU DW D VSHFLÂż F SUHVVXUH LQ WKLV FDVH really low kW/hr/kg ratios and very high kg/ 4 bar at the machines. The Frigel system

The crate moulds, from Schoeller Allibert Germany, are serviced by personnel from the in-plant Schoeller toolroom at the MCG site in Malvern, Johannesburg

Crates for the beverage sector constitute the main product

The plant now boasts a complete new materials handling and blending/ dosing system from Moretto of Italy

JUST BRIEFLY

Fluidra of Spain buys WaterLinx in SA

MCG is making maximum use of factory space and has literally squeezed the four new KraussMaffei machines as it progresses towards the goal of doubling crate output from the same footprint

also supplies the new Microgel chilling system, which operates at 5.8 bar for the mould cooling. At present the unit supplies chilled water to the four new machines with additional capacity to accommodate the new 1300-ton machine arriving in August.

The Frigel Ecodry closed-loop adiabatic cooling tower uses up to 99% less water than conventional open cooling towers. The system does not require insulated pipes (further reducing installation costs) and cools the returning process water via heat exchangers that are cooled via variable speed fans – further reducing energy consumption. Due to its modular construction, the system can also be expanded.

The chiller installation is backed up by an enhanced materials handling system from Moretto, together with a DVX dosing unit.

This dosing unit, with vertical mixer, can dose up to 10 machines simultaneously.

Both the Frigel cooling system, the Microgel and Moretto equipment was supplied by Demaplastech.

Operations director Bobby Damalis, who has been at MCG for over 30 years, LV D ORW KDSSLHU ZLWK WKH HI¿ FLHQW PDWHULDO supply achieved on the Moretto system. The DVX dosing system with vertical mixer can accommodate up to 10 dosing units

The peripheral equipment was vital for the KraussMaffei machines to achieve optimum performance, but the project management at MCG must have held their nerves as the budget ballooned. Now, according to MCG operations director Bobby Damalis, all the system’s production targets have been achieved – and it’s all systems go at the Malvern site.

www.mcg.co.za

WATERLINX, the pool and spa supply business which, almost unseen by all except those in the plastics pool cleaner supply sector, had over the past few years put together a virtual cluster of associated suppliers, has just as unnoticed been purchased by Fluidra, a Spanish group.

South Africa was at one stage a world leader in automated pool cleaning systems, with marques such as Kreepy Krauly and Aquanaut becoming household names worldwide. WaterLinx gained ascendancy in this market over the past few years by buying component manufacturers such as Injecta Plastics and Sharmark Plastics, backed up by its supply of pool chemicals and other consumables and pool/spa products. This duly attracted the interest of Fluidra, a multinational group listed on the Spanish Stock Exchange, which recently acquired 72% of WaterLinx; the founding WaterLinx shareholders retain the remainder.

Fluidra operates in 44 countries and its products are distributed to more than 170 countries. The company specialises in solutions for water conservation, handling, treatment and enjoyment.

South Africa is the sixth largest pool market in the world with an estimated 800,000 residential pools (surely not?) and about 2000 public pools; it also serves as a gateway towards other markets on the African continent, the company said in a statement.

• Fluidra-WaterLinx SA has just completed a move from Wynberg in Johannesburg to Denver, where it has taken over the premises previously used by the Astrapak companies Cinqplast and Plastop.

GreenTech is new Engel agent So cool! – The massive ‘Ecodry’ closed-loop cooling system from Frigel supplies chilled water to the new machines at 16° and 4 bar pressure

In a project with an estimated value of R7-million, MCG installed what is effectively an entirely new toolroom at its plant in Malvern, Johannesburg, late last year. Enjoying themselves at the opening of the tool room were Chris Oberem, Riccardo Paoletti from Frigel Italy, Ian Victor, managing director of MCG Industries and Jacques Kleynhans, managing director of Demaplastech.

GREENTECH Machinery is the new Engel representative in Southern Africa.

One of the most widely used injection moulding machines in South Africa, (QJHO RULJLQDOO\ RSHUDWHG LWV RZQ RI¿ FH in Johannesburg. Then, in about 2009; WKH RI¿ FH ZDV VKXW DQG WKH (QJHO SHU sonnel merged into Maritime Marketing, and moved to Maritime’s premises in Kyalami.

The new GreenTech team recently separated from Maritime and moved to premises in Quellerina, Johannesburg.

Patrick Bracke is the managing director of GreenTech and Johnny Lendia, Martin Uys and Marc van Tonder are the new company’s service engineers.

The change is fully supported by Engel Austria GmbH, said Bracke.

INDUSTRY NEWS

Lack of quality material highlights need for waste separation at source 3ODVWLFV_6$ UHOHDVHV SODVWLFV UHF\FOLQJ Âż JXUHV

THE lack of a consistent incoming stream of recyclables was the single biggest challenge plastics recyclers had to face during 2015.

This is according to the latest Plastics|SA recycling report which points out that a large quantity of the materials that were made available for recycling were recovered by waste SLFNHUV RII ODQGÂż OO VLWHV ZKHUH WKH\ ZHUH contaminated and very poor quality.

In the Northern Province, where the demand for recyclable materials exceeds supply, up to 40% of materials had to be scrapped or rejected due to impurities.

According to Plastics|SA executive director Anton Hanekom, this clearly highlights the need for an effective separation-at-source infrastructure to be implemented throughout the country. â&#x20AC;&#x153;The plastics recycling industry around the world is taking strain. Analysts agree that 2015 was one of the toughest years

for recyclers both locally and abroad in more than a generation, owing to historically low oil prices that led to lower polymer prices. This in turn had a direct impact on the price of recycled material, which resulted in minimal growth and a slowdown in the amount of plastics we DUH DEOH WR GLYHUW IURP ODQGÂż OO ´ KH DGGHG .H\ Âż QGLQJV IRU WKH SODVWLFV UHF\FOLQJ Âż JXUHV LQFOXGH South Africa mechanically recycled 292 917 tons of plastics in 2015 â&#x20AC;&#x201C; an increase of 3% year-on-year from 2014.

2YHU WKH ODVW Âż YH \HDUV WKH FRPSRXQGHG growth in plastics recycling was 5.5% per annum Domestic production of virgin polymers totalled 1 490 000 tons in 2015, growing 6.4% from 2014. This growth is a result of the weakening exchange rate against international currencies that lead to local procurement of plastics products rather than imports.

A total of 310 641 tons of plastics were

3ODVWLFV PDWHULDOV UHF\FOHG LQ WKH ODVW Âż YH \HDUV Âą DOO PDWHULDOV Tonnages recycled

120 000 100 00 80 000 60 000 40 000 20 000 0 PE-LD/LLD

PE-HD

PET

PP

PVC

PS & PS-E

2011

95 852

38 979

30 690

40 282

16 704

3 213

Other 4 388

2012

98 971

45 950

35 786

47 080

16 812

3 394

6 060

2013

97 778

50 519

41 302

46 331

16 205

3 796

4 998

2014

98 563

62 809

42 911

50 718

18 488

4 801

6 231

2015

104 881

59 992

53 493

47 685

15 363

5 873

5 631

$QQXDO 6RXWK $IULFDQ FRQVXPSWLRQ DQG UHF\FOLQJ IRU WKH ODVW Âż YH \HDUV 2011

2012

2013

2014

2015

1 300 000

1 370 000

1 400 000

1 400 000

1 490 000

-1,0%

5,4%

2,2%

0,0%

6,4%

230 111

254 054

260 930

284 521

292 917

0,9%

10,4%

2,7%

9,0%

3,0%

Recycling rate

17,7%

18,5%

18,6%

20,3%

19,7%

Waste exported

9 758

14 744

18 919

31 087

17 724

% growth (waste exported)

7,8%

51,1%

28,3%

64,3%

-43,0%

239 869

268 798

279 849

315 607

310 641

Total tons converted % growth (conversion) Total tons locally recycled % growth (recycled)

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8 JUNE / JULY 2016

NEWS-RECYCLING.indd 8

18,5%

19,6%

20,0%

22,5%

20,8%

1 060 131

1 101 202

1 120 151

1 084 393

1 180 459

-1,4%

3,9%

1,7%

-3,2%

8,7%

GLYHUWHG IURP ODQGÂż OO LQ less than in 2014 and is due to the VLJQLÂż FDQW UHGXFWLRQ LQ WKH H[SRUW RI recyclable waste.

7KH RYHUDOO GLYHUVLRQ IURP ODQGÂż OO UDWH was 20.8% â&#x20AC;&#x201C; decreasing from 22.5 % in 2014.

Strong growth was seen in the recycling of PET, PE-LD/LLD and PS due to new capacities that came on line in 2015.

Recycling rates of PE-HD, PP and PVC declined as some of the products traditionally made from recyclate of these materials are directly linked to consumer spending and mining activities.

Formal employment in the recycling sector increased by 3.3% to 6 234 permanent jobs.

Informal employment has grown by 3% to an estimated 48 820 collectors.

The recycling industry invested 48% more in capital equipment per ton of material processed in 2015 to deal with increasing demands and improved quality requirements.

Processing costs increased 15.4% year-on-year with the biggest contributors to cost being water, electricity and transport.

The way forward According to the Plastics|SA report, the following elements are needed to grow 6RXWK $IULFDQ UHF\FOLQJ Âż JXUHV RYHU WKH QH[W IHZ \HDUV WR FRPH SROLWLFDO will, stakeholder commitment, quality RI UHF\FODEOHV HQHUJ\ HIÂż FLHQF\ SXEOLF awareness and education, alternate technologies. â&#x20AC;&#x153;The plastics recycling industry has achieved outstanding results in the face of many obstacles and challenges.

However, we need to use these challenges to help us adapt to changing market needs and expectations. With the help of brand owners and retailers who are willing to get actively involved by putting pressure on the converters to design products that are recyclable and contain a percentage of recycled material, we will be able to take SODVWLFV UHF\FOLQJ WR D WRWDOO\ QHZ OHYHO ´ Hanekom concluded.

To read the complete 2015 Plastics Recycling report or for more information, visit www.plasticsinfo.co.za

2016/06/08 11:36

NEWS Steve van Rensburg and Hermann Naudé, veterans of the PVC compounding sector, have been steadily honing the systems at Alpha Plast in Johannesburg for close to three decades, partly by focusing on different parts of the business, with Steve running admin and Hermann production. This has enabled the Alpha ship to sail steadily as well as expand into the Cape and export markets.

Alpha Plast hits with on-going plant Strategy enables Johannesburg compounder to expand into Cape, Elco turnaround

10 JUNE / JULY 2016

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Solar solution â&#x20AC;&#x201C; The photo-voltaic inverter system at Alpha Plast is generating approximately 1000 KVA a day. An A â&#x20AC;&#x2DC;grid tiedâ&#x20AC;&#x2122; solution, in which all the self-generated current is used in the compounding operation, the roof-mounted PV panels and inverter system were supplied by Kaco Energy and Solareff, with most of the accessories sourced from China

The PV systemâ&#x20AC;&#x2122;s control panel shows how much CO2 is saved daily, on this day an estimated 990kg was kept out of the atmosphere, the equivalent of half a barrel of oil

SRVHG WR EDWFK WHFKQRORJ\ VLQFH DQG DOO LWV V\VWHPV DUH QRZ JHDUHG WR FRQWLQX RXV SURGXFWLRQ DOWKRXJK EDWFK SURGXFW LV VWLOO XVHG IRU VPDOO YROXPH SURGXFWLRQ 7KH IRFXV WKHQ IHOO RQ (OFR ZKHUH SURGXFWLRQ WR HPSOR\HH UDWHV GLGQ¶W PDWFK WKH UHVXOW ZDV D VLJQL¿ FDQW UHGXFWLRQ LQ WKH KHDGFRXQW « DQG DQ LQFUHDVH LQ RXWSXW )DLOXUH WR DGGUHVV WKLV VLWXDWLRQ PD\ KDYH UHVXOWHG ORQJ WHUP LQ GLPLQLVKLQJ RSWLRQV %XW 1DXGp ZDV VWLOO QRW FRQWHQW WKH QH[W VWHS ZDV WR RIIHU FRORXU FRPSRXQGLQJ DQG Ready to roll â&#x20AC;&#x201C; The name of the game at all stages of the PVC compounding operation LV WR PDLQWDLQ ¿ UP FRQWURO RI SURGXFWLRQ costs and QC; here bulk bags and bagged material await shipment

JUST BRIEFLY Here we see the Alpha/Elco owners in front of one of the lines which has been moved to the Johannesburg plant, where maximum utilisation is the order of the day

jackpot improvements

colour spectrophotometers were installed at both Alpha and Elco. The DataColour units have presented a value-adding opportunity and both group companies are now seeing the colour service gaining popularity. One of the early successes from this venture has been an increase in exports, one notable achievement being sales of a luminous JUDGH WR D 3DFLÂż F 5LP FRXQWU\ 7KLV VXUSULV ing boost has spurred the Alpha/Elco sales team on and increased exports now offer real potential.

Elco team â&#x20AC;&#x201C; The management team at Elco Plastics, the now wholly-owned Alpha Plast subsidiary in Bellville, includes general manager Richard Black, factory manager Gerd Koekemoer, sales manager Ewert Schnetler and FM Dave Dollman

That is just one side of the new service though: batch tracking had to be improved simultaneously and that too has been achieved with commensurate coding and labelling to enable effective traceability â&#x20AC;&#x201C; and hence analysis of problem areas. But, according to the sales team, that hasnâ&#x20AC;&#x2122;t been necessary so far as there have been very few returns.

NaudĂŠâ&#x20AC;&#x2122;s licence to automate and improve is largely due to the scope created by co-MD 9DQ 5HQVEXUJÂśV DVWXWH PDQDJHPHQW RI WKH groupâ&#x20AC;&#x2122;s admin and sales areas. That has freed the respective teams up to do what they do best. Both gentlemen seem averse to being involved with the otherâ&#x20AC;&#x2122;s responsibilities and, with the formula working, long may it last.

The combined Alpha/Elco output is in the region of 40,000 tons a year, making the group one of South Africaâ&#x20AC;&#x2122;s top PVC compounding operations. Although Elco is now a wholly owned subsidiary of Alpha, the separate names have been retained and give the group dual brands. Main applications include pipe, FDEOH SURÂż OH IRRWZHDU DQG PLQLQJ SURGXFWV DV well as, surprisingly, containers. Many thought PVC had been phased out of the container market in favour of PET, but PVC is still the material of choice in several instances, including cosmetic containers. %RWK 1DXGp DQG 9DQ 5HQVEXUJ KDYH SDVVHG WKH PDUN DQG WKH Âż QLVKLQJ WRXFK IRU them must surely be a continuity plan, which now too appears to be in place. www.elcoplas.co.za

Colour match â&#x20AC;&#x201C; Colour spectrophotometers installed in the labs at Alpha Plastics in Devland as well as at the Cape Town subsidiary Elco Plastics have proved extremely useful, allowing the companies to add colour match to their materials. This is a new service from Alpha and Elco which has proved popular in all the sectors they supply

ReproPlast takes over shareholding of Burcap NEWS in the industry is that the shareholding of Burcap Plastics has changed hands, LQ D VWUDWHJLF SDUWQHUVKLS ZLWK 5HSUR3ODVW Âą a Durban company focused on polypropylHQH ÂľXSF\FOLQJÂś 5 ' DQG FROOHFWLRQ LQ YLHZ RI UHGXFLQJ SRO\ROHÂż Q SDFNDJLQJ WR ODQGÂż OO Burcap Plastics re-opened its doors in 2015 with the introduction of a paint container using recycled material, along with a novel closing ring and lid system originating in the USA. The concept of decorated recycled packaging is in line with 5HSUR3ODVWÂśV YLVLRQ RI XSF\FOLQJ SRO\ROHÂż QV for packaging and other injection moulded products.

It made sense to partner with a sustainable brand like Burcap Plastics, who become the missing puzzle piece that completes the pictures of a company able to consistently supply high quality recycled material in packaging through a premium, sustainable outlet.

As all players in the industry know, the quality and consistent supply of recycled polymers has historically been a problem, VR 5HSUR3ODVW KDV LQYHVWHG KHDYLO\ LQ premium equipment, securing exclusive rights to a European technology that is able to recycle and compound in one process.

What this means is that the companyâ&#x20AC;&#x2122;s upcycling capacity has grown to over 1000 tons a month. â&#x20AC;&#x153;Through sophisticated processes and a PDWHULDO VFLHQFH ODERUDWRU\ 5HSUR3ODVW LV able to re-engineer polymers and consistently supply compound that performs even better than virgin material. Using this material to supply the range of Burcap decorated packaging is a very exciting innovation into the marketplace,â&#x20AC;? said a 5HSUR3ODVW VSRNHVPDQ

Japanese pneumatics +W WXMV[ ;) WNĂ&#x2026; KM SMC Pneumatics of Japan, a world leader in pneumatics and industrial automation, RIÂż FLDOO\ RSHQHG LWV GRRUV LQ 6RXWK $IULFD LQ April, with plans for expansion into the rest of Africa. Established in 1959, SMC has been voted one of the worldâ&#x20AC;&#x2122;s most innovative companies in Forbes Magazineâ&#x20AC;&#x2122;s Top 100 for three consecutive years. It supplies a staggering 12 000 basic automation components in over 700 000 variant forms, offering solutions for almost every industry imaginable, ranging from electronics and automotive to food and packaging and life sciences.

SMC has invested heavily in the SA operation and its production lines at its new Midrand HQ are equipped with the latest technology. The facility will be fully operational by July. SMC will also offer an extensive training programme.

NEWS

Mpact Polymers is closing the loop Will process 29 000 tons of post-consumer PET bottles annually

12 JUNE / JULY 2016

MPACT Polymersâ&#x20AC;&#x2122; unveiled its new 20 000m² bottle-to-bottle â&#x20AC;&#x2DC;Savukaâ&#x20AC;&#x2122; rPET factory in Wadeville on 10 May and immediately announced that 6000 tons of the expected 21,000 tons of rPET it will produce annually has been contracted to Coca-Cola bottler ABI. The R350-million state-of-the-art recycling operation was opened by Minister of Environmental Affairs Edna Molewa. The Krones process being used complies with European Union (EU) Food Safety AuthorLW\ VSHFLÂż FDWLRQV DQG LV WKH Âż UVW LQ $IULFD to meet The Coca-Cola Companyâ&#x20AC;&#x2122;s full FHUWLÂż FDWLRQ IRU 3(7 ERWWOHV WR SDFNDJH LWV soft drinks.

It enjoys the backing of the departments of Environmental Affairs (DEA), Trade and Industry (DTI) and Economic Development (EDD) in promoting job creation, reducLQJ ZDVWH WR ODQGÂż OO DQG LPSURYLQJ U3(7 production that will ultimately help to reduce

consumption compared to other options. the carbon footprint of the food and beverage industry.

PET recycling growing rapidly â&#x20AC;&#x153;This successful venture illustrates what The opening of the Mpact Polymers plant, is possible when industry and the public one of the biggest ventures in the industry sector collaborate on initiatives with a over the past few years, comes at a time positive societal impact, in this case, waste when collection and recycling of plastic reduction,â&#x20AC;? said Molewa.

PET bottles is on the rise in South Africa.

Mpact Polymers will process 29 000 According to PETCO, tons of post-consumer PET post-consumer PET collecbottles diverted from landâ&#x20AC;&#x2DC;No society can tion and recycling grew Âż OOV HDFK \HDU WR SURGXFH sustain itself from 16% in 2004 to 52% 21 000 tons of food-grade in 2015 â&#x20AC;&#x201C; with tonnages rPET, supplied under the without proactively processed going from brand â&#x20AC;&#x2DC;Savukaâ&#x20AC;&#x2122; (â&#x20AC;&#x2DC;revivalâ&#x20AC;&#x2122;) â&#x20AC;&#x201C; tackling the 9840 tons to 73 710 tons which is to be used for food wastage of any p/a over the period. and beverage packaging.

PETCO believes the Recovered labels and lids resourceâ&#x20AC;&#x2122; PET container recycling will be sold to customers for sector will collect and recycle a landmark IXUWKHU EHQHÂż FLDWLRQ 70% by 2022. Currently 68% of all virgin Krones supplied the state-of-the-art rPET and recycled PET is processed into PET processing line, in which area the German bottles for the beverage industry. machine manufacturer has a proven track Mpact Polymers has, together with record as well as a reputation for excelindustry partners Coca-Cola South Africa, lence and innovation. Another primary moABI and PETCO, spent a lot of time and eftivation was the lineâ&#x20AC;&#x2122;s low energy and water

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The main polymerisation plant, including the Krones processing unit and Piovan decontamination system, will produce 21 000 tons of rPET a year at the Mpact Polymers plant in Wadeville. An estimated 29,000 tons of used bottles will EH GLYHUWHG IURP ODQGÂż OO Âą D saving of the equivalent of about 186,000 cubic metres and a reduction in CO2 emissions of approximately 53,000 tpa

fort researching the PET recycling industry and developing a PET recycling business that would be sustainable, said group CEO Bruce Strong. â&#x20AC;&#x153;Mpact Polymers is backed by the required skills, experience and infrastructure to take advantage of the prospects in the collection and recycling of PET bottles in South Africa. Âł0SDFW 3RO\PHUV DOVR UHĂ&#x20AC; HFWV WKH LPSRU tance of our governmentâ&#x20AC;&#x2122;s manufacturing incentive programmes, which we hope will be granted a greater proportion of the national budget in the future, considering the importance of manufacturing in South Africa,â&#x20AC;? said Strong.

The rPET facility has been granted a Section 12i tax allowance incentive. Income opportunities will be created through an estimated 1 000 jobs as there will be greater demand for collectors, small businesses and buy-back centres which will assist Mpact in reaching their collection targets.

JUST BRIEFLY

Helukabel: Demand for quality cable is growing Near-infrared (NIR) sorting â&#x20AC;&#x201C; This faster sorting stage looks at the wavelength for different material chemistries and consequently can be used to separate materials by resin type. It is used extensively in MRFs to separate HDPE and PET containers

INTERNATIONAL cable and accessories manufacturer and distributor Helukabel is growing beyond bounds in South Africa, necessitating a second move to considerably larger premises in just six years since entering the local market.

Escalating demand for its products has once again prompted the company to seek larger warehousing and operations facilities, this time in the more centrally-situated Lazer Park industrial area north of Johannesburg, where it is now operating from 6000m² premises.

Helukabel SA managing director Doug Gunnewegh ascribes the rapid growth of the local operation to a strong trend towards quality approved cables that meet both local and international standards. Another key to the companyâ&#x20AC;&#x2122;s success is its high availability of stock.

Mondi to buy <]ZSQ[P Ă&#x2020; M`QJTM XIKSIOQVO Ă&#x2026; ZU for â&#x201A;Ź90-m Pellets pass through a vibrating jig before bagging

According to Geoffrey Qhena, CEO of the ,'& ,QGXVWULDO 'HYHORSPHQW &RUSRUDWLRQ

which provided a R210-million loan as well as R30-million for its 21% equity stake in Mpact 3RO\PHUV ZDQWV WR Âż QG QHZ LGHDV WR UHDO world problems. â&#x20AC;&#x153;The enhancement of skills transfer as well as the development of entrepreneurship and promotion of growth within the SMME sector fuels further optimism,â&#x20AC;? added Qhena. www.mpact.co.za

Ribbon cutting â&#x20AC;&#x201C; *XHVWV RI KRQRXU DW WKH RIÂż FLDO RSHQLQJ RI WKH SODQW JDWKHU WR FXW WKH FHUHPRQLDO ULEERQ including Bruce Strong (Mpact Group CEO), councillor Mondli Gungubele, Therese Gearhart (president of Coca-Cola SA), Edna Molewa (Minister of Environmental Affairs), Mzwandile Masina (Deputy Minister of the DTI), Velaphi Ratshofola (managing director of ABI), Cheri Scholtz (CEO, PETCO), Geoffrey Qhena (CEO of the IDC) and Tony Philips (Mpact chairman)

MONDI of South Africa has DFTXLUHG 7XUNLVK Ă&#x20AC; H[LEOH SDFNDJLQJ Âż UP .DOHQREHO ,VWDQEXO 7XUNH\

for â&#x201A;Ź90-million as it expands its international packaging business.

The paper and packaging group will purchase 90% of the outstanding share capital from private equity group Argus Capital and Olcay Hephiz, one of the companyâ&#x20AC;&#x2122;s founders.

The transaction remains subject to competition clearance and other customary closing conditions and is H[SHFWHG WR EH Âż QDOL]HG GXULQJ WKH VHFRQG KDOI RI WKH \HDU .DOHQREHO operates two manufacturing sites northwest of its headquarters in Istanbul exporting roughly half of its production, mainly to Western Europe, the Middle East and North Africa. Âł7KH DFTXLVLWLRQ RI .DOHQREHO supports the growth of our consumer packaging business, broadening our product portfolio and geographic reach to better serve our customers in high-growth markets,â&#x20AC;? Mondi CEO David Hathorn said in a statement.

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NEWS

Continental Compounders unveil state-ofthe-art polymer testing facility

14 JUNE / JULY 2016

Aimed at product testing and new product development CONTINENTAL Compounders (Pty) Ltd recently unveiled its upgraded, state-of-the art polymer testing facility located at the FRPSDQ\¶V KHDG RI¿ FH LQ 3LQHWRZQ .ZD=XOX 1DWDO 2QH RI RQO\ D handful of similar facilities in South $IULFD WKH QHZ WHVWLQJ ODERUDWRU\ LV VSHFL¿ FDOO\ DLPHG DW SURGXFW WHVWLQJ DQG QHZ SURGXFW GHYHORSPHQW IRU Continentalâ&#x20AC;&#x2122;s local and international FXVWRPHUV ³7KH ZRUOG RI HQJLQHHULQJ SRO\PHUV LV ERWK H[FLWLQJ GLYHUVH DQG G\QDPLF 1HZ FRPSRXQGV DUH FRQWLQXRXVO\ EHLQJ developed in this ever-evolving industry in order to meet the requirements of

WKH HQJLQHHULQJ IUDWHUQLW\ *OREDOO\ compounding companies are at the forefront of these developments, pushing WKH HQYHORSH RI PDFKLQH DQG PDWHULDOV In order for Continental Compounders to remain on the cutting edge of these DGYDQFHPHQWV ZH LQYHVWHG D VLJQL¿ FDQW DPRXQW RI ¿ QDQFHV WHFKQLFDO LQQRYDWLRQ and intellectual capital into creating a ODERUDWRU\ WKDW LV FDSDEOH RI RIIHULQJ RXU customers a highly specialised, technical VHUYLFH ZKLFK JRHV KDQG LQ KDQG ZLWK WKH UHFHQW LQYHVWPHQW ZH PDGH LQWR RXU QHZ HQJLQHHUHG SRO\PHUV FRPSRXQGV IDFLOLW\ ´ H[SODLQHG *HRUJH 'LPRQG FKLHI H[HFXWLYH RI¿ FHU RI &RQWLQHQWDO Continental manufactures engineering polymers that are primarily used for

LQMHFWLRQ DQG H[WUXVLRQ LQ ZKLWH JRRGV automotive, metal replacements and RWKHU KLJK SHUIRUPDQFH SURGXFWV 7KH\ KDYH DOVR UHFHQWO\ H[SDQGHG WKHLU range and product offeriQJ E\ DGGLQJ polypropylene (PP) and nylon (PA66 and 3$ WR WKHLU ORFDO FRPSRXQG UDQJH ³2XU QHZ H[SDQGHG (QJLQHHULQJ 3RO\PHUV IDFLOLW\ DOORZV XV WR GHYHORS DQG

&RQWLQHQWDO &RPSRXQGHUV KDYH LQYHVWHG D VLJQL¿ FDQW DPRXQW RI ¿ QDQFH WHFKQLFDO LQQRYDWLRQ DQG LQWHOOHFWXDO FDSLWDO LQWR FUHDWLQJ D ODERUDWRU\ WKDW LV FDSDEOH RI RIIHULQJ LWV FXVWRPHUV D KLJKO\ VSHFLDOLVHG WHFKQLFDO VHUYLFH

produce compounds that were designed to meet the unique requirements of the African continent, as well as ensure that our products meet and maintain stringent quality standards,â&#x20AC;? Dimond said.

They are now able to perform various QHZ WHVWV LQFOXGLQJ +HDW 'HĂ&#x20AC; HFWLRQ Tests (HDT), Melt Flow Index (MFI), Ash Content, Impact Strength, Tensiles, Elongation, Limited Oxygen Index (LOI), Density, Shrinkage, Flexural, Congo

Red, Colour Spec, Melt Rehologies and Volume Resistivity (VR). â&#x20AC;&#x153;Having this facility in place gives our customers the peace of mind that the compounds we supply them, will meet their product and process requirements, allowing smooth and consistent operations,â&#x20AC;? Dimond added.

ZZZ FRPSRXQGHUV FR ]D

JUNE / JULY 2016 15

Continental Compounders offer various tests at their new laboratory: +HDW 'HĂ&#x20AC; HFWLRQ 7HVWV +'7 0HOW )ORZ ,QGH[ 0),

$VK &RQWHQW ,PSDFW 6WUHQJWK 7HQVLOHV (ORQJDWLRQ /LPLWHG 2[\JHQ ,QGH[ /2, 'HQVLW\ 6KULQNDJH )OH[XUDO &RQJR 5HG &RORXU 6SHF 0HOW 5HKRORJLHV DQG 9ROXPH 5HVLVWLYLW\ 95

NEWS

*UHHQDFUHV LQWURGXFHV LWV

Ă&#x20AC; UVW IRDP FXWWLQJ V\VWHP Malmesbury company takes its cutting edge technology to next level

BY SHAWN VAN BAALEN GREENACRES -BĂ&#x201E;UMER of the Western Cape has designed, built and commisVLRQHG LWV Âż UVW IRDP FXWWLQJ PDFKLQH 7KH Malmesbury company used key components from its global partner Bäumer to build the VBK-1 (Vertical Band Knife â&#x20AC;&#x201C; series 1) unit, which is an entry-level yet world FODVV IRDP FXWWLQJ V\VWHP Âł7KH PDFKLQH LV UREXVW FRVW HIIHFWLYH and aimed at emerging markets,â&#x20AC;? said Des Green of Greenacres, a man who â&#x20AC;&#x201C; although now operating happily from the Swartland, has extensive experience from WKH JOREDO IRDP DQG 38 PDUNHWV *UHHQ even spent an extended period in Singapore heading up a multinational polyurethanes subsidiary responsible for the SE $VLD PDUNHW *UHHQDFUHV %lXPHU UHFHQWO\ VROG LWV Âż UVW foam cutting system to a happy customer in &DSH 7RZQ 7KH FRPSDQ\ KDV EHHQ LQ SDUWQHUVKLS with Bäumer, of Germany, since 2008: it quite literally got involved in cutting edge technology at that point when it began to manufacture blades and cutting equipment IRU 38 IRDP LQ D MRLQW YHQWXUH ZLWK %lXPHU 7KH EODGHV DUH XVHG LQ WKH SURGXFWLRQ environment for the continuous cutting of PUâ&#x20AC;&#x2122;s as well as plastics, rubber and WHFKQLFDO IRDPV *UHHQDFUHV %lXPHU has steadily expanded its activities since, including the manufacture of complete cutting systems, such as band and WRRWKHG NQLYHV DQG EDQG VDZV Main applications for the new cutting system are foams for bedding, mattress,

automotive, technical and furniture products, where high levels of accuracy and FRQVLVWHQF\ DUH QHFHVVDU\ ,W LV DOVR HV sential for the blades to remain extremely sharp to achieve minimal friction, which is necessary for accurate cutting of the foam VWUXFWXUH $OO WKHVH IHDWXUHV DUH RIIHUHG E\ WKH QHZ FXWWLQJ V\VWHP Whatâ&#x20AC;&#x2122;s really interesting is that, with its streamlined South African operation, Greenacres- Bäumerâ&#x20AC;&#x2122;s operating costs DUH ORZ ,W LV IRU WKLV UHDVRQ WKDW LW UHPDLQV VR FRPSHWLWLYH LQ WKH ORFDO PDUNHW *UHHQ DFUHV KDV D VWDII FRPSOHPHQW RI MXVW QLQH ,WV ZHOGLQJ HTXLSPHQW DQG WHFKQLTXH LV state of the art, ensuring superior quality that is so sought after in WKLV PDUNHW ,W RIIHUV ORFDO VXSSRUW in terms of spares, consumables, after sales service and WHFKQLFDO VXSSRUW

Blade and cutting products and equipment are produced mainly for the export market, and containerised for shipping into $IULFD 0RVW UHFHQWO\ *UHHQDFUHV %lXPHU appointed Kenzar Limited in Nairobi for UHSUHVHQWDWLRQ LQ (DVW $IULFD 7KLV LV DQ important market for the companies which ZLOO DVVLVW LQ ZLGHQLQJ WKHLU IRRWSULQW $V D result, Des is spending a lot of time travelOLQJ LQ WKDW UHJLRQ Processes at the Malmesbury plant are managed in accordance with the Albrecht Bäumer Quality Management System 'LUHFWLYHV 7KH QHZ PDFKLQH WKRXJK EDVLF LQ design, is set to transform Greenacresâ&#x20AC;&#x2122; EXVLQHVV $W WKLV VWDJH WKH FRPSDQ\ LV aiming to produce two or three machines a PRQWK GHSHQGLQJ RQ GHPDQG

The new VBK-1 (Vertical Band Knife series 1) cutting system from Greenacres of Malmesbury, Western Cape, used for the cutting of PU foam, is designed for emerging market applications

16 JUNE / JULY 2016

www.greencorp.co.za

www.baeumer.com

Seecor Blow moulding systems for every application SEECOR BLOW MOULDERS, manufacturer of a wide range of blow moulding machines over the past three decades, has mainly supplied systems based on European technology but designed to suit the African environment. We have now widened our scope in order to supply built-for-purpose

and ultra-efficient production systems.

We now represent a wider range of machine manufacturers who in every case offer optimum cost-performance value. Our goal remains, as before, to supply technology that it suited for profitable production in Africa, and even further afield.

SEECOR supplies Extrusion, IBM and PET blow y moulding machinery

Custom rebuilds of blow moulding y machines, with enhanced controls and automation

Supply of technical service, spares y and automation system to the entire blow moulding industry in Africa

WE REPRESENT SIKA (Taiwan), a world leading manufacturer of extrusion blow moulding shuttle machines for containers up to 2000-litres, including handle/non-handle and multi-layer systems. Over 60 SIKA systems are in daily operation in South Africa, including: continuous extrusion machinery for containers from 50ml to 30-litres; accumulator head systems for technical parts and large containers up to 2000 litres; fully electric machines; machines for multi-layer and multiple cavitation production. All these systems are available with fully automated handling technology.

Rocheleau Tool & Die (USA), recip blow moulding machines for lightweight containers suited for high-quantity production. RTD offers reciprocating-screw and continuous-extrusion machines suited for high-speed production of small containers.

ERMP (France), wheel extrusion blow moulding machines for lightweight non-handle containers with multi-layer capability for the UHT and food markets. The ERMP team includes experts previously involved at Sidel in France, a world leader in ISBM machinery. The ERMP machines have capability for up to 28 cavity production of volumes up to 15,000 containers/hr.

Side (Spain), linear PET stretch blow moulding machines for the water, CSD and juice sectors with outputs up to 9000 bottles/hr and containers up to 50-litres. Side has exceptional expertise in electronics and its linear PET/PP reheat stretch blow moulding machines are popular for full-electric, high output production of both standard and complex shape containers. Side (in operation for over 40yrs) is a leader in T-handle (deep grip) container production.

Baixing (China), lower cost ISBM machines for low output production of PET containers and specifically for start-up companies (for basic round or square containers up to 20 litres) Keli (China), injection blow moulding (IBM) machines for the low-to-medium output of small containers up to 700ml (medical bottles and jars, roll-on deodorant and cream jars)

ADDITIONAL SERVICES View production videos of all these systems on our website y Turnkey project management y B low mould design and production y

Jeffrey Weakley

Clive Corder

Darrin Botha

John Craw

Joe Spohr

(including moulds for closures)

Supply of ancillary equipment (leak testers, neck cutters, y conveyors, granulators, compressors, chillers)

Weusthoff SA pty Ltd, trading as Seecor | www.seecor.com

+27 21 532 2144/5 | +27 83 326 2187 | info@seecor.co.za 23 Thor Circle, Viking Place, Epping, Cape Town

NEWS

Space! MGMWâ&#x20AC;&#x2122;s new premises certainly have a lot of that which they will need to accommodate increased demand from customers

MGMWâ&#x20AC;&#x2122;s new premises will accommodate increased demand MGMW Trading has moved to larger premises in Johannesburg to handle increased demand from customers.

The larger premises at Unit 17, Log Road, Roodekop, Germiston, now enable MGMW to refurbish barrels and screws up to 8 metres long.

MGMW offers three different welding processes. Besides refurbishing barrels and screws, the company can join broken

screws, tiebars and granulator shafts, amongst others. Other popular services LQFOXGH WKH UHIXUELVKPHQW RI EORZQ Âż OP GLHV as well as T-dies. *XQWKHU 0DUDOLN :ROÂż 0DUDOLN DQG 0LNH Grandcourt also offer customers design advice on how to upgrade old extruders to improve output and material quality, as well as queries regarding any other plastic machinery.

Besides its standard metallic work, MGMW Trading also represents Hitech China, a manufacturer of recycling systems.

Lyzon Lee, MD of Hitech China, has worked on several projects with Gunther and has so far installed systems in Malawi, Zambia, Zimbabwe, Namibia, Botswana and Mozambique, and South Africa. www.mgmwtrading.com

MGMWâ&#x20AC;&#x2122;s new, larger premises now enable the company to refurbish barrels and screws up to 8 metres long

Wolfgang and Gunther Maralik of MGMW Trading hosted Lyzon Lee, managing director of Hitech China, on their stand at Propak Africa this year

JoJo Tanks aid for drought stricken communities 130 000 litres water for drought affected Thaba Nchu & surrounds GLOBAL humanitarian aid organisation, World Vision South Africa has in partnership with Bloemwater and the Mangaung Metropolitan Municipality successfully installed 26 Jojo Water Tanks in Thaba Nchu and surrounds as part of its 150-tank/750 000 litres of water project funded by the FirstRand Foundation and other stakeholders.

The project was headed by World Visionâ&#x20AC;&#x2122;s Thaba Nchu Area Development Programme (ADP).

The 26 tanks will provide 130 000 litres to community members residing in Thaba Nchu and surrounding villages and bring critical relief in an area which is still plagued by drought and resultant food shortage. The tanks will EH Âż OOHG UHJXODUO\ E\ %ORHPZDWHU DQG maintained by the various communities and the municipality.

In celebration of the project completion, two water tanks were handed over to the community of Middeldeel village situated outside Thaba Nchu. The ceremony was attended by members of the Mangaung Municipality, Bloemwater, Barolong traditional leaders, World Vision and the community.

The 5000-litre Jojo water tanks were constructed on ground level concrete slabs and met municipal engineering criteria during quality control and sign off of the installations.

The remaining 124 water tanks are currently being rolled out in KwaZulu/ Natal (Ixopo and Umzimkhulu), and Limpopo (Thusalushaka, Kodomela and Giyani) provinces. www.clariant.com

Two JoJo Tanks water tanks were handed over to the community of Middeldeel village situated outside Thaba Nchu 18 JUNE / JULY 2016

MGMW Trading advert Edited-BLEED.indd 94

2016/04/07 1:17 PM

NEWS

Ensuring that Ferroâ&#x20AC;&#x2122;s produces black masterbatch 24/7 are Warren Morton, Douglas Lushaba, Sipho Simelane and Kenneth Mngomezulu

Ferroâ&#x20AC;&#x2122;s multi-million rand investment in black, white masterbatch lines

PHOTO: LOWRIE SHARP

20 JUNE / JULY 2016

Dramatic increase in local and export demand for quality masterbatches FERRO Plastics, a division of Ferro South Africa, has made a multi-million rand investment in two new lines for its black and white masterbatch plants.

Tinus van der Merwe, Ferroâ&#x20AC;&#x2122;s director in charge of plastic masterbatches, said the investment resulted as a response to the dramatic increase in both local and export demand for quality masterbatches over the past few years.

Situated on the East Rand, Ferro Plastics has been producing both black and white masterbatches for over four decades; it is the largest manufacturer of black masterbatch in sub-Saharan Africa.

7KH %ODFN SODQW ZDV WKH Âż UVW WR DFTXLUH an additional extruder, a Coperion ZSK twin-screw unit, considerably expanding output above the existing capacity. â&#x20AC;&#x153;Ferroâ&#x20AC;&#x2122;s priority is to meet customersâ&#x20AC;&#x2122; preferences with regard to pellet conformation,â&#x20AC;? said Tinus. The 92mm, twin-screw

ZSK machine was commissioned at the end of 2015 and can produce more than one ton per hour of pellets in die-face cut formation, similar to the existing German-engineered Berstorff extruder in the same facility.

The Black plant produces 24/7 and manufactures a variety of black masterbatch grades, from â&#x20AC;&#x2DC;entry-levelâ&#x20AC;&#x2122; material to high quality, in a variety of polymers. â&#x20AC;&#x153;With its twin screw technology and highly accurate gravimetric material handling systems from Brabender Europe, the new ZSK and Berstorff extruders are able to maintain and uphold the quality of product which is manufactured and distributed within the domestic and international plastics markets,â&#x20AC;? said Tinus.

Ferro Plasticsâ&#x20AC;&#x2122; White plant also received a new SHJ-92 co-rotating twin-screw extruder which was commissioned earlier this year.

This line can also produce at a rate of one metric ton per hour, generating water-ring

The recently acquired Coperion ZSK twin-screw extruder can produce more than a ton per hour of Black masterbatch pellets in die-face cut formation

die face cut pellets.

Various formulations of Filler or White masterbatch, in a variety of polymers, can be produced.

The SHJ-92 extruder now runs alongside a Farrel CP45 system, with the increased capacity able to meet demand for both Filler and White masterbatch. â&#x20AC;&#x153;Along with these multi-million rand investments, a substantial amount of management time and preparation was DOVR GHYRWHG WR Âż QH WXQLQJ ERWK SURMHFWV ´ said Tinus. â&#x20AC;&#x153;With the upgrade of both production plants, Ferro Plastics can remain a cost HIÂż FLHQW SURGXFHU DQG FDQ RIIHU DVVXUDQFH that market demands will be met, all the while ensuring quality. It is with pride that we continue to be the market leader in all Black, White and Filler masterbatch grades and continue to produce high quality masterbatches at competitive prices.â&#x20AC;?

The White masterbatch plant, where a new Giant SHJ-92 co-rotating twin-screw extruder was installed earlier this year, is skillfully managed

by Raymond Dyzel, Daniel Dhladla and Warren Morton

www.ferrosa.co.za

“CHECKMATE” – WE REMAIN KING IN THE INDUSTRY OF BLACK, WHITE AND FILLER MASTERBATCH. HEAD OFFICE - GAUTENG Telephone: +27 (0) 11 746 4000

EASTERN CAPE - Port Elizabeth Telephone: +27 (0) 41 451 2571

KWA-ZULU NATAL - New Germany Telephone: +27 (0) 31 713 0636

WESTERN CAPE - CAPE TOWN Telephone: +27 (0) 21 935 1788

www.ferrosa.co.za

NEWS

Jannock managing director Jimmy Warne with the companyâ&#x20AC;&#x2122;s production manager Willem van Zyl, TMC product manager Marc Gerasimo and -DQQRFNÂśV Âż QDQFH GLUHFWRU -RKQQ\ 3UH]LDWL WHFKQLFDO GLUHFWRU -DPHV :DUQH DQG JHQHUDO PDQDJHU &DU\QH :DUQH ZLWK VRPH RI WKH 70& PDFKLQHV LQ WKHLU WLG\ DQG XOWUD HIÂż FLHQW PRXOGLQJ SODQW

Jannock Tool & Die, Jannock Plastics celebrate 30yrs +LJK HIÂż FLHQF\ WRROV SOXV HTXDOO\ HIÂż FLHQF\ SURGXFH ZLQQLQJ FRPER

Jannock Tool & Die was established in 1986 as a general toolmaking facility to industry, manufacturing injection moulds as well as press tooling and tooling for the rubber industry. â&#x20AC;&#x153;Our facility has the equipment to handle all aspects of tool making consisting of CNC milling, including full 4-axis machining, wire cutting, Renishaw scanning, lathes and cylindrical grinding as well as all the standard conventional equipment,â&#x20AC;? said Jannock technical director James Warne.

Handling of the CAD, industrial GHVLJQ EXLOGLQJ RI KLJK HIÂż FLHQF\ WRROV and tool maintenance on an in-house basis by Jannock has obviously been an advantage and the positive momentum gained is self-evident.

It later expanded into the manufacturing sector, resulting in the formation of Jannock Plastics in 1999.

Key to Jannockâ&#x20AC;&#x2122;s success is their approach to a turnkey solution to all their customers, from technical support product & tooling design, mould build and manufacturing and understanding tooling requirements to ensure the most cost effective solution ensuring project success.

Jannock processes a variety of engineering Polymers (such as PBT, polysulphones, PEEK, Nylons, polycarbonate to name a few) and precision machinery is thus a prerequisite.

A major aspect of the continuation of this successful cooperation has been Jannock Plasticsâ&#x20AC;&#x2122; choice of machinery: it has purchased a large number of TMC injection machines over the past

The businessesâ&#x20AC;&#x2122; premises in Roodepoort, West Rand

one-and-a-half decades. Supplied by local agent Maritime Marketing, these reliable, robust machines built in Taiwan have proved to be mainstay in the ongoing production programme.

ISO 9001-accredited Jannock has just recently taken delivery of another three new TMC servo machines, including a 150-ton and two 200-ton machines.

James is happy with the â&#x20AC;&#x153;impressiveO\ HIÂż FLHQW´ 70& LQMHFWLRQ PDFKLQHV â&#x20AC;&#x153;The servo energy-saving machines allowed for reduced energy cost, plus the excellent back-up support from Maritime Marketing and TMC over the years has allowed us to keep maintenance costs at exceptionally low rates. â&#x20AC;&#x153;The reliability of the TMC machines also means we have had minimal downtime, which is obviously very good from a cost ratio point of view,â&#x20AC;? he added.

www.jannock.co.za

Jannocks Tool Room manufactures all tooling to complement its production facility â&#x20AC;&#x201C; which has proved to be an important advantage

PHOTOS: LOWRIE SHARP

22 JUNE / JULY 2016

JANNOCK, which is celebrating 30 years in operation, has established its industry leading position through building its own extremely reliable tools.

That skill in turn gave the West Rand company the springboard to create its own manufacturing business, in the form of its injection moulding subsidiary Jannock Plastics, which in turn has allowed it to partner effectively with clients.

$ Ă&#x20AC; UVW IRU 6DIULSRO

New PP resin aimed at thin walled injection moulding market SAFRIPOL has introduced an improved Polypropylene impact copolymer for highspeed injection moulding. The new grade, produced with Spheripol technology, DIIRUGV SRWHQWLDO VXVWDLQDELOLW\ EHQHÂż WV WR convertors, including cost saving and a decreased environmental footprint.

This new PP resin is aimed at the thinwalled injection moulding (TWIM) market, which includes end products such as yoghurt and margarine containers, promotional drink cups and many more. â&#x20AC;&#x153;Safripolâ&#x20AC;&#x2122;s continued commitment to product innovation provides the local market with a high quality resin that offers the

reliability and quality consistency required to compete on the international stage,â&#x20AC;? said Mark Berry, sales and marketing manager at Safripol.

The resin, commercialised as SafronÂŽ C790-90RNA (MFR2.16kg@230°C of 90 g/10min), shows a further enhancement LQ Ă&#x20AC; RZ SURSHUWLHV RYHU WKH SUHYLRXVO\ XVHG SafronÂŽ & 51$ ZKLOH VLJQLÂż FDQWO\ and very importantly, retaining impact and stiffness properties. This enables packaging manufacturers to achieve cost savings as a result of faster cycle times, lower processing temperatures, future lightweighting and pressures and energy

&ODULDQW¡V QHZ UDQJH RI $URPD &DQ FDQLVWHUV Suits high-speed canister insertion CLARIANTâ&#x20AC;&#x2122;S Healthcare Packaging unit is introducing a new and improved family of Aroma-CanÂŽ canisters to enhance nutritional products by adding a pleasant scent to product packaging.

Modelled after Clariantâ&#x20AC;&#x2122;s desiccant canisters for pharmaceutical and nutraceutical packaging, Aroma-Can canisters employ aroma technology that can give consumers a positive

sensory experience when they open product packaging. The technology HPEHGV IRRG JUDGH Ă&#x20AC; DYRXUV VXFK DV vanilla, orange and lemon, directly into a plastic canister, which can be inserted easily into a container.

Although the new Aroma-Can bears the same overall dimensions of standard desiccant canisters, its new and innovative one-piece design reduces further process and assembly and contains more surface area, which improve the canisterâ&#x20AC;&#x2122;s DURPD SURÂż OH %HFDXVH RI WKHLU dimensional uniformity with desiccant canisters, Aroma-Can canisters can be automatically inserted into packaging at rates up to 300/minute using standard desiccant canister insertion equipment. www.clariant.com 24 JUNE / JULY 2016

Safripolâ&#x20AC;&#x2122;s new PP resin is aimed at the thin-walled injection moulding market, which includes end products such as yoghurt and margarine containers, promotional drink cups and many more

cost savings.

SafronÂŽ C790-90RNA is South Africaâ&#x20AC;&#x2122;s Âż UVW ORFDOO\ SURGXFHG FRPPHUFLDOO\ DYDLO able 90 MFR resin.

Safripol has been a committed polyROHÂż Q VXSSOLHU WR WKH 6RXWKHUQ $IULFDQ plastics market for more than 40 years, providing a wide range of high density polyethylene and polypropylene grades that conform to high global standards.

Technical information about this grade can be found on the Safripol website. www.safripol.com

*UHDWHU IUHHGRP IRU FRIIHH ORYHUV GLOBAL Closure Systems (GCS) has developed a bespoke closure solution to help the worldâ&#x20AC;&#x2122;s largest food company NestlĂŠâ&#x20AC;&#x2122; Coffee-mateÂŽ 2GOâ&#x201E;˘ satisfy the lifestyle expectations of â&#x20AC;&#x2DC;on-the-goâ&#x20AC;&#x2122; coffee drinkers in North America.

NestlĂŠâ&#x20AC;&#x2122;s new Coffee-mate 2GO creamer dispenser incorporates a silicone valve sub-assembly designed and manufactured

by Zeller Plastik, GCSâ&#x20AC;&#x2122;s production plant in Libertyville, Illinois. Coffee-mate 2GO is a conveniently-sized 90ml portable creamer that doesnâ&#x20AC;&#x2122;t require refrigeration.

7KH VLOLFRQH YDOYH KDV EHHQ VSHFLÂż FDOO\ GH signed to match the product formulation. The FORVXUHÂśV UHG JORVV\ Âż QLVK RIIHUV VWDQG RXW on-shelf appeal, while the need for tamper evidence is provided by a full body sleeve. www.gcs.com

PHOTO: LOWRIE SHARP

NEWS

MGMW Trading advert Edited-BLEED.indd 94

2016/05/30 11:11

NEWS

Diego Donoso, president of Dow Packaging & Specialty Plastics; Javier Constante, vice president for EMEA; Carsten Larsen (MD of Dow Southern Africa); and Dana Mosora, director for sustainability and advocacy, gave presentations at the Dow Africa media event in Johannesburg

'RZ UHDIĂ&#x20AC; UPV FRPPLWPHQW WR VXVWDLQDELOLW\ LQ $IULFD

Âľ&LUFXODU HFRQRP\Âś IRFXVHV RQ UHGXFLQJ IRRG ZDVWH LPSURYLQJ UHVRXUFH HIÂż FLHQF\ DQG LQFUHDVLQJ UHF\FODELOLW\

26 JUNE / JULY 2016

EXECUTIVES with Dowâ&#x20AC;&#x2122;s Packaging & Specialty Plastics business met with African media recently to discuss Dowâ&#x20AC;&#x2122;s commitment to sustainability and WKH LPSRUWDQW UROH RI Ă&#x20AC; H[LEOH SODVWLF packaging in spurring economic development and supporting a more sustainable world.

Africa is the worldâ&#x20AC;&#x2122;s fastest growing region after Asia, together with the Middle East. In total, 45% of GDP growth on the continent comes from consumer-facing sectors, pointing to rising consumer power and income. Africa is also undergoing rapid urbanisation, with 40% of the population now living in cities. As a consequence, food safety, shelf life and supply chain transportation assume greater importance as food will have to travel much longer distances to supply growing urban populations. â&#x20AC;&#x153;Demand for more sophisticated shopping and retail in Africa is increasing.

Consumers have rising disposable income, and they want food which is fresh, healthy and conveniently packed,â&#x20AC;? said Diego Donoso, business president of Dow Packaging & Specialty Plastics.

To better meet rising demand for plastic products from Africa and other regions, Dow entered into a joint venture with Saudi Aramco in 2011 to construct the worldâ&#x20AC;&#x2122;s ODUJHVW LQWHJUDWHG FKHPLFDO FRPSOH[ HYHU built in a single phase â&#x20AC;&#x201C; Sadara. The project recently achieved a key milestone ODVW 'HFHPEHU ZLWK Âż UVW SRO\HWK\OHQH production, meeting previously announced targets to begin production by year-end 2015. This landmark investment has been a key pillar of Dowâ&#x20AC;&#x2122;s targeted, strategic growth actions over the last several years and all 26 of Sadaraâ&#x20AC;&#x2122;s manufacturing assets remain on schedule for a sequenced start-up process, beginning ZLWK WKH SRO\ROHÂż QV HQYHORSH WR PD[LPL]H timing in the ethylene cycle, followed by HWK\OHQH R[LGH SURS\OHQH R[LGH DQG WKHLU derivatives.

Committed to sustainability In 2015, Dow announced a strategic set RI FRPPLWPHQWV GHVLJQHG WR UHGHÂż QH WKH role of business in society, to be achieved by 2025. This includes a commitment to advance the worldâ&#x20AC;&#x2122;s transition to a circular economy, where waste is designed into new products and services.

Dana Mosora, sustainability director for Dow Packaging & Specialty Plastics for Europe, Middle East and Africa, said the â&#x20AC;&#x2DC;circular economyâ&#x20AC;&#x2122; would focus on reducing IRRG ZDVWH LPSURYLQJ UHVRXUFH HIÂż FLHQF\ and increasing recyclability, as well as work with initiatives globally to address marine debris. )OH[LEOH SODVWLF SDFNDJLQJ SOD\V D NH\ UROH LQ UHGXFLQJ IRRG VSRLODJH DQG ZDVWH )OH[ LEOH SODVWLF SDFNDJLQJ FDQ H[WHQG WKH VKHOI life of food from three days to over 14 days in-store, with in-store waste reduced from an average 3% of stock to less than 1%.

www.dow.com

SDF;SHUW ² Ă H[LEOH DOWHUQDWLYH WR ULJLG FRQWDLQHUV Offers huge variety of advantages over existing solutions pacXpert containers can be used for the packaging of a huge range of products, such as edible oils, sauces, water/juices, dry foods such as rice and grains, ground coffee, SDLQW DQG FRDWLQJV PRWRU RLO DQG IXHO Âż QH aggregates â&#x20AC;Ś you name it

A NEW system presented by Dow at the media event in Johannesburg in April, PacXpertâ&#x201E;˘ Packaging Technology is an innovative technology that enables the transition from larger traditional rigid FRQWDLQHUV WR Ă&#x20AC; H[LEOH SDFNDJLQJ RSWLRQV 7KH GLVWLQFWLYH Ă&#x20AC; H[LEOH VWDQG XS SRXFK is durable, lightweight and cost effective. :KLOH Ă&#x20AC; H[LEOH WKH FXEH VKDSHG SDFNDJH is shelf stable and can stand equally well upright or on its side. $YDLODEOH LQ D UDQJH RI VL]HV IURP RQH to 20 litres, the innovative packages made possible through PacXpertâ&#x201E;˘ Packaging Technology has the potential for use in

numerous household, institutional, and industrial applications. $IWHU RSHQLQJ WKH Ă&#x20AC; H[LEOH SDFNDJLQJ made using PacXpertâ&#x201E;˘ Packaging Technology can be compacted as its contents are dispensed.

PacXpertâ&#x201E;˘ Packaging Technology is licensed globally by Dow through an H[FOXVLYH DJUHHPHQW ZLWK 6PDUW %RWWOH ,QF 'RZ LV VXE OLFHQVLQJ WKLV H[FLWLQJ technology to select converters who may then leverage the technology to promote GLIIHUHQWLDWHG Ă&#x20AC; H[LEOH SDFNDJLQJ VROXWLRQV to the marketplace.

(PacXpert is a trademark of The Dow Chemical Company)

Injection moulding machines

Injection stretch blow moulding machines

Gravimetric blenders & central feeding systems

Water flow regulators

Robotics and IML

Recycling and grinding

SERVING THE PLASTIC AND PACKAGING INDUSTRY FOR MORE THAN 50 YEARS SINCE 1962

e-mail: nickie.s@hestico.co.za

NEWS

Coordinated assembly â&#x20AC;&#x201C; :LWK DV PDQ\ DV IRXU PDFKLQHV XQGHU FRQVWUXFWLRQ DW RQH WLPH 0DYHULFN (QJLQHHULQJ KDV EHHQ PDNLQJ PD[LPXP XVH of its factory at Airport Industria in Cape Town; the design and planning department at left is situated conveniently close to the action

SAâ&#x20AC;&#x2122;s Maverick Engineering is a leader in pouch bag machines Cape companyâ&#x20AC;&#x2122;s modular, automated system prove a hit among bag-in-a-box manufacturers

28 JUNE / JULY 2016

MAVERICK Engineering has surprised just about everyone, including itself, by its unexpected success in the global market: the Cape Town machine maker has become one of the world leaders in pouch making systems in a little over 15 years.

One of its recent successes was the supply of its biggest machine yet, a 33m long â&#x20AC;&#x2DC;Juggernaut Comboâ&#x20AC;&#x2122; line for the production of 1000-litre pouches, to the United States.

Maverick Engineering was started in 1999 by Derek Fay, formerly of Nampak.

The company began manufacturing pouch making machines immediately and supSOLHG WKH Âż UVW VPDOOHU PRGHOV IRU WKH SUR duction of â&#x20AC;&#x2DC;bag in a boxâ&#x20AC;&#x2122; or liquid packaging pouches shortly thereafter. Fayâ&#x20AC;&#x2122;s formula has worked exceptionally since: Maverick Engineering handles design and assembly, with all components being bought in.

The bulk of machine components are now sourced from China, after it became apparent that Cape engineering component makers were uncompetitive in terms of both price and availability.

Having seen the opportunity in the market for pouches, which has shown dramatic and above-average growth since the millennium, Fay and the Maverick Engineering

team have honed their process to the point where machine assembly is expedited to a high degree. The machines systems are PRGXODU DQG Ă&#x20AC; H[LEOH ZKLFK KDV KHOSHG GULYH their popularity. Basically, laminated and/ RU FR H[ Âż OPV HQWHU RQH HQG RI WKH PDFKLQH and just about anything that can happen to D Âż OP LV FRPSOHWHG DXWRPDWLFDOO\ DIWHU WKDW whether it be the insertion of a tap, a gusset, ]LSORFN RU RWKHU GHVLUHG Âż [WXUHV LV SRVVLEOH after that.

Maverickâ&#x20AC;&#x2122;s journey from a virtual standing start reached an early milestone in 2002 ZKHQ LW VXSSOLHG LWV Âż UVW OLWUH PDFKLQH to Cape cargo securing specialist Stopak.

Impressively, the machine continues to operate 24/7.

Maverick was subsequently bought by GN Packaging of Canada, which at that point specialised in 1000-litre bag lines. This resulted in Maverick focusing on machines for smaller pouches, from 2-200 litres, and it zoned in on the development of high-speed solutions. Cooperation with its Canadian partner opened some international markets for Maverick, particularly in the United States, where few South African companies have managed to compete. Then, after GN closed its operation, Maverick returned to the 1000-litre market, with lessons learned

Commercial manager Andrew Slater on the assembly line at the Maverick Engineering plant in Cape Town with one of the larger pouch-making machines under construction

with the smaller machines proving useful.

Also, the company was by that stage familiar with international sales: in fact, Maverickâ&#x20AC;&#x2122;s machines â&#x20AC;&#x201C; with catchy names such as Beast, Dream, Double-Up and Super, let alone the aforementioned Juggernaut â&#x20AC;&#x201C; have become relatively sought-after by major bag-in-box manufacturers around the world.

Maverick has spread its wings local too, ZLWK Âż OP PDQXIDFWXUHU 0DYHULFN )OH[LEOHV and packaging contractor Maverick Packaging now also part of the group.

Over at Maverick Engineering in Airport Industria, MD Hilton Traviss and commercial manager Andrew Slater are overseeing the construction of several machines simultaneously. The team includes expert Âż OP EORZHUV ODPLQDWLRQ VSHFLDOLVWV EDJ makers and engineers who together form a highly skilled and specialized team.

The technology has now reached a mature stage, and there are possibly opportunities for further development, but the emphasis remains on using quality components throughout: according to sales man Slater, â&#x20AC;&#x153;It costs a bit, but if you stuff it up the cost is going to be far higherâ&#x20AC;?. www.maverickengineering.co.za

9DULRXV Âż [WXUHV FDQ EH EXLOW LQWR WKH SRXFKHV DV WKH ZHE SURFHHGV DORQJ WKH PDFKLQH WKH MLJV KHUH SRVLWLRQHG RQ WKH Ă&#x20AC; DQN RI WKH PDFKLQH DUH WR KROG DQG RULHQW WDSV IRU Âż WWLQJ

Industry concerned about Govtâ&#x20AC;&#x2122;s proposed packaging charge or tax Govt must be integral part of solution, work with the successes already achieved within the industry WITH pending changes to the legislation and tax on packaging, South Africaâ&#x20AC;&#x2122;s packaging industry is concerned that increased government regulation may have a detrimental effect on all concerned.

30 JUNE / JULY 2016

The pricing strategy document gazetted last year, in what is being referred to as the Paper & Packaging Industry Waste Management Plan, suggests that: an Extended Producer Responsibility (EPR) scheme for paper and packaging may become government-managed; existing EPR schemes will have two years to align their funding models to the pricing strategy and other waste management legislation; that a South African Revenue Services collected â&#x20AC;&#x2DC;waste management chargeâ&#x20AC;&#x2122; or tax would be charged for all paper and packaging placed onto the market; Charles Muller, director of Packaging SA, who has been closely involved in the dialogue process between the industry and the Department of Environmental Affairs (DEA), said Packaging SA has responded to the Gazette and requested formal feedback from the Department of Environmental Affairs.

interference does not negatively LPSDFW WKH SDFNDJLQJ VHFWRU ´ VDLG Charles.

Another fear is that the many successful voluntary initiatives, particularly those of the seven mainstream material organisations, may collapse as they are currently all funded Irrespective of through voluntary Industry concerns contributions which where a levy is Obviously industry are generally collected applied it will has concerns that, upfront. Delays in with increased ultimately get funding could see government the disintegration of passed on to the regulation (including projects. consumer the possible A further concern is imposition of a that industry may seek SARS collected â&#x20AC;&#x2DC;waste management to recover costs through increased charge), the paper and packaging automation and job reduction. industry may abdicate their current It is even possible that a responsibilities as they are unlikely to government imposed waste want to or be able to pay twice â&#x20AC;&#x201C; i.e. management charge or tax could also both a voluntary levy and a mandatory result in a decrease in recycling rates. waste management tax. â&#x20AC;&#x153;There is ample international â&#x20AC;&#x153;With some exceptions, the evidence to suggest that recycling packaging manufacturers in South rates will regress, such as what Africa are not in good economic occurred in Hungary and Croatia shape. Government needs to use where the State assumed control from caution that undue taxation and â&#x20AC;&#x153;Thereâ&#x20AC;&#x2122;s been no formal response from the DEA yet. We understand, however, that both the pricing strategy and the intention to call for plans are sitting with the Minister for signature, which means weâ&#x20AC;&#x2122;ll probably get no content feedback prior to these being Âż QDOO\ JD]HWWHG ´ VDLG Charles.

The complexity of the packaging sector is evident in differing trends prevailing with the different materials, and the changes have been quite dramatic over the last few years.

For example, consumption of glass packaging increased from 2009-2011 (from 872,296 tons to 897,790 tons) and then declined quite sharply from 2012 to 2014 (865,507 tons to 712,714 tons).

Metal has been the most consistent performer, but tonnages are the lowest of the four materials recorded; consumption of paper (the largest sector, although not all paper is used in packaging) also increased steadily to 2012 (1,936,695 tons), but then fell sharply in 2014 (1,696,163 ton). All three show relatively high recycling percentages. Plastic is possibly the odd one out: consumption has increased throughout the period recorded here and recycling of plastic DOVR VKRZHG D VLJQLÂż FDQW LQFUHDVH IURP WR FORVH WR SHUFHQW EXFNLQJ WKH WUHQG

NEWS-PACKAGING TAX.indd 30

2016/06/08 11:19

INDUSTRY NEWS privately-run recycling organisations.

In Hungary the recycling rates fell from 59% to 49% within a year,â&#x20AC;?

Charles said.

A key objective of the previous Paper & Packaging Industry Waste Management Plan was to increase the recycling rate for new packaging and paper from 44.2% in 2009 to over 54% by 2018. The industry, however, wants to revisit these targets as they believe that much more is still possible.

Another concern is that the revenue collected by the waste management charge will be swallowed up by the national treasury. Government has advised that there will be no â&#x20AC;&#x2DC;softâ&#x20AC;&#x2122; or â&#x20AC;&#x2DC;hardâ&#x20AC;&#x2122; ring-fencing of any revenue generated and collected. This could mean that other State expenditure such as housing and education may take preference. â&#x20AC;&#x153;Also, the SA consumer can ill afford any further cost of living increases. Irrespective of where a levy is applied it will ultimately get passed onto the consumer. Packaging is also an integral part of the food sector and cost increases here will affect the lower LSMâ&#x20AC;&#x2122;s as well,â&#x20AC;? Charles added.

How will the tax or levy be calculated?

Charles: Probably by using a Randper-kg charge which will vary between substrates. Some, however, favour a straight percentage of turnover, for example, as it is easy to calculate and manage.

How will â&#x20AC;&#x2DC;free ridersâ&#x20AC;&#x2122; and imports be handled with regards compliance and enforcement?

Charles: Government assistance will be required here. Packaging SA and the other PROs will act as a watchdog.

What marketing and awareness campaign will be rolled out?

Charles: National anti-litter programmes will be required.

Information campaigns to support household separation-at-source initiatives are also key to getting the recycling rates up.

What will be done about education?

Charles: This is a massive and

expensive challenge, but to get to all the 26000 or so schools in South Africa is absolutely key to our future. â&#x20AC;&#x153;Packaging SA awaits formal feedback from the Department of Environment Affairs on the Gazettes.

Meanwhile we continue to engage with the DEA, Department of Trade & Industry and other stakeholders. We recognise that government must be an integral part of the solution and work with the successes already achieved within the industry,â&#x20AC;? said Charles. â&#x20AC;&#x153;There are also many other challenges facing the paper and packaging waste management sector, including issues around transformation, formalizing the waste SLFNHUV Âż QGLQJ HQG XVH PDUNHWV IRU additional recyclate and maximizing job creation through developing the 2nd resources economyâ&#x20AC;? added Charles. â&#x20AC;&#x153;These will have to form an integral part of all future plansâ&#x20AC;?. www.packagingsa.co.za JUNE / JULY 2016 31

The way ahead $OWKRXJK QRWKLQJ KDV EHHQ Âż QDOLVHG yet, the packaging industry in SA would like to have answers to the following: Single or multiple EPR schemes?

Charles: The industry is multi-facetted so it is likely that a number of different schemes will be required.

Who in the value chain (obliged industry) will pay?

Charles: The Government has indicated that converters should be the obliged industry. Converters, KRZHYHU JHQHUDOO\ FDQ RQO\ LQĂ&#x20AC; XHQFH the choice of packaging â&#x20AC;&#x201C; the decision lies with the brand-owner. Packaging SA believes that brand owners is the correct place to levy a charge as it is ultimately the brand-owners who decide and specify the type and nature of the packaging to be used. This will also capture imports.

Another consideration is that all in the value chain play a role, so a combination of raw material producers, brand owners, converters and retailers share the cost.

NEWS-PACKAGING TAX.indd 31

2016/06/08 11:19

ASSOCIATION NEWS

0DQG\ 1DXGp 32/<&2 FKLHI H[HFXWLYH RI¿ FHU

POLYCO focuses on building strong recycling value chain 5HF\FOHG SRO\ROH¿ QV FRQWULEXWHG LQ H[FHVV RI 5 ELOOLRQ WR FRXQWU\¶V *'3 THE low market demand for recycled SRO\ROH¿ QV WRJHWKHU ZLWK ULVLQJ FRVWV KDV PDGH WKH UHF\FOLQJ VHFWRU D WRXJK VSDFH WR RSHUDWH LQ 7KH LPSDFW RI WKHVH GLI¿ FXOW WUDGLQJ FRQGLWLRQV ZDV VHYHUHO\ IHOW E\ 32/<&2 SURMHFW SDUWQHUV ZKR UHSRUWHG ORZHU WKDQ H[SHFWHG UHF\FOLQJ YROXPHV IRU WKHLU ¿ QDQFLDO \HDU ³7KLV SDVW \HDU KDV XQGRXEWHGO\ EHHQ D WRXJK \HDU IRU WKH SRO\ROH¿ Q UHF\FOLQJ LQGXVWU\ LQ 6RXWK $IULFD DQG DURXQG WKH ZRUOG :KLOVW ORZHU YLUJLQ UHVLQ SULFHV KDG DQ LPSDFW LQ 6RXWK $IULFD WKH\ ZHUH IRUWXQDWHO\ RIIVHW E\ WKH ZHDNHQLQJ 5DQG +RZHYHU ORFDO UHF\FOHUV RI SRO\ROH¿ Q SODVWLFV DOVR KDG RWKHU FKDOOHQJHV WKH\ QHHGHG WR FRQWHQG ZLWK GXULQJ LQFOXGLQJ ORDG VKHGGLQJ H[SHQVLYH HOHFWULFLW\ FRVWV ZDWHU VKRUWDJHV DQG D JHQHUDO GRZQWXUQ LQ WKH HFRQRP\ ´ VDLG 0DQG\ 1DXGp 32/<&2 FKLHI H[HFXWLYH RI¿ FHU 32/<&2 WKH 3RO\ROH¿ Q 5HF\FOLQJ &RPSDQ\ KRVWHG WKHLU IRXUWK $*0 LQ -RKDQQHVEXUJ UHFHQWO\ $GGUHVVLQJ WKH DVVRFLDWLRQ¶V ERDUG PHPEHUV ZKLFK UHSUHVHQW WKH OHDGLQJ SDFNDJLQJ FRQYHUWHUV LQ 6RXWK $IULFD &(2 0DQG\ 1DXGp SUHVHQWHG D GHWDLOHG UHSRUW RQ WKHLU EXVLQHVV DQG WKH VWDWH RI WKH ORFDO SRO\ROH¿ QV UHF\FOLQJ LQGXVWU\ ³:H KDG KRSHG WKDW WKH 1HZ <HDU ZRXOG EULQJ LPSURYHG PDUNHW FRQGLWLRQV EXW WKH ¿ UVW TXDUWHU RI VDZ WKH ZRUVW HYHU GHPDQG SHULRG LQ WKH ODVW WR \HDUV LQ 6RXWK $IULFD ´ VDLG 0DQG\ 32 JUNE / JULY 2016

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5HF\FOHG SRO\ROH¿ QV FRQWULEXWH WR GDP +RZHYHU DOO LV QRW GRRP DQG JORRP DFFRUGLQJ WR 32/<&2 DV WKH UHF\FOHG WRQV SRVLWLYHO\ FRQWULEXWHG LQ H[FHVV RI 5 ELOOLRQ WR WKH FRXQWU\¶V *'3 7KH WRWDO SODVWLFV UHF\FOLQJ LQGXVWU\ FRQWULEXWHG LQ H[FHVV RI 5 ELOOLRQ WR *'3 LQ DQG FUHDWHG RYHU HPSOR\PHQW RSSRUWXQLWLHV ³:H WUXO\ EHOLHYH WKDW WKH FKDOOHQJHV ZH IDFH WRGD\ FUHDWH RXU RSSRUWXQLWLHV IRU WRPRUURZ 7DNH WKH PHFKDQLFDO UHF\FOHUV IRU H[DPSOH ZKR DUH QRZ EHLQJ IRUFHG WR ORRN DW WKHLU EXVLQHVV GLIIHUHQWO\ )RU WKHP WR VHFXUH QHZ DQG UREXVW HQG XVH PDUNHWV ZLWK D FRQVLVWHQW GHPDQG WKH\ QHHG WR DFWLYHO\ LQYHVW LQ WKHLU TXDOLW\ WHVWLQJ FDSDELOLWLHV $V D UHVXOW ZH DUH VWDUWLQJ WR VHH D JURZLQJ QXPEHU RI UHTXHVWV IRU TXDOLW\ WHVWLQJ HTXLSPHQW WR EH LQWURGXFHG DW UHF\FOLQJ IDFLOLWLHV LQGLFDWLQJ WKH LQGXVWU\¶V GHVLUH WR HQWHU QHZ HQG XVH PDUNHWV E\ RIIHULQJ D TXDOLW\ UHF\FOHG SRO\PHU ZKLFK LQ WXUQ ZLOO DOVR DOORZ WKHP WR FORVH WKH SULFH GLIIHUHQWLDO EHWZHHQ YLUJLQ SRO\PHU DQG TXDOLW\ UHF\FOHG SRO\PHU 7KLV ZLOO KDYH D SRVLWLYH VSLQ RII IRU WKH SODVWLF SDFNDJLQJ FRQYHUWHUV ZKR UHTXLUH FRQVLVWHQW TXDOLW\ PDWHULDO WKDW LV IUHH RI FRQWDPLQDWLRQ WR UXQ WKURXJK WKH H[SHQVLYH HTXLSPHQW WKDW KDV EHHQ LQYHVWHG LQ ´ 0DQG\ DGGHG 7KH ZD\ IRUZDUG 6LPLODU VWHSV DUH EHLQJ WDNHQ ZLWK WKH RWKHU UROH SOD\HUV LQ WKH UHF\FOLQJ YDOXH FKDLQ LQ RUGHU WR KHOS WKHP

RYHUFRPH WKHLU FKDOOHQJHV DQG PRYH WRZDUGV PRUH VXVWDLQDEOH VXSSO\ FKDLQ SURFHVVHV 32/<&2 LV DOVR FDOOLQJ RQ EUDQG RZQHUV WR EHFRPH LQYROYHG ZLWK WKHLU FXUUHQW LQLWLDWLYHV LQ RUGHU WR FUHDWH D VWURQJ VXVWDLQDEOH FLUFXODU HFRQRP\ ZKLFK HOLPLQDWHV ZDVWH 2WKHU IRFXV DUHDV LQFOXGH (PSOR\LQJ D FRQVLVWHQW FRQVXPHU VRFLDO PHGLD HGXFDWLRQ FDPSDLJQ WR EULQJ DERXW D FKDQJH LQ WKH SXEOLF¶V SHUFHSWLRQ UHJDUGLQJ WKH YDOXH RI UHF\FODEOH PDWHULDO DQG FUHDWH D VKLIW WRZDUGV D FRQVFLRXV HIIRUW WR UHGXFH UHXVH DQG UHF\FOH WKHLU SODVWLFV %XLOGLQJ NH\ LQGXVWU\ QHWZRUNV DQG UHODWLRQVKLSV LQ WKH UHF\FOLQJ VHFWRU WR JURZ FROOHFWLRQ DQG UHF\FOLQJ YROXPHV 3UHSDULQJ WR ODXQFK WKH 3DFNDJLQJ %DQN 0RELOH 6ZRS 6KRS SLORW SURMHFW LQ LPSRYHULVKHG FRPPXQLWLHV LQ 6RXWK $IULFD LQ -DQXDU\ ZKLFK ZLOO GHPRQVWUDWH WR *RYHUQPHQW WKDW WKH SDFNDJLQJ LQGXVWU\ DQG WKH EUDQG RZQHUV WDNH WKHLU UHVSRQVLELOLW\ VHULRXVO\ &RQWLQXLQJ WR VXSSRUW WKH HIIRUWV RI 3DFNDJLQJ 6$ DQG 3ODVWLFV_6$ LQ WKHLU HQJDJHPHQW ZLWK GHFLVLRQ PDNHUV WR HQVXUH WKDW WKH YLHZV RI WKH SRO\ROH¿ Q SDFNDJLQJ DQG UHF\FOLQJ LQGXVWU\ DUH KHDUG LQ WKH OLJKW RI WKH SRVVLELOLW\ RI QHZ ZDVWH PDQDJHPHQW FKDUJHV DQG FDUERQ WD[HV ZKLFK ZLOO EH LPSOHPHQWHG WKURXJK WKH 1DWLRQDO 3ULFLQJ 6WUDWHJ\ DQG DOVR WKH &DUERQ 7D[ ELOO *URZLQJ WKH 32/<&2 IRRWSULQW E\ HQFRXUDJLQJ PRUH FRQYHUWHUV WR VLJQ XS DV PHPEHUV www.polyco.co.za

2016/06/08 11:20

ASSOCIATION NEWS

The 100-ton machine is the latest model servo-hydraulic toggle system with most current Techmation controller that is well suited from training

Userve donates machine for training at Plastics|SA 100-ton machine was installed by a joint Userve-Spicoly team USERVE Machinery has, together with its principal Tederic of China, a manufacturer of a complete range of injection moulding machines, donated a machine for training at Plastics/ SA in the Western Cape.

According to Umberto Favini of Userve, the basic Tederic injection system is very suitable for training and he had approached Tederic with a request that a machine be made available for this purpose, the aim being to improve the level of setter training education. Tederic, based in Zhejiang, China, responded positively and the machine was installed at the Plastics|SA training centre in Cape Town in May. David Venter of Spicoly Plastics of Cape Town was the initiator of the project. Spicoly is one of the biggest users of 7HGHULF PDFKLQHV LQ WKH UHJLRQ DQG VLQFH 9HQWHU LV D Âż UP convert to the value of training, he suggested that Userve consider making such a donation to the cause.

The wheels were set in motion and the 100-ton machine was installed by a joint Userve-Spicoly team, amidst considerable enthusiasm by the Plastics|SA training staff.

The machine operates on a Techmation electronic control

system, also supplied by Userve, which is a big plus for the training process. Now a full setter programme can be conducted at the setter, thanks for Favini, Venter and co. ww.userve.co.za Umberto Favini of Userve Machinery (standing, second from left) at the installation of the Tederic machine at the 3ODVWLFV6$ WUDLQLQJ FHQWUH in Cape Town. Also there were (standing) Willie Vermeulen of 6SLFRO\ 3ODVWLFV ,VDEHOOH %UHWWHQQ\ RI 3ODVWLFV6$ and David Venter, MD of Spicoly, one of the biggest users of Tederic machines in the Western Cape; and (in front) Userve technicians Taldon Conn and Cesare Favini

Training at Transpaco generates skills, succession QC, extrusion, bag-making trainees achieve success in Plastics|SA programme A GROUP of ten Transpaco Flexibles employees recently graduated to NQF OHYHOV DQG DW WKH Âż OPV DQG EDJ making groupâ&#x20AC;&#x2122;s Cape Town plant. The Transpaco plant in the Cape is one of the largest in the country, processing as much as 50 tons a day and supplying both printed shopping and boutique bags to retailers across SA and subSaharan Africa.

The process was guided by Transpaco HR manager Martin Nel, with the training programmes supplied by Plastics|SA. Three of the trainees completed the NQF (National 4XDOLÂż FDWLRQV )UDPHZRUN OHYHO

which involved training at the PSAâ&#x20AC;&#x2122;s UHJLRQDO RIÂż FH WKH RWKHU WUDLQHHV ZKR achieved NQF level 2, underwent inplant training.

A varied group, including trainees from all parts of the business such as QC, extrusion and bag-making, undertook the programme. Individuals who showed potential and the ability to accept responsibility were selected.

The NQF level 3 training involves setter OHYHO WUDLQLQJ DQG EHVLGHV EORZQ Âż OP extrusion (the obvious need at the 7UDQVSDFR EXVLQHVV LQFOXGHV EORZ DQG injection moulding setter training â&#x20AC;&#x201C; with the result that graduated trainees have

34 JUNE / JULY 2016

Congrats â&#x20AC;&#x201C; Transpaco Flexibles HR manager Martin Nel (left) with a group of the graduates, including extrusion manager Allan Roodman (second from right), who completed NQF 3, at the plant in Bellville. The traineesâ&#x20AC;&#x2122; efforts were recognised with the presentation of their MerSETA National &HUWLÂż FDWHV LQ 3ODVWLFV 0DQXIDFWXULQJ

the ability to set and control all these main processing technologies.

The main need for the on-going training at the plant, according to HR manager Nel, is the skills and/or knowledge shortage that could otherwise occur.

And the main goals, he added, were to create succession structures at the plant as well as to retrain and entrench skills. The plant operates 24/7 and runs virtually non-stop throughout the year, so having well-trained personnel in all departments is vital. â&#x20AC;&#x153;We want to take this further and get modules for bag-making setting introduced,â&#x20AC;? added Nel. Modern bagmakers are complicated machines and require considerable skills to operate optimally.

According to Isabelle Brettenny, Plastics|SAâ&#x20AC;&#x2122;s regional training manager, the training involved skills programmes linked together to form a learnership. â&#x20AC;&#x153;Employees will be acquiring new knowledge and skills and applying these in the workplace, companies will be raising the skills levels of employees while improving work performance,â&#x20AC;? added Isabelle. www.plasticsinfo.co.za

ASSOC-PLASTICS SA.indd 34

2016/06/08 11:21

ASSOCIATION NEWS

9LQ\O 9HULÃ&#x20AC; HG moves south Corrects misconceptions about the safe manufacture, use and recycling of PVC products

Richard Doyle, CEO and president of the Vinyl Institute and Delanie Bezuidenhout and SAVAâ&#x20AC;&#x2122;s CEO, Delanie Bezuidenhout who are to meet to discuss SAVAâ&#x20AC;&#x2122;s plans to also become members of Vinyl 9HUL¿ HG

THE Southern African Vinyls Association (SAVA) has welcomed news that an industry consortium known as Vinyl 9HUL¿ HG ZLOO EH H[SDQGLQJ LWV LQÃ&#x20AC; XHQFH LQWR WKH VRXWKHUQ KHPLVSKHUH $FFRUGLQJ WR 6$9$¶V CEO, Delanie Bezuidenhout, 9LQ\O 9HUL¿ HG LV DQ LQWHUQDWLRQDO DVVRFLDWLRQ WKDW KDV EHHQ IRUPHG WR FRUUHFW PLVLQIRUPDWLRQ DERXW YLQ\O PDWHULDOV LQ WKH PHGLD ³,W LV PDGH XS RI LQGXVWU\ RUJDQL]DWLRQV SULPDULO\ EDVHG LQ North America who are concerned ZLWK FKDOOHQJLQJ QHJDWLYH PHGLD FRYHUDJH DQG PLVLQIRUPDWLRQ DERXW YLQ\O PDWHULDOV 7KH SODWIRUP FRQIURQWV PHGLD ELDV alarmist commentary and FRPSHWLWLYH PLVFKDUDFWHUL]DWLRQV DERXW YLQ\O LQ RQOLQH GLVFRXUVH ´ 'HODQLH H[SODLQHG 0HPEHUV RI 9LQ\O 9HUL¿ HG LQFOXGH WKH 3ODVWLF 3LSH DQG )LWWLQJV $VVRFLDWLRQ 30& *URXS 39& 3LSH $VVRFLDWLRQ 5HVLOLHQW

)ORRU &RYHULQJ ,QVWLWXWH 7KH 9LQ\O ,QVWLWXWH DQG 9LQ\O 6LGLQJ ,QVWLWXWH DQG WKH )OH[LEOH 9LQ\O $OOLDQFH $XVWUDOLD¶V 9LQ\O ,QVWLWXWH recently joined the international YLQ\O FRQVRUWLXP WR OHQG LWV ZHLJKW WR HIIRUWV DLPHG DW H[SRVLQJ inaccuracies, omissions and Ã&#x20AC; DZHG GDWD ³9LQ\O LV D UHPDUNDEOH YHUVDWLOH GXUDEOH DQG HFRQRPLFDO PDWHULDO EXW D VHOHFW QXPEHU RI FRPSHWLWLYH LQWHUHVWV DQG DJHQGD GULYHQ DFWLYLVWV KDYH DGYDQFHG GLVLQJHQXRXV FDPSDLJQV WR PLVOHDG FRQVXPHUV DQG GHQ\ WKHP WKHLU ULJKW WR PDNH WKHLU RZQ GHFLVLRQV DERXW YLQ\O ´ VDLG 5LFKDUG 'R\OH &(2 DQG SUHVLGHQW RI WKH 9LQ\O ,QVWLWXWH ³9LQ\O 9HUL¿ HG KROGV UHSRUWHUV DFFRXQWDEOH WR WKHLU RZQ journalism standards in how they cover vinyl, and will call out JURXSV DQG RWKHUV ZKR PLVLQIRUP WKH SXEOLF DERXW WKLV LQQRYDWLYH PDWHULDO ´ 'R\OH VDLG LQ UHFHQW

FRPPXQLFDWLRQ WR YLQ\O ERGLHV DURXQG WKH ZRUOG 'HODQLH VDLG VKH ZLOO EH PHHWLQJ ZLWK 'R\OH LQ $XVWUDOLD QH[W PRQWK WR GLVFXVV 6$9$¶V SODQV WR DOVR EHFRPH PHPEHUV RI 9LQ\O 9HUL¿ HG 6$9$ LV DOUHDG\ VSHQGLQJ PXFK RI LWV WLPH DQG HQHUJ\ RQ EXLOGLQJ WKH YLQ\OV EUDQG LQ 6RXWK $IULFD DQG WR FRUUHFW ORFDO PLVFRQFHSWLRQV DQG PLVXQGHUVWDQGLQJV DERXW WKH VDIH PDQXIDFWXUH XVH DQG UHF\FOLQJ RI 39& SURGXFWV ³7KH REMHFWLYHV RI 9LQ\O 9HUL¿ HG are in line with our own as set RXW LQ RXU 3URGXFW 6WHZDUGVKLS &RPPLWPHQW 36& %HORQJLQJ WR VXFK DQ LQWHUQDWLRQDO SUHVVXUH JURXS ZLOO RQO\ KHOS WR VWHP WKH WLGH RI LUUHVSRQVLEOH DWWDFNV RQ YLQ\O SURGXFWV WKDW KDV QRW RQO\ EHFRPH KDUPIXO WR WKH ORFDO LQGXVWU\ EXW DOVR FRPHV DW WKH H[SHQVH RI FRQVXPHU VDIHW\ DQG HI¿ FDF\ ´ 'HODQLH DGGHG www.savinyls.co.za

Rubber 3ODVWLFV LQGXVWU\ HQFRXUDJHG WR conference in create sustainable future Free State in March â&#x20AC;&#x2DC;017 7+( ,QVWLWXWH RI 0DWHULDOV¶ 1DWLRQDO 5XEEHU &RQIHUHQFH LV WR WDNH SODFH IURP 7KXUVGD\ 0DUFK WR 6XQGD\ 0DUFK ,W¶V WR EH KHOG DW .KD\D L%KXEHVL /RGJH ZKLFK LV ORFDWHG LQ WKH VPDOO town of Parys in the Free State and LV RQ WKH EDQNV RI WKH 9DDO 5LYHU ,W is also situated in The Dome World +HULWDJH 6LWH 7KH YHQXH LV D PHUH KRXU DQG D KDOI¶V GULYH IURP 25 7DPER ,QWHUQDWLRQDO $LUSRUW VR LW LV HDVLO\ DFFHVVLEOH ,W ZLOO EH WKH UG HGLWLRQ RI WKH E\ QRZ LQWHUQDWLRQDOO\ NQRZQ ,20 UXEEHU HYHQW

The South African plastics industry and government have the power to invent the future of the VXVWDLQDEOH XVH RI SODVWLFV LI WKH\ KDUQHVV LPDJLQDWLRQ DQG FUHDWLYLW\ ZLWK WKH ODWHVW VFLHQWL¿ F and international developments. This was the underlying message of the six keynote speakers who addressed delegates at the Plastics|SA Conference at the Propak Africa Exhibition. The WKHPH RI WKH VHFRQG LQGXVWU\ VSHFL¿ F FRQIHUHQFH KRVWHG E\ 3ODVWLFV_6$ DQG VSRQVRUHG LQ part by POLYCO and the Polystyrene Packaging Council (PSPC), was â&#x20AC;&#x2DC;The Triple Bottom Line DQG WKH 3ODVWLFV ,QGXVWU\ 3HRSOH 3ODQHW 3UR¿ W¶ &RPPLWWHG WR D VXVWDLQDEOH SODVWLFV LQGXVWU\ are Monya Vermaak (Plastics|SA communications executive), Anton Hanekom (Plastics|SA H[HFXWLYH GLUHFWRU 'DPH $QQH *ORYHU &KLHI 6FLHQWL¿ F $GYLVHU WR WKH 3UHVLGHQW RI WKH (XURSHDQ Commission), Alec Erwin (ex-Trade and Industry Minister), Mefane Makutla (Astrapak HR director), Jason Drew (environmental entrepreneur and sustainability expert), Douw Steyn (director of sustainability at Plastics|SA) and Mandy Naude (CEO of Polyco)

www.plasticsinfo.co.za

36 JUNE / JULY 2016

ASSOC-SAVA.indd 36

2016/06/08 11:22

candice@relloy.co.za

ASSOCIATION NEWS

Pipes for gas installations â&#x20AC;&#x201C; make sure they comply!

www.sappma.co.za

SAPPMA forms task team to investigate requirements of gas pipelines SOUTH Africaâ&#x20AC;&#x2122;s gas industry is on the cusp of huge growth and expansion in light of a potential global oversupply of shale gas. /RFDOO\ WKH 'HSDUWPHQW RI (QHUJ\ KDV FRQÂż UPHG WKH SRWHQWLDO GHYHORSPHQW RI UHJLRQDO JDV Âż HOGV ZKLFK ZLOO OHDG WR QDWXUDO gas becoming a more important fuel in South Africa. â&#x20AC;&#x153;In view of these developments, local plastic pipe manufacturers have to ensure that the pipes used in gas pipelines, have been PDQXIDFWXUHG DFFRUGLQJ WR VWULQJHQW VSHFLÂż FDWLRQV DQG DGKHUH to global standards,â&#x20AC;? said Jan Venter, CEO of the Southern African Plastic Pipe Manufacturers Association (SAPPMA).

According to Venter, pipes made from HDPE are widely used for the distribution of natural gas as they have a well-documented inertness to both the external soil environment and to natural gas. â&#x20AC;&#x153;Extensive testing has taken place over the last 45 years, FRQÂż UPLQJ WLPH DQG DJDLQ WKDW WKH ORQJ WHUP VWUHQJWK RI plastic pipes are unaffected by natural gas and its common constituents â&#x20AC;&#x201C; making them the ideal material to use in gas pipelinesâ&#x20AC;?, Venter said.

9HQWHU KDV Âż UVW KDQG NQRZOHGJH RI WKH SRWHQWLDO FKDOOHQJHV of a pipeline and why it is crucial to ensure that the materials used are up to the task, as he was involved in installing the Âż UVW JDV SLSHOLQH LQ 0R]DPELTXH XVLQJ +'3( SLSH $Q NP cross-border, natural gas pipeline was later installed from the 7HPDQH JDV Âż HOGV LQ 0R]DPELTXH WR 6DVROÂśV V\QIXHOV SODQW DW Secunda in the early 2000, also using HDPE pipe. +'3( SLSHV RIIHU QXPHURXV EHQHÂż WV IRU JDV SLSH LQVWDOODWLRQV such as being lightweight and easy to handle, easy to join,

DYDLODEOH LQ D UDQJH RI VL]HV DQG SUHVVXUH UDWLQJV DQG KDYH ORZ frictional resistance, with hydraulic properties that remain virtually unchanged over its useful life, resulting in lower energy use and SXPSLQJ FRVWV 3LSHV UDQJLQJ EHWZHHQ PP WR PP DV SHU 6$16 DUH JHQHUDOO\ XVHG LQ JDV SLSHOLQHV Rapid Crack Propagation (RCP) One of the biggest dangers of gas pipe lines, however, is the ULVN RI 5DSLG &UDFN 3URSDJDWLRQ 5&3 Âą D UDUH EXW VLJQLÂż FDQW catastrophic pipe failure that results in a rapidly progressing FUDFN W\SLFDOO\ ! IW VHF ZKHQ D SUHVVXUL]HG SLSHOLQH LV subjected to a sudden or intense impact. RCP can also be the UHVXOW RI D SUH H[LVWLQJ Ă&#x20AC; DZ RU FUDFN LQ WKH SLSH DQG FDQ RFFXU in most piping materials including steel and PVC pipes. â&#x20AC;&#x153;RCP is a concern in piping systems that are used to convey compressed gasses due to the fact that the rapid energy dissipation from a compressed gas provides the energy UHTXLUHG WR VXVWDLQ FUDFN JURZWK ´ 9HQWHU H[SODLQHG )RU WKLV reason, pipes bearing the SAPPMA mark are regularly tested to ensure that they meet and exceed industry standards.

6$330$ KDV DOVR UHFHQWO\ IRUPHG D VSHFLÂż F WDVN WHDP KHDGHG XS *HRUJH 'LOL\DQQLV ËŞWHFKQLFDO VXSSRUW HQJLQHHU DW 6DIULSRO ZKR KDV EHHQ WDVNHG ZLWK WKH VSHFLÂż F IRFXV RI LQYHVWLJDWLQJ WKH UHTXLUHPHQWV RI WKH FXUUHQW VSHFLÂż FDWLRQ compiling a guiding document and as an industry body, ultimately ensuring high standards of pipe manufacture and installation when it comes to gas installations.

38 JUNE / JULY 2016

Plastics|SA celebrates 20 years of coastal cleanup successes 6287+ $IULFD ZLOO FHOHEUDWH \HDUV RI RIÂż FLDOO\ participating in the annual International Coastal CleanUp (ICC) this year. What started on a Texas beach in E\ WKH VLQJOH HIIRUW RI RQH ZRPDQ ZDONLQJ DORQJ D beach has since grown into the worldâ&#x20AC;&#x2122;s biggest volunteer HIIRUW IRU RFHDQ KHDOWK (DFK \HDU PRUH WKDQ YROXQWHHUV LQ FRXQWULHV YROXQWHHU WZR KRXUV RI WKHLU time on the third Saturday in September to remove litter This yearâ&#x20AC;&#x2122;s Clean-Up and Recycle SA Week will take place from the from beaches and the marine environment.

12-17 September, with Recycling Day SA taking place on 16 September South Africaâ&#x20AC;&#x2122;s participation is coordinated by and the International Coastal Clean-up Day on 17 September 3ODVWLFV_6$ DQG (]HPYHOR .=1 :LOGOLIH ZKR MRLQHG WKH The Glass Recycling Company, Paper Recycling Association of JOREDO FOHDQ XS FDPSDLJQ LQ Âł,QLWLDOO\ ZH VDZ WKLV 6$ 7HWUDSDN &ROOHFW D &DQ 7KH 5RVH )RXQGDWLRQ 3ODVWLFVâ&#x20AC;ŤŰ&#x201E;â&#x20AC;Ź6$ DV D SLORW SURMHFW 7KH Âż UVW \HDU ZH PDQDJHG WR UHPRYH WRQV PETCO, POLYCO, SAVA, PSPC and the Aerosol Manufacturing RI OLWWHU IURP NP RI EHDFK LQ .ZD =XOX 1DWDO ZLWK WKH KHOS RI Association all actively participate in this weekâ&#x20AC;&#x2122;s events and help SHRSOH /DVW \HDU ZH KDG PRUH WKDQ YROXQWHHUV to promote the message about the importance of recycling,â&#x20AC;? who supported the ICC along the entire South African coastline 6WH\Q VDLG DGGLQJ WKDW 3ODVWLFV_6$ SURYLGHG PRUH WKDQ and offshore islands,â&#x20AC;? said Douw Steyn, sustainability director bags for clean-up initiatives that took place around the country at Plastics|SA. during the month of September last year. â&#x20AC;&#x153;Clean-Up and Recycle SA Week, Recycling Day SA and the This yearâ&#x20AC;&#x2122;s Clean-Up and Recycle SA Week will take place ICC are initiatives that clearly demonstrate the plastics, oil and IURP WKH 6HSWHPEHU ZLWK 5HF\FOLQJ 'D\ 6$ WDNLQJ SODFH packaging industriesâ&#x20AC;&#x2122; commitment to actively reduce the amount RQ 6HSWHPEHU DQG WKH ,QWHUQDWLRQDO &RDVWDO &OHDQ XS 'D\ of litter found in our environment and water sources. Other leading packaging industry associations, including Packaging SA, RQ 6HSWHPEHU www.plasticsinfo.co.za

ASSOC-SAPPMA.indd 38

www.recyclingday-sa.co.za

www.cleanup-sa.co.za

2016/06/08 11:23

PEOPLE

Sun Ace South Africa 20th anniversary â&#x20AC;&#x2DC;Think Globally, Work Locallyâ&#x20AC;&#x2122; Today Sun Ace South Africa SUN ACE South Africa is yet another successful commands a strong market position foreign investment story and celebrates its 20th playing a responsible role in the plastics anniversary later this year. industry as a whole.

Longevity is in the Sun Ace genes, with the MD Gary van Eyk has been founding company established in Japan 76 years fortunate to be part of the South African ago and the investment holding company in investment story since its inception, Singapore 36 years ago. and will retire at the end of 2016. Gary The group philosophy â&#x20AC;&#x2DC;Think Globally, Work Locallyâ&#x20AC;&#x2122; is at has mentored a strong local team who the core of the companyâ&#x20AC;&#x2122;s global vision. Today Sun Ace has today add value into the groupsâ&#x20AC;&#x2122; needs. investments in 12 countries, employing 635 people. Recent Mention should be made of Alistair investments include Columbia and Brazil, whilst Sun Ace Calder, who was appointed as global Kenya (established 2013) is the forerunner for South Africaâ&#x20AC;&#x2122;s business development director last year. vision and further expansion into African markets.

More recently the board announced Group CEO Ryo Sasaki is a visionary and runs the groupsâ&#x20AC;&#x2122; the appointment of Terence Cecil global business interests with a management team of ten Hobson to succeed Gary. Terence is SHRSOH IURP Âż YH GLIIHUHQW QDWLRQDOLWLHV RI ZKLFK RQO\ WZR DUH ZHOO TXDOLÂż HG KDV VXLWDEOH H[SHULHQFH Japanese. He refers to the team as an â&#x20AC;&#x153;international alliance and will add of SMEâ&#x20AC;&#x2122;sâ&#x20AC;?. value to the With a matrix type organisation there is no traditional growth and headquarters, integrated, yet de-centralised management. responsibility Operating close to customers is a key strategy of the objectives group. Localised production was the key to success of the set by the investment in South Africa. In 1996 a joint venture was board. More IRUPHG ZLWK ORFDO PDQDJHPHQW ZLWK VSHFLÂż F REMHFWLYHV WR importantly he develop the market. These goals were realised by the end LV D SHUIHFW Âż W of 2001 and in January 2003 the South African production for the Sun Ace facility was switched on. culture.

In 2008 a new purpose built site was commissioned with World Class manufacturing in Jet Park. This timing mirrored Alistair Calder, the responsible move by industry to voluntarily phase global business www.sunace.co.za out heavy metals chemistry in the vinyl sector. development director

Sun Ace SA managing director Gary van Eyk is to retire later this year after 20yrs at the helm of the local company

Terence Hobson is to take over as MD at the end of the year

Plastomark golf day winners

Winning fourball â&#x20AC;&#x201C; Cliff Rostowsky of Bidvest Afcom, Annette Hart of Precision Value, Rael Meyers of Plastic Bag Manufacturers and Martin Wells of Summit Publishing were the winners of the Plastomark golf day, the â&#x20AC;&#x2DC;5th Majorâ&#x20AC;&#x2122;, played on a fabulous Highveld day in May. Wells has previously been on the winning side, even when spending a lot of time in the rough, but on this occasion he went one better, he didnâ&#x20AC;&#x2122;t play a shot â&#x20AC;Ś due to getting the day mixed up. In spite of being ribbed remorselessly, the results are here to see. The team, including the non-player, won much sought after Ping drivers

Top player â&#x20AC;&#x201C; Rael Meyers of PBM was also the top player on the day, really shooting the lights out at the immaculate River Club in Bryanston. That was a good UHVXOW IRU WKH YHWHUDQ Âż OPV FRPSDQ\ 0' ZKR KDG EHHQ struggling slightly with his game in the weeks before the event. Happy to present the trophy were Plastomark MD Wolfgang Raffalsky and marketing manager Zelda Vikos

Shaun Bouwer joins Vinmar in Nigeria SHAUN Bouwer, formerly of Performance Colour Systems (PCS) in Johannesburg, has been appointed country manager for Vinmar International in Lagos, Nigeria. Before joining (PCS), Shaun also worked with ColorMatrix.

From humble beginnings in a Queens, New York apartment in 1978, Vinmar has steadily grown into a major player in the global petrochemicals

industry today with a $5 billion turnover. The organisation supplies polymers and chemicals internationally, and will also soon branch out into masterbatch. The Houston headquarters DQG RIÂż FHV LQ PDMRU PDUNHWV ZRUN WRJHWKHU WR serve over 100 countries around the world with tailored business solutions that deliver value.

Shaun Bouwer â&#x20AC;&#x201C; now in Lagos, Nigeria

40 JUNE / JULY 2016

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2015/06/02 9:11 PM

PEOPLE

APPOINTMENTS & people on the move Saneliso Mangisa has been appointed as a process assistant at Mpact Versapak, the Mpact group company which produces polystyrene trays, PVC cling film and rigid plastic trays in Paarl, Western Cape. Saneliso was previously at Nampak R&D in Cape Town, where he gained experience in various testing technologies of plastic as well as paper board products, hence suiting him for the new post in the plant at Versapak. He is a qualified polymer technologist.

Grant Matthews has joined Waterlinx in Johannesburg.

One of the most experienced people in the local industry, due to having worked with most of the main packaging manufacturers (he has previously been with Nampak, MCG and Astrapak, which few others have done). Grant was most recently GM of Cinqpet, the Astra PET business in Denver.

Ken Morris and Justin Strout have started Healthy Brands, a new brands business targeting the low-carb nutrition market. Morris was involved in sales at Versapak in Paarl (now Mpact Paarl) for many years, marketing its range of PS containers and PVC films; he was also responsible for the Versapak business in Zimbabwe during this time. He

Saneliso Mangisa has joined Mpact Versapak

Grant Matthews has joined Waterlinx in Johannesburg

Khalid Al-Rumaihi of SABIC has been transferred to Nairobi

recently left corporate life, relocated from the Cape to Johannesburg and, literally, made a new and Healthy start.

The Healthy Brands team is taking it step by step and is currently in the process of developing packaging and labelling solutions for their products.

Khalid Al-Rumaihi of SABIC has been transferred to Nairobi where he has been appointed manager of the Saudi Arabian petrochemicals group’s East Africa branch. Besides polymers, SABIC supplies chemicals and fertilisers. Khalid has managed SABIC polymers business in South Africa for a number of years, based in Cape Town.

Dr Eino Vuorinen has started a consultancy in the field of vapour phase corrosion inhibitors, also known as volatile corrosion inhibitors (VCIs). VCIs are used in metal packaging to prevent atmospheric corrosion. Dr Vuorinen can give advice, evaluate and source VCI-products and masterbatches. www.vci-services.co.za

Tough day on the course didn’t spoil a fine day Western Cape golf day attracts field of 72 THE action at the PISA Western Cape golf day in April played out at the hilly Bellville course, which proved challenging for most – if not all the players – but that did not detract from what was a fine day all round.

The Wrapetfill team finished nicely in front on 85 points, which according to the aficionados is not a fabulous score.

Congrats are nevertheless due to all the winners and in fact all the players too.

Many thanks are due to our sponsors

Winning fourball – Henk de Klerk and Louis Moodie of Wrapetfill were in fine form on the day and, together with Richard Crail of Andy Cab and Jono Toerien of Iveco won the day with 85 points. Here we see them with Nina Dimitru of Idwala, who was also one of the sponsors, and Martin Wells, PISA W Cape treasurer

Farewell to Doreen Rose Doreen Rose, dedicated treasurer and record keeper for the KZN PISA region for an impressive 28 years, passed away on 7 June.

After close to three decades of dedicated service, Doreen Rose had only recently decided to hang up her pens and papers and retire from the regional committee of PISA KZN. Doreen acted as treasurer and record keeper for the KZN region for an impressive Doreen Rose has given PISA KZN 28 years of unselfish service, during which she served several chairmen and committees and always gave of her best. She really was a ‘diamond in the rough’

too, especially our main sponsor Plastomark. We also wish to thank the sponsors of the fabulous prizes, including Alplas, Clariant, Idwala, InStep, Progetto and SPI. See you again next year people.

Runners-up – In second place on the day, hot on the heels of the leaders, was the AG Plastics fourball including Richard Gill of Corporate Cup, Andy Hennings of AG, Jacques le Roux of Electro Enterprises and Gary Crawford of Aquamark

Served KZN branch of PISA for 28yrs

28 years. This she did with gusto and was always present at meetings.

Being of the ‘old school’ like so many of us, she always kept written records as well as computer generated records. This proved to be her saving grace as her written records proved the committee wrong on several occasions. Doreen was dedicated to the nth degree and was well-known to all members regionally and in most cases, nationally. Her husband Peter served as National Chairman, and she rubbed shoulders with the other regions as a result.

“She was a GEM and will always be part of PISA KZN,” said PISA national

chairman Garth Taylor, who was also a former KZN chairman.

Towards the end of Doreen’s tenure as treasurer she struggled with some health issues, but she fought through this hurdle and after an operation was back in the seat. Whilst sick she still sent financials in to committee meetings and Peter had strict instructions what to say. Even when Peter could not be present, she’d send the books with her grandson. All correctly done. Never was an AGM held without the audited books tabled. We shall miss you Doreen!

Pemula salagwazi ! (Rest old Lady)

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Plastics making our lives Plastics for Life global parts competition showcases best of the best THE Society of Plastics Engineers (SPE) have honoured plastic products that meet the ultimate test of value by in some way making our lives better. A panel of judges selected the winners of the third annual Plastics for Life™ Global Parts

Competition from among a wide range of parts that had already won in competitions at previous SPE events during the past year. The award categories and winners are: www.4spe.org

GRAND PRIZE Plastitel Inc for vacuum thermoformed TPU pods serving as the support surface of the Isolibrium patient bed from Stryker Corp. The pods are the main support surface of the IsoLibrium bed, facilitating patient mobility and ensuring regular movement. This aids in the function of vital organs, reduce bed sores, and improve circulation. Two major challenges were ensuring a minimum thickness on every individual pod and accurately measuring them. www.plastitel.com

SUSTAINING LIFE Delphi Automotive PLC for an overmoulded polyamide heated tip fuel injector for Honda Motor Company. An electrical heater within the injector is energized by the vehicle controller, rapidly heating the ethanol fuel and thereby dramatically improving vaporization and reducing emissions. By making possible reduced fuelling during engine warm-up, these injectors also offer reduced emissions on ethanol and gasoline applications. Total hydrocarbon and carbon monoxide emissions were reduced by 40% - 70%. www.delphi.com

PROTECTING LIFE Promogroup 3URPRJURXS IRU D SODVWLF PHWDO K\EULG À RRU URFNHU reinforcement for the 2015 Fiat Chrysler Jeep Renegade. This honeycomb reinforcement was designed for high-energy, high-speed side impact crashes. The use of this solution reduces the component weight by 45% versus the steel solution, or 1kg/vehicle, ZLWK WKH DGGHG EHQH¿ W RI D FRVW UHGXFWLRQ 7KLV QHZ technology sets a precedent for similar applications across the body structure, including 30-40% mass reduction for each reinforcement, performance comparable to high strength steel, and ease of assembly.

44 JUNE / JULY 2016

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www.paginegialle.it/milano-mi/automobili/autounion-promogroup

2016/06/08 11:24

DESIGN

better!

QUALITY OF LIFE Sonoco Plastics Sonoco Plastics for a 39ml blow moulded VariBlend dual dispensing bottle. The VariBlend dispenser sits atop a twocompartment bottle. A new design locks securely to ensure the package will travel without leaking and the product will maintain its integrity. Consumers can select different formula strengths by turning the dial on the dispenser, satisfying their demand for product personalization and freshness. Six positions exist, or EUDQG RZQHUV FDQ VHW ¿ [HG UDWLRV .HHSLQJ SURGXFWV VHSDUDWH until time of use keeps them fresher for longer. The component is designed for products that come in multiple strengths, require ingredient segregation, offer shade/ colour selection, or need mixing and blending. www.sonoco.com

IMPROVING LIFE Productive Plastics Inc Productive Plastics Inc for nine pressure formed parts for covers for an MRI medical scanning device. Using cast and machined moulds to ensure no shrink tolerance and CNC linear tolerances for moulded in dimensions. All parts utilized pushers to pre-stretch materials. Use RI 6HNLVXL¶V .\GH[ 7 VKHHW PDGH LW SRVVLEOH WR PDLQWDLQ WKH UHTXLUHG wall thickness and consistency over multiple runs. The parts include XQGHUFXWV DQG DUH IRUPHG LQ PDWLQJ SDUWV WR EHWWHU OLQH XS IRU ¿ W 7KH DVVHPEO\ DOORZV IRU WKH SDUWV WR ¿ W D VHSDUDWH PHWDO IUDPH that is assembled at the staging location. This custom hardware reduced the amount of tools required to install and service, and reduced the total time required for installation and service. www.productiveplastics.com

PEOPLE’S CHOICE SureCan Inc

DESIGN-SPE AWARDS.indd 45

JUNE / JULY 2016 45

SureCan Inc for a blow moulded gasoline can. The 2.2 and 5.0 gallon can makes it possible to direct how and where fuel is dispensed, with a rotating nozzle, thumb trigger, and hand support grips at the bottom. The thumb safety trigger securely seals the vent on top of the can. The thumb button assembly is made up of two main parts, the thumb button itself and the safety trigger. The vent does not open or release any air unless the safety trigger is pulled straight back and then depressed with the main thumb button. On average the SureCan releases fuel at a rate of about 2 gallons per minute. www.surecanusa.com

2016/06/08 11:24

DESIGN

Colourful chairs win design award

46 JUNE / JULY 2016

Clariant ColorWorks helps Italian company with colour ideas for new furniture lines CLARIANTâ&#x20AC;&#x2122;s ColorWorks® Europe design & technology centre played a key role in helping Italian furniture manufacturer %UDGR GHYHORS ¿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and plastics processing technology to assist designers and EUDQG RZQHUV LQ EULQJLQJ FRORXU LQWR WKH HDUO\ VWDJHV RI SODVWLF SURGXFW GHYHORSPHQW The Mork chair and another line named Loola have ERWK UHFHLYHG D *RRG 'HVLJQ $ZDUG IURP 7KH &KLFDJR $WKHQDHXP 0XVHXP RI $UFKLWHFWXUH DQG 'HVLJQ 7KH *RRG 'HVLJQ $ZDUGV LV WKH ZRUOG¶V ROGHVW DQG PRVW LPSRUWDQW LQGXVWULDO GHVLJQ SURJUDP RUJDQL]HG DQQXDOO\ E\ WKH PXVHXP LQ FRRSHUDWLRQ ZLWK WKH (XURSHDQ &HQWUH IRU $UFKLWHFWXUH $UW 'HVLJQ DQG 8UEDQ 6WXGLHV LQ 'XEOLQ www.clariant.com

Clariantâ&#x20AC;&#x2122;s ColorWorksâ&#x20AC;&#x2122; Europe design & technology centre played a key role in helping Italian furniture manufacturer Brado develop ¿ YH QHZ FKDLU GHVLJQV WZR RI ZKLFK KDYH DOUHDG\ ZRQ DZDUGV

DESIGN-CLARIANT.indd 46

2016/06/08 11:25

COMPOSITES

Formo Fibreglass founders Japie Naude and Elmarie Smit with the pultrusion machine Japie designed and constructed at the Somerset West company. Kobus Mabie operates the machine

Formo Fibreglass celebrates 10 years!

48 JUNE / JULY 2016

Dedication, commitment to research development, high quality, cost-effective products FORMO Fibreglass in Somerset West celebrates its 10th year of operations this year. The company was established when two like-minded and skilled individuals, Japie Naude and Elmarie Smit, joined forces and their extensive experience in the design and manufacturing of GRP products.

Both have been involved at senior management level in the composites and pultrusion industry for many years. ElmaULH LV D TXDOLÂż HG VFLHQWLVW 06F &KHPLV try) with 27 years composite experience at Somchem, Vectus Pipes and Fibretek, while Japie has more than 25 yearsâ&#x20AC;&#x2122; experience, using different open and close mould processes to design and manufacture composite products.

The company designs and specialises LQ PDQXIDFWXULQJ Âż EUHJODVV SURGXFWV using hand lamination, light resin transfer PRXOGLQJ /570 UHVLQ LQIXVLRQ FROG press moulding and pultrusion.

Ten years on and they are reaping the Items such as hospital headboards and TV mounting brackets are produced by open and close moulding processes

rewards of their dedication and commitment to research development, and high quality and cost-effective products.

Elmarie said that at least 40% of the companyâ&#x20AC;&#x2122;s products manufactured currently are for the medical/hospital sector, including intensive care unit components and items such as headboards and TV brackets.

Formo also produces mouldings for ZDVWH ZDWHU WUHDWPHQW DQG SXULÂż FDWLRQ plants; including hand rails, sluice gates, support structures, walkways, platforms, cat ladders and other customized prodXFWV XVLQJ SXOWUXGHG SURÂż OHV They also produce electrical kiosks HQFORVXUHV DQG PDQXIDFWXUH YDULRXV components for the automotive industry.

Japie designed and built the companyâ&#x20AC;&#x2122;s own pultrusion machine using the knowledge and experience gained in the industry over the years. Itâ&#x20AC;&#x2122;s a challenging task, but with the help of an engineer friend and lots of enthusiasm, the pultru)RUPRÂśV GHVLJQHG IRU SXUSRVH electrical enclosures achieve H[FHSWLRQDO LQVXODWLRQ DQG QRQ conductive functionality

sion machine was completed and now takes pride of place at the Formo premises in Somerset West. The machine can produce pultruded channels, angles, boxes, solid rods and round tubes.

7KH VWUXFWXUDO SXOWUXGHG SURÂż OHV compete with stainless steel, aluminium, ZRRG DQG JDOYDQL]HG VWHHO SURÂż OHV DQG are becoming more and more popular in the electrical, civil, industrial, mining and marine industries. â&#x20AC;&#x153;A pultruded product has a high weight-to-strength ratio, is a quicker and less labour intensive process, and offers excellent non-conductive properties, corrosion resistance and low maintenance,â&#x20AC;? said Japie.

â&#x20AC;˘ Formo Fibreglass, Tel 021 851 2692

www.formo.co.za

The pultrusion process at Formo allows for the SURGXFWLRQ RI D ZLGH UDQJH RI SURÂż OH VKDSHV ZKLFK H[KLELW JRRG FRORXU GLVSHUVLRQ ULJLGLW\ ZHDWKHU UHVLVWDQFH FRUURVLRQ UHVLVWDQFH DQG DUH OLJKWZHLJKW

A row of fully assembled Covestro wind turbines in action

Less is more (YRQLN LQWURGXFHV VROXWLRQV IRU JUHDWHU FRVW HIÂż FLHQF\ LQ OLJKWZHLJKW GHVLJQ

+W^M[\ZWÂź[ _WZTLĚ&#x2030;Ă&#x2026; Z[\ KMZ\QĂ&#x2026; KI\QWV NWZ 8= ZM[QV COVESTRO has developed an innovative technology for manufacturing wind turbine rotor blades from a PU UHVLQ DQG D JODVV Âż EUH IDEULF 7KH company has received Det Norske Veritas and Germanischer Lloyd (DNV */ FHUWLÂż FDWLRQ IRU WKH UHVLQ VLJQLI\ ing the safety, reliability and performance of the wind turbine technology.

7KH FHUWLÂż FDWLRQ ZKLFK LV D Âż UVW IRU polyurethane resin, is also a landmark in renewable wind power. The resin KDV D PDMRU LQĂ&#x20AC; XHQFH RQ VWDELOLW\ DQG durability, the two critical properties of rotor blades. www.covestro.com

JUST BRIEFLY

8]T\Z][QWV OZW_\P NWZMKI[\ I\ ACCORDING to a new market report, the global pultrusion market could grow at a CAGR of 4.6% from 2016 to 2021, driven by a rise in demand for lightweight materials and durable products for corrosive environments, such as in rebar and gratings applications. ,QFUHDVLQJ HQHUJ\ HIÂż FLHQF\ requirements from consumers and a greater focus on the total lifecycle cost of end products, are further driving the market.

'HPDQG IRU ZLQGRZ SURÂż OHV are forecasted to experience the highest growth due to increasing HQHUJ\ HIÂż FLHQF\ UHTXLUHPHQWV IURP consumers and a higher degree of insulation than aluminum. During the forecast period, the window SURÂż OH LV H[SHFWHG WR HPHUJH DV the largest market by value and the second-largest market by volume consumption, after ladder rail.

North America is expected to remain the largest market due to growth in end user applications and a wider acceptance of pultruded parts.

Meanwhile, the rest of the world is H[SHFWHG WR ZLWQHVV VLJQLÂż FDQW JURZWK over the forecast period because of the growing awareness of pultruded products.

COMPOSITE materials are light, extremely robust and offer a wide range of design options. Although they are an essential part of modern production â&#x20AC;&#x201C; for example when it comes to lighter cars or high-performance wind power plants â&#x20AC;&#x201C; production at the industrial scale has so far been hampered by complex and costly processes.

This may now change. Evonik assigned an interdisciplinary team to search for solutions for a three-year term in its Composites Project House. The recently completed project house came up with materials and processes that enable automated production at economical prices.

The global composites market reached a volume of approx. â&#x201A;Ź74 billion and about 9 million tons in 2015, with further growth projected. Experts forecast a growth rate of 6% annually for the years to come.

The newly invented PulPress procedure, which allows for the economical, fully automated production of complex moulded parts, may provide a solution. â&#x20AC;&#x153;In comparison with identical parts made of steel, the weight can be reduced by up to 75% and the cost per unit decreases by 30 to 60% compared to other manufacturing processes for composites.

A new material system solution for the Âż UVW VWHS LQ WKH SURGXFWLRQ RI FRPSRVLWHV

Almost ready for mass production â&#x20AC;&#x201C; Built for the purpose of manufacturing unidirectional (UD) tapes, the pilot plant constructed by the Composites Project House is currently producing tapes 160mm in width

Âą WKH SURGXFWLRQ RI SUH LPSUHJQDWHG Âż EUHV SUHSUHJV Âą DOVR DLPV DW JUHDWHU HIÂż FLHQF\ The newly developed thermally controllable hybrid polymers combine quick and easy processing with ultra-high stress resistance â&#x20AC;&#x201C; properties that were previously considered LQFRPSDWLEOH 6LJQLÂż FDQW SURJUHVV ZDV DOVR achieved in the surface quality of composite materials as well as for the production of Ă&#x20AC; DPH UHWDUGDQW SUHSUHJV DQG XQLGLUHFWLRQDO tapes, the thin synthetic strips embedded in SDUDOOHO LQ HQGOHVV UHLQIRUFHPHQW Âż EUHV www.evonik.com

Dow supplying adhesives for Audi, Lamborghini MATERIALS Today reports that Dow Automotive is now supplying its customised structural bonding solutions for weight reduction in motorsports vehicles. Among manufacturers using the adhesive solutions based on Dowâ&#x20AC;&#x2122;s Betaforce composite bonding adhesives are Audi for the new R8 and Lamborghini on the HuracĂĄn, the company says.

Betaforce composite bonding adhesives are designed to support hybrid constructions such as lightweight solutions. Multi-material vehicles can reach weight reduction without compromising on other priorities such as safety or comfort and composites from car-

ERQ Âż EUHV DUH QRZ VHHLQJ D JURZLQJ VKDUH in the material mix. Audi and Lamborghini DUH XVLQJ FDUERQ Âż EUH LQ FRPELQDWLRQ ZLWK aluminum coated structural parts.

Besides weight reduction, structural adheVLYHV DOVR SURYLGH SURFHVVLQJ EHQHÂż WV 'RZ says. Among the production advantages are the pre-treatment free joining of carbon Âż EHU LPSURYHG RSHQ WLPHV DQG EDODQFHG mechanical properties regarding optimal stiffness and driving properties. www.materialstoday.com

50 JUNE / JULY 2016

7KH QHZ /DPERUJKLQL +XUDFiQ LV D OHDQ PHDQ FDUERQ Âż EUH PDFKLQH

COMPOSITES

SwiftCarbon unveils lightweight frame Using TeXtreme resulted in 24% improvement in strength-to-weight ratio SOUTH African bicycle manufacturer SwiftCarbon has shown a sneak preview its 2017 product range which includes their top-end Ultravox SSL frame design, reinforced

by TeXtremeÂŽ FDUERQ Âż EUH IDEULFV 8VLQJ TeXtreme resulted in a 24% improvement in strength-to-weight ratio.

TeXtreme is the next-generation stateRI WKH DUW FDUERQ Âż EUH PDWHULDO QRZ EHLQJ used in the bicycle industry; it is based on using Spread Tows instead of yarns to create ultra-light weight, high-performance products.

Companies utilizing the TeXtremeÂŽ Technology DFKLHYH VLJQLÂż FDQW UHVXOWV LQ PLQLPL]LQJ ZHLJKW while increasing rigidity, strength, etc., in FRPSDULVRQ WR RWKHU FDUERQ Âż EUH PDWHULDOV â&#x20AC;&#x153;The unique TeXtreme Technology and its 6SUHDG 7RZ FDUERQ Âż EUH PDWHULDOV UHGXFH WKH amount of material needed while still delivering the same strength. This increases the strength-to-weight ratio for the new Ultravox SSL by 24% and also allows us to adapt the technology to full-carbon accessories like the headset and seat clamp,â&#x20AC;? said Mark Blewett, founder of SwiftCarbon. â&#x20AC;&#x153;SSL is a project that explores the boundaries of whatâ&#x20AC;&#x2122;s possible in working with composites. We started out with us saying: â&#x20AC;&#x2DC;Imagine ifâ&#x20AC;Śâ&#x20AC;&#x2122; and wove together

what weâ&#x20AC;&#x2122;ve learned by creating the ultra-light 6ZLIW&DUERQ 6&8/3 ZLWK PRQWKV RI VFLHQWLÂż F experimentation and the instinctual feeling you get from years of always working with the latest materials and manufacturing methods.

TeXtreme is the perfect partner for us because we can work with their team of engineers, who really helped in reaching our weight and performance goals,â&#x20AC;? he added.

The Ultravox SSL will be available for the coming 2017 season. www.swiftcarbon.com JUNE / JULY 2016 51

I.P.P Inkulu Plastic Pipes

(Pty) Ltd

Quality Pipe Manufacturers of HDPE pipe Think big, â&#x20AC;&#x153;Inkuluâ&#x20AC;? is Gabriel Reddyâ&#x20AC;&#x2122;s motto, who started the new pipe manufacturing business Inkulu Plastic 3LSHV LQ +DPPDUVGDOH .=1 $QG VHOOLQJ LW PLQG \RX 7KH Âż UVW SLSHV SURGXFHG DW KLV QHZ FRPSDQ\ ZHQW GLUHFWO\ IURP PDFKLQH WR WKH EDFN RI WKH GHOLYHU\ WUXFN Âą ZLWKRXW HYHQ WRXFKLQJ WKH IDFWRU\ Ă&#x20AC; RRU Inkulu Plastic Pipes leased a 3440m2 factory in Hammarsdale. Inkulu Plastic Pipes has not looked back since, and the machines DUH QRZ UXQQLQJ 7KH FRPSDQ\ KDV DOVR DFTXLUHG 6$%6 FHUWLÂż FDWLRQ *DEULHOÂśV WKLUG PDFKLQH DUULYHG LQ $XJXVW *DEULHO believes in always making a plan and satisfying his clients and keeping them happy. His success is due to the support and the good wishes of his very loyal customers and suppliers.

Products include: HDPE (High Density Polyethylene) Pipes, LDPE (Low Density Polyethylene) Pipes, PP (Polypropylene) Pipes and Fabricated Fittings

Contact us: 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 | www.inkuluplastics.co.za

COMPOSITES

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www.gmscomposites.com

For thinner laminates, GMS EP-540 FR prepreg has a rapid gel time down to as short as 6 minutes at 120C, with parts fully cured within 2 hours GMS EP-540 FR epoxy prepreg is fully compatible with all standard sandwich core materials, as well as carbon, glass and DUDPLG ¿ EUH UHLQIRUFHPHQWV

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A decade of research has gone into the development of this low-cost clean energy technology 52 JUNE / JULY 2016

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

COMPOSITES

Here comes the sun

BY INÃ&#x2C6;S A. MELAMIES

54 JUNE / JULY 2016

Atmospheric pressure plasma makes CFRP solar race car lighter ON 24 September, the starting shot for the international 2016 Sasol Solar Car Challenge running from Pretoria to Stellenbosch ZLOO EH ¿ UHG 7R VSHHG XS WKH ERQGLQJ SUR FHVV RSWLPL]H DGKHVLRQ DQG VDYH VHYHUDO kilos in weight, a participating team of stuGHQWV IURP .8 /HXYHQ 8QLYHUVLW\ LQ %HOJLXP SUHWUHDWHG WKH &)53 FRPSRQHQWV RI WKHLU solar racing car with atmospheric pressure SODVPD SULRU WR ERQGLQJ 3URGXFWLRQ PDQDJHU 'RNXV 6RHWHPDQV DQG KLV IHOORZ VWXGHQWV ZKR PDNH XS WKH 3XQFK 3RZHUWUDLQ 6RODU 7HDP DUH EXGGLQJ HOHFWURQLF DQG PHFKDWURQLF HQJLQHHUV ZLWK DQ DYHUDJH DJH RI \HDUV )RU RYHU WHQ \HDUV /HXYHQ 8QLYHUVLW\ KDV ZRUNHG FORVHO\ ZLWK LQGXVWU\ SDUWQHUV WR RIIHU LWV PDVWHUV VWX GHQWV D VSHFLDO SRVWJUDGXDWH FRXUVH 7KRVH taking part in the biennial Solar Car Project KDYH WR EXLOG D VLQJOH VHDWHU UDFLQJ FDU SRZHUHG HQWLUHO\ E\ WKH VXQ DQG HQWHU LW LQ FRQWHVWV IRU WKH ZRUOG¶V PRVW HI¿ FLHQW HOHFWULF FDUV 7KH ¿ UVW DLP ZDV WR FRPSHWH VXFFHVV IXOO\ LQ WKH ORQJHVW DQG WRXJKHVW VRODU FDU UDOO\ LQ WKH ZRUOG WKH :RUOG 6RODU &KDOOHQJH LQ $XVWUDOLD 7KDW JRDO ZDV DFKLHYHG LQ DXWXPQ 7KLV \HDU WKH 6RXWK $IULFDQ VXQ EHFNRQV DQG WKH WHDP LV KHDGLQJ IRU WKH :HVWHUQ &DSH 7KH \RXQJ WHDP ± ZKR ZHUH HQWLUHO\ UHVSRQVLEOH IRU HYHU\ GHWDLO RI WKLV ¼ PLO OLRQ HXUR FDU SURMHFW ± KDG MXVW PRQWKV WR PDNH WKHLU GUHDP RI FRPSHWLQJ LQ LQWHUQD WLRQDO VRODU FDU UDFHV D UHDOLW\ %XW EHIRUH WKH\ FRXOG HYHQ WKLQN RI WKH WULS WKH VRODU FDU KDG WR EH GHVLJQHG DQG EXLOW IURP VFUDWFK

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Plasma-treated monocoque bottom shell showing ribs and torsion box (left). Plasma-treated structure of the stiffening ribs in the top shell (middle), and assembly of the different car body layers (right) 3+2726 381&+ 32:(5 62/$5 7($0

IPEX Tel.:

Powered only by the sun: The aerodynamic vehicle is covered with 391 ultra-thin silicon solar cells PHOTO: ROB STEVENS KU LEUVEN

Cleaning and activation with AP plasma Openair-Plasma jet technology developed by Plasmatreat 20 years ago is employed today ZRUOGZLGH LQ DOPRVW DOO ¿ HOGV RI LQGXVWULDO production. The process uses potential-free plasma for surface pre-treatment. Produced inside plasma nozzles by an intensive, pulsed arc discharge, the plasma is conditioned at WKH QR]]OH RXWOHW $ WDUJHWHG À RZ RI DLU DORQJ the discharge path separates parts of the plasma and transports them via the nozzle head to the surface of the material being treated, whilst retaining the voltage-carrying SDUWV RI WKH SODVPD À RZ LQVLGH WKH QR]]OH head. The nozzle head also determines the geometry of the plasma beam being emitted.

The process performs three operations in a single step lasting only a matter of seconds: ,W VLPXOWDQHRXVO\ EULQJV DERXW WKH PLFUR ¿ QH cleaning, electrostatic discharging and activa-

tion of the plastic surface. This triple action far outweighs the effectiveness of conventional pre-treatment systems. The result is homogeneous wettability of the material surface and long-time stable adhesion of the adhesive bond or coating even under challenging load conditions.

The surface is activated through the chemical and physical interaction of the plasma with the substrate. When the AP plasma hits a plastic surface, groups containing oxygen and nitrogen are incorporated into the mainly non-polar polymer matrix. Plasma activation brings about an increase in surface energy, rendering the substrate polar.

Convincing test results Never before had the students experienced a material pre-treatment with

Adhesive fracture before plasma treatment (left) and cohesive fracture after plasma treatment (right) PHOTOS: PUNCH POWER SOLAR TEAM

plasma and they were keen to see the process.

Two different tests had to be performed to verify the effect, one before and one after the ERQGLQJ SURFHVV 7KH DLP RI WKH ¿ UVW WHVW ZDV to determine the surface energy of the CFRP before and after plasma treatment. These were the results: Before treatment, the smooth side of the CFRP sample which was to be bonded had a surface energy of only 24mJ/m² (24 dyne), EXW DIWHU SODVPD WUHDWPHQW WKLV ¿ JXUH URVH WR 74mJ/m² (74 dyne) – ideal conditions for the subsequent adhesive process. The second test, a repeat of the tensile-shear-strength test provided the proof: The fracture behaviour had changed. Instead of the earlier adhesive fracture, this time the desired cohesive fracture was obtained.

Lighter and faster The students carried out the plasma treatment and bonded all the stiffening ribs to the two body shells. To make the job easier, Plasmatreat provided a hand-held rotary nozzle jet normally used for laboratory work or smallscale applications which weighed only 2.5kg.

The process proved to be very straightforward: Whilst one person guided the plasma nozzle across the surfaces to be treated, the next person followed on behind applying the adhesive.

Some pressure was applied to the bonded ribs and off the shell went into the oven for one hour at 90°C to cure the adhesive.

While previously it had taken far longer than a week to laminate the stiffening ribs, now with the aid of plasma the job was completed in three days. But even more importantly: The new plasma bonding process had reduced the weight of the solar car body by almost three kilograms and the targeted 165kg overall weight had now been achieved.

• Plasmatreat GmbH is represented in SA by Resin Processing Solutions cc, Tel: 021 510 6903

www.resinprocessingsolutions.com

JUNE / JULY 2016 55

1976 – 2016

Years

PowerSeries The fastest growing range of IMM machines.

Have you got yours?

EcoPower

SmartPower

MicroPower

MacroPower

55 – 300 t

25 – 350 t

5 & 15 t

400 – 1600 t

IPEX Holdings (Pty) Ltd. Tel.: +27 (0) 11 493 7816 | Fax: +27 (0) 11 493 2389 | sean.kleingeld@ipex.co.za | john.davies@ipex.co.za | www.ipex.co.za

FEATURE

Products such as this transistor radio were state of the art in their time, and led the way towards todayâ&#x20AC;&#x2122;s massive popularity of electrical and electronic devices

The entrance to the museum in the rolling hills of Somerset in south-west England

Bakelite

opens world of

56 JUNE / JULY 2016

BY JOHN BYETT

decades of the 20th century, Bakelite, a trademarked â&#x20AC;&#x2DC;BAKELITEâ&#x20AC;&#x2122; might seem an odd subject upon which to open phenolic plastic, revolutionized the market for moulded and a museum, but as far as plastics are concerned, probably laminated parts for use in electrical equipment. one of the most interesting. This one in Somerset, southOther plastics followed with similar properties, such as west England, houses a remarkable range of objects that urea and melamine formaldehyde, but had the added value were made of this material. A trip back in time â&#x20AC;&#x201C; 1850 to of being in lighter colours.

1950 â&#x20AC;&#x201C; which, I suppose, is in the nature of museums, a trip taken back in time amongst familiar Huge collection everyday objects.

Patrick Cook, artist, collector and author, ,Q WKH Âż UVW GHFDGHV If your recollections of Bakelite are bought a Bakelite-housed radio in 1968 FRQÂż QHG WR GDUN EURZQ OLJKW VZLWFKHV EODFN of the 20th and is now the curator of this huge electrical plugs and distributor housings, collection of vintage plastics. The museum FHQWXU\ %DNHOLWH D then a visit to the Bakelite Museum certainly is housed in a former 17th century WUDGHPDUNHG SKHQROLF opens up the world of the plastics in which Somerset-driven water mill and the rustic our parents and grandparents grew up. It SODVWLF UHYROXWLRQL]HG EDFNGURS DGGV D ORW RI Ă&#x20AC; DYRXU WR WKLV seems that anything could be made from, unusual assembly of memorabilia. Patrick WKH PDUNHW IRU PRXOGHG or partially made from, these early plastics, does not employ any standard museum the designers tackling products from toys to DQG ODPLQDWHG SDUWV practice of labelling exhibits; they are there 79V D FUDGOH WR D FRIÂż Q to be picked up and examined.

IRU XVH LQ HOHFWULFDO â&#x20AC;&#x2DC;Bakeliteâ&#x20AC;&#x2122; was invented by the BelgianThere are thousands of items on display, HTXLSPHQW born American Leo Baekeland. Baekeland mostly from the 20th century. Some of used phenol, an acid derived from coal them have you guessing as to what use tar. A hard, infusible, and chemically resistant plastic, they were put to, others are of iconic design. This odd Bakelite was based on a chemical combination of phenol museum is stuffed full of not only Bakelite items, but early and formaldehyde (phenol-formaldehyde resin), two plastics items such as â&#x20AC;&#x2DC;LingaLonga,â&#x20AC;&#x2122; â&#x20AC;&#x2DC;Bandalasta,â&#x20AC;&#x2122; â&#x20AC;&#x2DC;Beetleâ&#x20AC;&#x2122; compounds that were derived from coal tar and wood (later â&#x20AC;&#x2DC;Beatlâ&#x20AC;&#x2122;) and early household items such as hoovers, alcohol (methanol), respectively, at that time.

IULGJHV FRRNHUV UDGLRV 79V DQG Ă&#x20AC; DW LURQV 7KHUH UHDOO\ LV This material could be moulded into any shape and something for everyone.

ZRXOG QRW EXUQ ERLO RU PHOW RQFH LW VHW KDUG ,Q WKH Âż UVW Itâ&#x20AC;&#x2122;s a real nostalgia fest and I will guarantee that at some point you will say, â&#x20AC;&#x2DC;I remember that.â&#x20AC;&#x2122; The Bakelite â&#x20AC;&#x2DC;hot bottleâ&#x20AC;&#x2122; was effective but apparently not quite as warm as the rubber equivalent Back to 3-D printing? Surely not â&#x20AC;Ś but this is what Bakelite moulders were able to produce in the late 1800s, quite a long time ago

FEATURE-BAKELITE.indd 56

Location: Williton, Somerset, England.

www.bakelitemuseum.co.uk Impressive colour combinations were possible on early plastics products

2016/06/08 11:26

Although not large, the museum houses a huge and impressive range of memorabilia

3LFQLFV WRRN RQ D QHZ OLJKWZHLJKW Ã&#x20AC; DYRXU courtesy of the new plastics

Exact models of cars were popular at the time

museum

early plastics

Comic toys of the 1960s were popular with children

Precursor to Lego?

JUNE / JULY 2016 57

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

FEATURE-BAKELITE.indd 57

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

2016/06/08 11:26

FEATURE

While only accounting for 4% of GCC polymer production the Kuwait polymer capacity is similar in size to South Africa, and there are plans to build SRO\PHU SODQWV DV SDUW RI WKH 2OH¿ QV ,,, FUDFNHU DQG UH¿ QHU\ SURMHFW DW $O =RXU

Middle East countries need to deliver

WV \PM »LQ^MZ[QÅ KI\QWV¼ \PMa PI^M TWVO KPIUXQWVML 8TI[\QK[ KWV^MZ\QVO QVL][\Za M`XMK\ML \W OZW_ I\ UWZM \PIV XI

BY DR NIALL MARSHALL

but they are also very different in size and the level of this investment. Usually when considering the GCC plastics industry the discussion is limited to the countries with the biggest industries, namely Saudi Arabia, UAE and Qatar who between them produce 23.5 million WRQV RI SRO\ROH¿ QV DQG FRQYHUW million tons but, although much smaller, the other three countries produce around 2 million tons of polymer and also have sizeable plastics converting industries.

THE ‘Middle East’ usually refers to countries by their geographical location at the intersection of Asia, Africa and Europe. At the heart of the ‘Middle East’ are the six countries of the GCC (Gulf Cooperation Council), a common market made up of Bahrain, Kuwait, Oman, Qatar, Saudi Arabia and the UAE with vague The Kuwait plans to form a fully integrated single polymer capacity market. is similar in size

Bahrain is made up of converters The smallest country in the GCC is Bahrain which is less than half the size of Ekurhuleni and has a The economies of to South Africa population about one-third the GCC countries that of the East Rand. are similar insofar %HIRUH WKH µRLO FULVLV¶ ZKLFK EURXJKW as they rely on their vast oil and gas a tsunami of petrodollars to the Middle reserves and have followed similar East and transformed it, or at least parts paths in diversifying their economies by of it, to the ostentatiousness of Dubai, developing the petrochemicals industry, 58

Bahrain was the most developed of the GCC countries with its advanced banking system, UK-based commercial law and world class airport visited by WKH &RQFRUG $OWKRXJK LW ZDV WKH ¿ UVW of the Arab countries to discover oil in the 1930’s, its small size and limited oil reserves mean that its economy did not grow the same way as its larger neighbour Qatar which, although smaller than Gauteng, has vast oil and gas UHVHUYHV DQG D *'3 ¿ YH WLPHV ODUJHU than Bahrain.

Bahrain did have plans to invest in a polypropylene plant, but these were shelved long before global economic crises and oil prices made such projects less viable and so the plastics industry in Bahrain is made up of converters, only one of which is ranked in the top 50 (in size) in the Middle East. It is HVWLPDWHG WKDW DURXQG WRQV RI polymer are processed in Bahrain, mostly pipes and conduit for the

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Liqu

construction industry as well as some packaging and roto moulded water tanks and road barriers.

Kuwait polymer capacity similar size to South Africa Unlike Bahrain, Kuwait is blessed with vast oil reserves and a larger petrochemical industry including polymer production. Kuwait is slightly larger both in area and population than Gauteng and it is home to Equate which produces 825 000 tons of LL/HDPE (a debottlenecking project will increase this to over one million tons) as well as 140 000 tons of polypropylene. So while only accounting for 4% of GCC polymer production the Kuwait polymer capacity is similar in size to South Africa, and there are plans to build polymer plants DV SDUW RI WKH 2OH¿ QV ,,, FUDFNHU DQG UH¿ QHU\ SURMHFW DW $O =RXU This will add 900 000 tons of polyethylene capacity and 450 000 tons of polypropylene, although this project is only expected after 2020. Kuwait also

has a larger converting industry than Bahrain, around double the size, with three converters listed in the GCC Top 50, again mostly pipes, roto moulded WDQNV DV ZHOO DV À H[LEOH DQG ULJLG consumer and industrial packaging.

Oman is home to Octal, one of the largest PET producers in the world Oman is the second largest country in the GCC – as big as the Western Cape, Eastern Cape and Gauteng combined (but still less than 20% the size of Saudi Arabia, which is about double the size of South Africa) and it is home to one of the largest PET producers in the world – Octal. Orpic produces 350 000 tons of polypropylene per year and will almost double this capacity when the new PP plant as part of the $3.6 billion Liwa project comes on-line in 2018-2019 together with 880 000 tpa of LL/HDPE. Apart from Octal, which also produces polyester sheet, Oman is home to a large BOPP plant as well as a number of smaller converters processing around

330 000 tons of polymer per year, mostly for the construction and packaging markets.

With low oil prices and rapidly growing populations relying on government subsidies, all the countries of the Middle East are having to start delivering on WKH µGLYHUVL¿ FDWLRQ¶ WKH\ KDYH ORQJ championed. One of the industries LGHQWL¿ HG DV EHLQJ DEOH WR DGG YDOXH LV the polymer industry and although there is a slow-down in new petrochemical projects being announced, at least partly due to slower growth in the important Asian and Chinese export markets, the GCC plastics converting industry is expected to grow at more than 5% per annum, and because of their relative size, it is in these smaller GGC-countries where this development ZLOO ¿ UVW EH REVHUYHG NIALL.MARSHALL@EVERSPRINGME.COM

JUNE / JULY 2016 59

Middle Eastad feature.indd Liquichiller '016 02.indd5986

2016/06/08 11:27 2016/01/27 10:55 AM

Designed for purpose, the vertical extruder is tightly integrated into the Thermwood CNC router systemâ&#x20AC;&#x2122;s bay to deliver precise resin distribution in this innovative new 3D printing system

How do the various types of dosing device work â&#x20AC;&#x201C; part 2?

Mo explains: The choice of dosing device depends on which materials and method you are using, and what throughput you require.

IN our Dec 2015/Jan 2016 issue we talked about dosing screws and cone valves. Now, letâ&#x20AC;&#x2122;s take a look at some other widely used dosing devices (see Figure 1): Slide-gate valves Disc dosing elements Rotary valves

Figure 1: Schematic of a slide-gate valve, disc dosing element and rotary valve (from left to right)

Like a cone valve, a slide-gate valve is a passive system â&#x20AC;&#x201C; i.e. the material VLPSO\ Ã&#x20AC; RZV RXW RI WKH VXSSO\ KRSSHU Output is controlled by the slide, which can be positioned either vertically or horizontally. Material can be metered continuously or in batches and the volume dosed each time will depend RQ WKH FURVV VHFWLRQDO DUHD RI WKH VOLGH and how long the valve is open. Slide60 JUNE / JULY 2016

MO'S CORNER.indd 60

Answering all your questions about materials management â&#x20AC;&#x201C; Storage, drying, conveying, dosing and mixing â&#x20AC;&#x201C; all these processes have an important part to play in the handling of raw materials for the production of plastics. In Moâ&#x20AC;&#x2122;s Corner, we will tackle troublesome terms and complicated concepts. Whatâ&#x20AC;&#x2122;s more, we will answer your questions about UHDO ZRUOG LVVXHV \RX IDFH LQ \RXU GD\ WR GD\ ZRUN 7KH JRDO LV WR GH¿ QH WHUPV LQ FOHDU language, explain the underlying technology, and provide practical tips for working with the relevant systems. If you have a question â&#x20AC;&#x201C; ask Mo by emailing askmo@moscorner.com

JDWH YDOYHV DUH VXLWDEOH IRU JUDQXODU DQG IUHH Ã&#x20AC; RZLQJ SRZGHUV ,I ZRUNLQJ ZLWK PDWHULDOV WKDW GR QRW Ã&#x20AC; RZ ZHOO RQ WKH RWKHU KDQG \RX UXQ WKH ULVN RI WKH material sticking or clumping together RIWHQ FDOOHG ³EULGJLQJ´ 7R DYRLG WKLV DQ DGGLWLRQDO GHYLFH WKDW SRVLWLYHO\ IHHGV WKH material is necessary. Slide-gate valves FDQ EH XVHG IRU VPDOOHU DQG ODUJHU material throughputs; however, they are RQO\ VXLWDEOH IRU JUDYLPHWULF EDWFK GRVLQJ systems. Synchronous operation is not possible, making a downstream mixer a must. (See Figure 2)

Figure 2: Schematic of a slide-gate valve

7KH GLVF GRVLQJ XQLW DQG WKH URWDU\ valve are based on the same concept: they actively meter the material by enclosing the required volume in chambers â&#x20AC;&#x201C; similar to measuring using a cup or tablespoon when cooking.

And just like in the kitchen, any H[FHVV PDWHULDO LV ³OHYHOHG RII´ EHIRUH GRVLQJ 7KLV PHWKRG LV DOVR NQRZQ DV ³GLJLWDO YROXPHWULF´ EHFDXVH ZKHQ WKH WHFKQRORJ\ ZDV LQ LWV LQIDQF\ RU LQ WKH FDVH RI YHU\ VLPSOH V\VWHPV WKH RQO\ way to create discrete volumetric units was to use entire chambers. Depending on the design, todayâ&#x20AC;&#x2122;s systems are FDSDEOH RI IDU JUHDWHU SUHFLVLRQ $QG you can achieve even more precise measurements by adjusting the dosing device to the required throughput.

Both the disc dosing unit and the rotary valve can meter material continuously or LQ EDWFKHV 7KH YROXPH GRVHG LQ D JLYHQ SHULRG RI WLPH GHSHQGV RQ WKH YROXPH RI WKH FKDPEHU DQG WKH URWDU\ VSHHG RI WKH wheel. Both devices can process granular DQG IUHH Ã&#x20AC; RZLQJ SRZGHUV DQG DUH VXLWHG to dosing very small to medium material WKURXJKSXWV ,I \RX DUH XVLQJ PDWHULDO WKDW GRHV QRW Ã&#x20AC; RZ ZHOO \RX ZLOO QHHG DGGLWLRQDO HTXLSPHQW WR SRVLWLYHO\ IHHG WKH PDWHULDO 7KLV DOORZV \RX WR HQVXUH HDFK FKDPEHU LV ¿ OOHG WR WKH VDPH GHJUHH %RWK dosing elements are deployed primarily in volumetric systems. (See Figure 3)

Figure 3: Powder dosing station with a disc dosing unit, featuring an agitator to eliminate material bridging and an additional disc to HQVXUH WKH GRVLQJ FKDPEHUV D FRUUHFWO\ ¿ OOHG

$ YDULHW\ RI GLVF HOHPHQWV DQG URWDU\ YDOYHV DUH DYDLODEOH IRU SURFHVVLQJ D UDQJH RI WKURXJKSXWV DQG PDWHULDOV In addition, disc dosing units can EH ¿ WWHG ZLWK D EODGH IRU OHYHOLQJ RII H[FHVV PDWHULDO 7KLV FDQ FXW JUDQXOHV LI UHTXLUHG HQVXULQJ HDFK FKDPEHU LV ¿ OOHG FRUUHFWO\ DQG HQKDQFLQJ WKH FRQVLVWHQF\ RI WKH YROXPH 7KLV W\SH RI GLVF GRVLQJ GHYLFH LV SDUWLFXODUO\ VXLWDEOH IRU VPDOO YROXPHV RI PLFUR granulate. (See Figure 4) Figure 4: Disc dosing element with an integrated blade for leveling off and cutting the material

â&#x20AC;¢ MOTAN COLORTONIC IS REPRESENTED IN SOUTH AFRICA BY MARITIME MARKETING

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MATERIALS

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([WUHPHO\ Á DW \HW YHU\ VWLII The highly reinforced polyamide 6 is the material of choice because its extremely high VWLIIQHVV HQVXUHV WKDW WKH À DQJHV DUH WLJKW GHVSLWH WKH YHU\ À DW GHVLJQ RI WKH RLO SDQ

Transmission oil pan of polyamide 6 for super sports car 75$160,66,21 RLO SDQV FDQ DOVR EH PDGH RI SRO\DPLGH UDWKHU WKDQ VWHHO VKHHW RU GLH FDVW DOXPLQXP 2QH H[DPSOH LV WKH 6 WURQLF WUDQVPLVVLRQ LQ WKH $XGL 5 ,WV RLO SDQ LV PDGH RI 'XUHWKDQ '3 %.9 + () IURP /DQ[HVV ZKLFK LV KLJKO\ UHLQIRUFHG ZLWK JODVV ¿ EUHV ³2XU KLJK WHFK PDWHULDO LV WKH PDWHULDO RI FKRLFH EHFDXVH LWV H[WUHPHO\ KLJK VWLIIQHVV HQVXUHV WKDW WKH À DQJHV DUH WLJKW GHVSLWH WKH YHU\ À DW GHVLJQ RI WKH RLO SDQ )XUWKHUPRUH LW LV YHU\ ZHOO VXLWHG IRU ZHOGLQJ WR D SRO\DPLGH IURP ZKLFK WKH RLO ¿ OWHU FRYHU LV PDGH ´ VDLG )UDQN .UDXVH D VSHFLDOLVW IRU RLO EHDULQJ SRO\DPLGH HQJLQH FRPSDUWPHQW FRPSRQHQWV DW /DQ[HVV 7KH V\VWHP VXSSOLHU IRU WKH FRPSOHWHO\ DVVHPEOHG WUDQVPLVVLRQ RLO SDQ LV ,%6 )LOWUDQ *PE+ LQ 0RUVEDFK *HUPDQ\ Low tendency to creep and warp 7KH RLO SDQ LV OHVV WKDQ PP WDOO HQDEOLQJ WKH HQWLUH HQJLQH WR EH PRXQWHG LQ D ORZHU SRVLWLRQ 7KLV ORZHUV WKH YHKLFOH¶V FHQWUH RI JUDYLW\ ZKLFK FRQWULEXWHV WR WKH RXWVWDQGLQJ JULS DQG URDG KDQGOLQJ RI WKH $XGL 5 $QRWKHU FRQVHTXHQFH RI WKH À DW RLO SDQ LV D ORZ À DQJH KHLJKW ,I D µQRUPDO¶ SRO\DPLGH ZHUH XVHG IRU WKH LQMHFWLRQ PRXOGLQJ RI WKH RLO SDQ WKH À DQJHV ZRXOG FUHHS DQG GHIRUP RQ H[SRVXUH WR VHDOLQJ IRUFH DQG WKXV OHDN ³2XU KLJKO\ ¿ OOHG SRO\DPLGH KDUGO\ FUHHSV DW DOO (YHQ DW

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:RUOG À UVW FDU URRI IUDPH PDGH IURP QDWXUDO À EUH Tough, heat-resistant lightweight components using water-based binder TOGETHER with the International Automotive Components Group (IAC), a global leading supplier to the automobile industry, BASF has developed the ZRUOGZLGH ¿ UVW URRI IUDPH IRU FDUV WKDW LV HQWLUHO\ PDGH RI QDWXUDO ¿ EUH 7KH $FURGXU® 950 L binder by %$6) HQVXUHV WKH QHFHVVDU\ ORDGLQJ FDSDFLW\ DQG KHDW UHVLVWDQFH RI WKH OLJKWZHLJKW FRPSRQHQW $V DQ DOWHUQDWLYH WR SKHQROLF UHVLQV WKH water-based and low-emission binder VWUHQJWKHQV WKH QDWXUDO ¿ EUHV DQG HQDEOHV DQ HQYLURQPHQWDOO\ FRPSDWLEOH dimensionally stable and, above all, OLJKWZHLJKW VROXWLRQ IRU FDU URRI IUDPHV The IAC FiberFrame lightweight

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Acrodur® 950 L binder by BASF provides an environmentally compatible, dimensionally stable and, above all, lightweight solution for car roof frames

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MATERIALS

Polyamide resonator makes hybrid sports car sound good 3URYLGHV ORQJ WHUP UHVLVWDQFH WR KLJK WHPSHUDWXUHV DJJUHVVLYH Ã&#x20AC; XLGV plug-in hybrid sports car is equipped with a sound modelling resonator made of DuPontâ&#x20AC;&#x2122;s high temperatureand chemicalresistant Zytel PLUS polyamide resin.

Thanks to the choice of Zytel PLUS, the resonator has long-term resistance to temperatures from -40°C to 190°C as well as hot HQJLQH JDVHV DQG Ã&#x20AC; XLGV DuPontâ&#x20AC;&#x2122;s proprietary SHIELD technology combines several innovations including a new polymer backbone,

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THE BMW i8 plug-in hybrid sports car IHDWXUHV D UHVRQDWRU PDGH RI JODVV ¿ EUH reinforced DuPontâ&#x201E;¢ Zytel® PLUS 95G35 which is tuned to reduce the typical highfrequency air intake sound to a lower level, so improving driving experience.

Zytel PLUS is a high-performance polyamide, produced with DuPontâ&#x20AC;&#x2122;s proprietary SHIELD technology which provides superior long-term resistance to KLJK WHPSHUDWXUHV DQG DJJUHVVLYH Ã&#x20AC; XLGV typical of under-the-hood applications.

Due to its function, the resonator has a relatively large volume, but â&#x20AC;&#x201C; thanks to an optimised design in terms of wall thicknesses and the use of this high stiffness and high strength grade of Zytel PLUS â&#x20AC;&#x201C; it weighs just 1.5kg. Installed EHWZHHQ WKH DLU ¿ OWHU DQG WXUER FKDUJHU in the rear of the i8, it is part of the air management system of the sports carâ&#x20AC;&#x2122;s compact 1.5 litre 3-cylinder petrol engine.

The turbocharged 1.5 litre 3-cylinder petrol engine of BMWâ&#x20AC;&#x2122;s revolutionary i8

The sound modelling resonator made of DuPont Zytel PLUS

SRO\PHU PRGL¿ FDWLRQV DQG D VSHFLDO VHW of additives which can double or triple the service life of standard nylon on exposure to hot environments and aggressive chemicals such as hot oil, automotive coolants and road salt.

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MATERIALS-PLASTICHEM.indd 63

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High impact step-change for transparent injection moulded applications Excellent transparency and very high gloss with no stress whitening &$50(/ 2OH¿ QV KDV ODXQFKHG D QHZ 33 JUDGH &DSLOHQH® &7 $ RIIHULQJ ERWK H[FHOOHQW WUDQVSDUHQF\ DQG KLJK LPSDFW SHUIRUPDQFH IRU LQMHFWLRQ PRXOGHG DSSOLFDWLRQV ,WV DGYDQFHG IHDWXUHV DUH FRPSOHPHQWHG ZLWK JRRG UHVLVWDQFH WR VWUHVV ZKLWHQLQJ KLJK JORVV DQG H[FHOOHQW RUJDQROHSWLF SHUIRUPDQFH &DSLOHQH &7 $ LV D FODUL¿ HG DQG DQWLVWDWLF PRGL¿ HG 33 JUDGH ZLWK D PHOW À RZ UDWH 0)5 SURGXFHG ZLWK 0LOOLNHQ¶V FODUL¿ HU WHFKQRORJ\ 0LOODG® NX™ ,W LV WKH ¿ UVW LQ D QHZ VHULHV XQGHU GHYHORSPHQW E\ &DUPHO WR HQKDQFH LWV H[LVWLQJ SRUWIROLR RI 33 FRSRO\PHUV EDVHG RQ 0LOODG 1; &DSLOHQH &7 $ FRPELQHV H[FHOOHQW À RZ ZLWK PDQ\ RI WKH W\SLFDO DGYDQWDJHV RI 33 UDQGRP DQG KHWHURSKDVLF FRSRO\PHUV WR DFKLHYH RXWVWDQGLQJ WUDQVSDUHQF\ SOXV YHU\ KLJK JORVV ZLWK D JRRG VWLIIQHVV LPSDFW 64 JUNE / JULY 2016

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MATERIALS

of polymer sorting E PolyVision completes our rPET sorting portfolio and positions us as the leading supplier and technology partner for colour, foreign material and polymer removal.â&#x20AC;?

The SORTEX E PolyVisionâ&#x201E;˘ will enable recyclers to provide U3(7 Ă&#x20AC; DNHV IRU KLJK HQG VSHFLÂż FDWLRQV such as for WKH SDFNDJLQJ industry and reinforced components for the automobile industry, where the emphasis is on achieving the lowest contamination, measured in parts per million.

BĂźhlerâ&#x20AC;&#x2122;s pioneering SORTEX E PolyVisionâ&#x201E;˘ optical sorter was revealed at IFAT 2016 show in Munich recently; the system â&#x20AC;&#x201C; which is particularly useful in PET recycling â&#x20AC;&#x201C; offers the plastics industry unrivalled polymer removal for high-end recycling

www.buhlergroup.com

JUNE / JULY 2016 65

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MATERIALS

Clariant presents ColorForward Automotive ÂŽ

66 JUNE / JULY 2016

Trend analysis and colour-design tool offers creative inspiration CLARIANT has released the Automotive Edition of ColorForwardÂŽ 2017. This is the second year Clariant has formatted its colour/trend analysis tool to meet the needs and interests of automotive designers and marketers.

Clariantâ&#x20AC;&#x2122;s ground-breaking ColorForward trend-analysis and colourdesign tool has been released every year since 2006 to help plastic product designers and marketing professionals make more informed colour choices. It presents four global societal trends that FDQ EH H[SHFWHG WR LQĂ&#x20AC; XHQFH FRQVXPHUV and then links them to colours that evoke an emotional response related to each trend.

The Automotive Edition is the work of the Clariant Masterbatches European Automotive Team in collaboration with the colour specialists at the Clariant ColorWorksÂŽ design and technology centres. It presents 20 colours, linked to the four trends, in several different forms: y Large, textured plastic plaques Fibre pompons and yarn wrap cards y (to illustrate carpet and textile options) Small â&#x20AC;&#x2DC;conceptâ&#x20AC;&#x2122; cars moulded in y plastic Leather swatches (new in the 2017 y edition) These samples are packaged in a

&ODULDQWÂśV &RORU)RUZDUG $XWRPRWLYH QHZ PDWHULDOV DQG FRORXUV JLYLQJ D Â&#x192; LQVLJKW LQWR WKH DXWRPRWLYH LQGXVWU\

presentation box and are meant to be handled, rearranged and studied as part of a creative exercise. â&#x20AC;&#x153;We are not trying to teach our automotive customers about colour,â&#x20AC;? explained Laura Carrillo, head of Market Segment Automotive, Clariant Masterbatches Europe. â&#x20AC;&#x153;They are already experts. We want to start a dialogue with them about global societal trends and, at the same time show them these different materials so they become more aware of

possible colour harmony issues. In any case it should be fun and inspirational.â&#x20AC;?

The colours for 2017 are more muted than in years past. People are a bit more IHDUIXO PRUH LQWURVSHFWLYH DQG UHĂ&#x20AC; HFWLQJ the disconnectedness that many seem to be feeling today. In general the colours are softer, darker and even ambiguous. www.clariant.com

SEBS polymers for soft touch medical devices Offer low cost alternative to other thermoplastic elastomers

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FOSTER Corporation, a leading supplier of polymer solutions for the healthcare industry, has introduced ProFlexâ&#x201E;˘ styrene-ethylene butylene-styrene (SEBS) for medical device applications. These polymers offer a low cost alternative to other thermoplastic elastomers with superior elastomeric properties.

Styrene block copolymers (SBCâ&#x20AC;&#x2122;s), including SEBS, offer the greatest value among all thermoplastic elastomers. SBCâ&#x20AC;&#x2122;s SURYLGH GHVLJQ Ă&#x20AC; H[LELOLW\ DQG UHVLOLHQFH properties similar to thermoset rubber, while maintaining desirable processing characteristics of thermoplastics. ProFlex SEBS is suitable for use in conventional injection moulding and extrusion equipment.

Soft touch over-moulding of ProFlex SEBS onto rigid thermoplastic or metal components

provides a high friction, ergonomically friendly surface. Vibration damping and insulating properties make ProFlex SEBS ideally suited for over-moulding of medical instrument handles and grips. Additionally, ProFlex 6(%6 SRO\PHUV DOVR KDYH ORZHU VSHFLÂż F gravity than other engineering thermoplastic elastomers, yielding more parts per weight.

Foster manufactures six standard grades of ProFlex SEBS that meet USP Class VI biocompatibility standards, ranging in Shore hardness of 35A to 85A. These formulations are available in minimum order quantities of 25 pounds. Foster also offers a comprehensive line of tear resistant SEBS grades, as well as a line of low friction SEBS formulation. Minimum order quantities for specialty SEBS materials begin at 50 pounds.

www.fostercomp.com

TEL: +27 (0) 11 462 2990

SOLUTION

MACHINERY (PTY) LTD

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

“One total solution for Injection Moulding”

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

Introducing the Objet500 Connex3 from Stratasys, the world’s only full-color and multi-material 3D printer. Select from incomparably brilliant and consistent colors, plus a full palette of transparent colors — the only 3D printer to offer such a wide array. And it’s the only 3D printer that prints ÀH[LEOH PDWHULDOV LQ D EURDG UDQJH RI VKRUH YDOXHV $OO ZLWK XOWUD ¿QH GHWDLO FUHDWLQJ WKH PRVW WUXH WR OLIH PRGHOLQJ SRVVLEOH 6WUDWDsys is the proven leader in multi-material ' SULQWLQJ For whatever your mind can imagine, visit stratasys.com/Objet500 Connex3.

®

Turning design into Reality faster than you can imagine

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Objet500 &RQQH[

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

2014/03/26 8:33 PM

MATERIALS

Robust, translucent plastic for mobile LED lamps Diffuser of Covestro polycarbonate ensures homogenous light dispersion WORKPLACE lamps have to illuminate the place where they are in use perfectly, while at the same time being robust and working reliably despite a variety of environmental factors. Covestro, formerly Bayer MaterialScience, offers various grades of its MakrolonÂŽ polycarbonate that are ideally suited as construction materials for lamp components and easily satisfy these different requirements. This is demonstrated in the Magnum Future mobile spotlight from Polish lamp manufacturer

Lena Lighting.

7KLV OLJKWZHLJKW ODPS LV Âż WWHG ZLWK HQHUJ\ HIÂż FLHQW /('V DV D OLJKW VRXUFH A diffuser made from Makrolon 2405 HQVXUHV RSWLPDO GLVSHUVLRQ RI WKH /(' OLJKW '\HG ZKLWH WKH WUDQVOXFHQW SRO\FDU bonate is tailor-made for use in light and lamp technology applications. Its high level of translucency and outstanding light-diffusing properties ensure that the diffuser disperses and homogenizes the VSRWV RI OLJKW IURP WKH /('V ZLWK OLWWOH loss. Thanks to the high impact resistance of the material, the diffuser is well protected against impacts.

Another advantage is the low level

of shrinkage and very limited tendency to warpage. Combined with low water absorption, these two characteristics provide a high level of dimensional stability in the diffuser and contribute to the tightness of the whole lamp construcWLRQ 7KDQNV WR LWV JRRG Ă&#x20AC; RZ SURSHUWLHV the product is particularly well suited for FRPSRQHQWV ZLWK ODUJH Ă&#x20AC; RZ SDWK ZDOO thickness ratios. The low melt viscosLW\ HQDEOHV WKH PDWHULDO WR Âż OO WKH PRXOG TXLFNO\ DQG FRPSOHWHO\ DQG WKH Âż QLVKHG parts are easily demoulded. â&#x20AC;˘ Plastichem is Covestroâ&#x20AC;&#x2122;s distribution agent for SA www.covestro.com www.plastichem.co.za

7KH 0DJQXP )XWXUH PRELOH VSRWOLJKW IURP /HQD /LJKWLQJ LV Âż WWHG ZLWK HQHUJ\ HIÂż FLHQW /('V DV D OLJKW VRXUFH $ GLIIXVHU PDGH IURP Makrolon 2405 from Covestro, formerly Bayer MaterialScience, HQVXUHV RSWLPDO GLVSHUVLRQ RI WKH /(' OLJKW

Large size containers: one stop solutions WHEN it comes to developing an application in PET containers, SIPA has the HTXLSPHQW WR SURGXFH WKH FRQWDLQHU Âą Âż OO LW and palletize it â&#x20AC;&#x201C; as well as the technology, material knowledge and design expertise to take an initial concept all the way through to reality.

SIPA can provide truly independent advice on the best resin to use, it can design the optimum preform, it can act as D SDUWQHU LQ Âż QH WXQLQJ WKH GHVLJQ RI WKH container itself, and it can produce and test prototypes.

This is a unique offering that applies to large containers (up to 30 litres and beyond) as well as bottles and jars.

SIPA can help design a container with improved ergonomics to make it easier to lift: one innovative example is the Grip Easy design. Besides the traditional inserted side handle, SIPA designed two new shapes of returnable containers for dispensers that enhance the convenience

68 JUNE / JULY 2016

on 5-gallon bottle handling.

SIPA can also suggest subtle changes WKDW HQDEOH PRUH FRQWDLQHUV WR Âż W RQWR D pallet â&#x20AC;&#x201C; vertically as well as horizontally so the pallet is full of bottles, rather than full of air. As a result the logistic cost can be dramatically reduced with any impact on the market distribution.

SIPA has also developed several beer bottle sizes (330ml and beyond) with barrier additives, some intended for pasteurization processes which expose the bottle to high temperatures. SIPA has processed various PET kegs based on different technologies

that required an indepth knowledge of barrier additives and permeation factors.

The company has also developed VHYHUDO OLJKW QHFN Âż QLVKHV DV ZHOO DV bottle body shapes, and is also concentrating some of its research on bases for further lightweighting of bottles for sparkling products. www.sipa.it

First hybridmoulded rear bumper beam

+21'$ KDV LQWURGXFHG WKH ZRUOG ¿ UVW development of hybrid-moulded rear bumper beam in the hydrogen electric vehicle ‘Clarity Fuel Cell’ using one-shot moulding technology. The component is made of Tepex, continuous – and ORQJ ¿ EHU UHLQIRUFHG WKHUPRSODVWLF composites with PA 6 matrix from Lanxess subsidiary Bond-Laminates, in combination with Durethan, a PA 6 high-tech plastic grade from Lanxess.

The worldwide automotive industry is facing increasing restrictions on CO2 emissions and therefore automakers

actively develop zero emission vehicles such as EV (electric vehicles) and FCV. This has resulted in developing a one-shot hybrid moulding process for making large components out of its SODVWLF DQG JODVV ¿ EUH FRPSRVLWH 7KH result is approximately 50% weight reduction compared to the metal VROXWLRQ DQG D VLJQL¿ FDQW VWUHDPOLQLQJ of the production process.

(PHOTO: HONDA MOTOR CO)

www.lanxess.com

JUNE / JULY 2016 69

Dave Moore: 083 675 8325 Email: mouldbasesa@gmail.com

STANDARD FEATURES • Energy saving servo system • Proportional back pressure adjustment 1SYPH [EXIV ¾ S[ VIKYPEXSV • 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

EQUIPMENT

The new Gapa, GG 1100, system was rolled out at the in-house show in Johannesburg ZLWK DOO WKH Ă&#x20AC; DVKOLJKWV DQG JOLW] RI D QHZ Formula 1 model PHOTO: LOWRIE SHARP

Latest version of

Gapa machine from Technimac New machine offers far easier operation BAG-MAKING machine manufacturer Technimac held an open-house show at its plant in Wynberg, Johannesburg, recently at which it introduced the latest version of the Gapa, the GG 1100 bottom seal bag-maker.

The GG (GĂźnter Gapa) machine has a proven system, with the recent innovations â&#x20AC;&#x201C; including the use of additional servo motors and an LPSURYHG Ă&#x20AC; \LQJ NQLIH FXWWLQJ V\VWHP Âą allowing faster operation and reducing maintenance requirements even further.

Technimac has continued the development of the GĂźnter-Gapa bottom seal system since the model since introducing the line into its machinery range a number of years ago.

Âł7KH UHVXOWV VLJQLÂż FDQWO\ EHQHÂż W ease of operation,â&#x20AC;? said Technimac MD Gerhart Mischinger.

Recent changes include: the machine frame has been extended to accommodate attachments such as hole punches; the frame height was lowered to be more ergonomic, and improved ease of access for operators; design of the slit seal blades has EHHQ PDUNHGO\ LPSURYHG EHQHÂż WWLQJ slit seal quality and consistency; and new servo packages give prospective purchasers a choice between Emerson and Lenze (both systems are now Windows-based and backed by excellent after sales service, plus with an extended 12 months warrantee

The new machine is being referred to as â&#x20AC;&#x2DC;Robbie Butschiâ&#x20AC;&#x2122;s grandchildâ&#x20AC;&#x2122;, after Robert Butschi who developed the original Gapa system while still at Adron in Johannesburg in the 1980s.

Itâ&#x20AC;&#x2122;s hard to believe that, although the same basic bag making system is still in use, the technology has been continually improved since. â&#x20AC;&#x153;Technimac will continue the quest to be in the forefront of bag making technology,â&#x20AC;? said Mischinger, whoâ&#x20AC;&#x2122;s at the heart of the process, interpreting suggestions and requests from machine users that have motivated most of the changes.

www.technimac.co.za

70 JUNE / JULY 2016

EQUIP-TECHNIMAC+ALPLA.indd 70

2016/06/08 11:30

Alpla rewarded for revolutionary EBMx development Foaming technology to reduce plastic consumption and weight ALPLA, a leading packaging moulder based in Hard, Austria, has received two awards for its innovative foaming technology in extrusion blow moulding (EBM). After receiving the Smart Packaging award from the Austrian government in 2014, this sustainable procedure has now also received the internationally renowned PackTheFuture and WorldStar awards.

Alpla has been working with Unilever and MuCellÂŽ to develop foaming technology in extrusion blow moulding (EBM) for around four years. The result is the successful application of foaming technology in the production of EBM plastic bottles. In microcellular foaming technology, a gas is injected into the

middle layer of the bottle wall. This creates bubbles in the material, similar to the structure of a honeycomb. Plastic consumption and weight are reduced by up to 15 per cent.

Alpla has been producing shower gel bottles for Unilever using this procedure VLQFH $FFRUGLQJ WR LWV RZQ Âż JXUHV Unilever will save up to 275 tons of plastic per year across Europe for this product line. The technology will be installed in other Alpla sites soon for customers in the body care and household products industries.

The process is a purely physical one and does not require any chemical additives. The bottles are therefore fully recyclable. â&#x20AC;&#x153;The thickness of the

material is reduced, but the thickness of the wall remains the same. The bottles therefore have practically the same high level of functionality in the bottling plants and during transportation and handling as conventional EBM bottles,â&#x20AC;?

RenĂŠ Plattner, head of packaging management at Alpla, explains. For the end user, the bottles look and function exactly the same.

ALPLA received the PackTheFuture award in Paris in November 2015. The award aims to promote the innovation potential and sustainability of plastic packaging in Europe.

www.advantageaustria.org JUNE / JULY 2016 71

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www.rawmacplastics.co.za

EQUIP-TECHNIMAC+ALPLA.indd 71

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Delene Williams

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- passionate about the plastic industry.

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

Supplier of:

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Injection Moulding Machine

Servo Klockner

Rebuild

JIANGSU VICTOR MACHINERY

REP offers its customers a competitive and SUR¿ WDEOH WXUQNH\ VROXWLRQ IRU UHGXFHG VL]H on the automatic stripping of EPDM pipe seals of any size

Automatic stripping of core-moulded pipe seals REP international offers simple, economic solution REP international offers a simple and economic solution to a problem that is familiar to manufacturers of pipe seals.

When performed manually, the stripping SURFHVV LV RIWHQ YHU\ GLI¿ FXOW DQG productivity is considerably impacted; when being performed automatically, the challenge is to do it quickly without any heat loss and without production stoppages, due to overlapping seals.

The solutions generally implemented in the industry today, such as moulding with two sets of rotating core bars, require a very large press opening stroke to perform the core bar rotation outside the press and/or front and rear stripping units that lead to considerable

space requirements and very high capital costs.

REP offers its customers a FRPSHWLWLYH DQG SUR¿ WDEOH WXUQNH\ solution for reduced size on the automatic stripping of EPDM pipe seals of any size.

The solution can be matched to any seal size. It is based on conveyor belts equipped with rotating belts, allowing for the individual stripping of the seals. The spacing between the bottom and top belts can be easily adjusted, thanks to a mechanical stopper system,

Project example for a pipe seal of a nominal diameter of 50mm and 100mm The equipment – A REP V69Y50 injection moulding machine with a clamping force of 400 tons, including a kit specially designed for automatic stripping, a vacuum system, hydraulic top and bottom ejectors and ancillary heating comprising heating elements inside the cores to hold the core temperature during the stripping process. The tooling consists of a 112-cavity mould (2 cores) and a 2-nozzle cold runner block for the part of a nominal diameter of 110mm. For the part of a nominal diameter of 50mm, we use a 208-cavity mould (4 cores) and a 4-nozzle cold runner block

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EQUIPMENT The cycle â&#x20AC;&#x201C; After the mould opens, the ejectors move out to lift the framesupported cores. The cores move to the rear of the press (electrical movement) and simultaneously the rotation of the two belts allows for sequential stripping of the pipe seals. The runners are automatically stripped and separated from the parts during the core bar translation: Metal guides are used to separate the runners as the core bars index on the kit. The runners are recovered in a receptacle inside the cage, whereas the parts are recovered at the discharge end of the cage extension in a receptacle or using an automatic conveyor. When the cores 7KLV QHZ 0,* move inside press, a laser detection unit is activated to guarantee seal adheres to the cores. If this is the case, an alarm signals for operator action at the SHUPDQHQW GHFRUDWLRQ RI URWR PRXOGHG SRO\ROH¿no Q SODVWLFV KDV end of the in-stroke of the cores.

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thus making it possible to switch over from one seal type to another. The rotation speeds of the top and bottom belts can also be adjusted independently.

The belts are designed in compliance with a multi-layer technology, in order to ensure the reliability of the stripping process and the speed, while observing

the quality of the stripped parts. In addition, the core bar in/out speeds on the kit (low/high speed, depending on the stroke limit) can be controlled. The kit is fully retractable for easy access to the cores on the rear side of the machine, allowing maintenance operations or more rapid production changes.

The result â&#x20AC;&#x201C; The stripping time reached for both types of seals was approximately 40 seconds. This is a simple, rugged solution that is both reliable and easy to control during production.

REP is represented by Carst & Walker

www.repinjection.com JUNE / JULY 2016 75

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EQUIPMENT

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thermoformed

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www.illig.de

Allows printing on plastic substrates that can be formed into 3-D shapes ILLIG Maschinenbau GmbH & Co KG, Heilbronn, Germany, demonstrated a digital printing technology using ultraviolet inkjet inks that allows thermoplastic sheet to be printed before thermoforming.

Illig demonstrated the technology on a UA 100g thermoforming machine, which formed a custom-designed shell of a replica sports car. It created the car from a 3mmthick PET glycol copolyester (PETG) pre-printed sheet, using a maximum forming area of about 96.5cm by 66cm. )XMLÂż OP GHYHORSHG WKH LQNMHW FRORXUV VSHFLÂż FDOO\ IRU thermoforming decorated thermoplastics. Because the colours harden when exposed to ultraviolet radiation, the printed sheet FDQ EH IRUPHG ULJKW DZD\ $FFRUGLQJ WR )XMLÂż OP WKH WHFKQRORJ\ allows printing on plastic substrates that can be formed into 3-D shapes. The company says that the process can create branded items in short runs and single-batch orders and with lower set-up costs than are typical with screen printing. ,OOLJ VDOHV PDQDJHU -RFKHQ %XW] VD\V WKDW ,OOLJ DQG )XMLÂż OP have been collaborating on the technology for about a year. He says previous attempts to thermoform thermoplastics printed with ink have not been successful. The key to the successful application of this technology is the ink, which does not crack RU Ă&#x20AC; DNH RII WKH WKHUPRIRUPHG SDUWV 3ULQWLQJ RQ WKH SODVWLF sheets is done in a separate stage prior to the thermoforming

process, $Q ,OOLJ WKHUPRIRUPLQJ on printing PDFKLQH FUHDWHG WKLV machines FXVWRP GHVLJQHG VKHOO RI supplied by D UHSOLFD VSRUWV FDU )XMLÂż OP Butz says that Illig ran successful trials on its UA-g series machines for six months prior to the demonstration. No alterations on the thermoforming machine were necessary, but certain features on the machine, particularly the chain drive that carries the sheet through the thermoformer and centering devices responsible for properly positioning the sheet in the press, help ensure the success of processing the pre-printed sheet, he says.

Single sheets can be fed into the machine and positioned manually, or sheets can be fed and positioned automatically with a loading and discharging device. The UA 100g machine used in the demonstration was equipped with servo drives for all machine movements. Butz explains that the servo drives on the forming tables provide precise movements of the sheet and the tool during the thermoforming process, as well as precise movements of the forming table during the demoulding process.

The UA-g series is an automatic universal thermoformer suitable for thermoforming from sheet and roll stock. Illig offers a number of other sizes, including the UA 150g, UA 155g, UA 200g, and UA 225g.

&XVWRP PDFKLQHU\ GHVLJQ IRU Ă H[LEOH JODVV VXEVWUDWHV Versatile unwinding, conveyance system allowing wide variety of downstream SURFHVVLQJ IRU Ă&#x20AC; H[LEOH JODVV WHAT began as a conceptual idea several years ago between a known leader in the glass industry and American company New Era Converting Machinery, has today become a complete, clean-room ready turnkey system for conveying and processing Ă&#x20AC; H[LEOH JODVV VXEVWUDWHV The glass manufacturer originally approached New Era with their ideas

DQG VSHFLÂż F FKDOOHQJHV 1HZ (UD FDPH back to them with the beginnings of what would become a versatile unwinding and conveyance system allowing a wide variety of downstream processing for the Ă&#x20AC; H[LEOH JODVV $IWHU VRPH FROODERUDWLYH Âż QH WXQLQJ EHWZHHQ WKH FOLHQWV HQJLQHHUV DQG 1HZ (UD WKH Âż QDO GHVLJQ ZDV engineered to operate with the high degree of precision and repeatability that the client required. â&#x20AC;&#x153;This project presented numerous challenges from a web handling perspective,â&#x20AC;? said Paul Lembo, vice president at New Era. â&#x20AC;&#x153;The ability to XQZLQG DQG FRQYH\ WKH Ă&#x20AC; H[LEOH JODVV substrates with as little tension as possible, while still maintaining control of the substrate for downstream processing was paramount.â&#x20AC;?

7KH SRWHQWLDO IRU Ă&#x20AC; H[LEOH JODVV LV very exciting. Its uses in markets 76 JUNE / JULY 2016

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such as portable electronics and building products are already well documented, but it seems the potential uses for these high quality, durable products are growing every day. The EHQHÂż WV RI Ă&#x20AC; H[LEOH JODVV LQFOXGH RSWLFDO transmission, surface roughness, thermal stability and moisture/gas barrier properties, all of which are well suited for electronics, both in the manufacturing process and for the devices end use.

Flexible glass can be used in a variety of display types for portable electronics. :KHWKHU WKH GLVSOD\ LV Ă&#x20AC; DW FXUYHG RU GHVLJQHG WR Ă&#x20AC; H[ DQG WDNH RQ GLIIHUHQW shapes, the properties described DERYH PDNH JODVV D QDWXUDO Âż W IRU WKHVH products. The potential to fold up a tablet or unroll the screen of a phone opens new doors for the portability of devices which we have come to rely on more and more for all types of information.

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2016/06/08 11:32

Governor Theo Bovens representing the Dutch Province of Limburg and Peter Borman, Regional Director Technology Affairs Europe inaugurated the new SABIC Research building in Geleen

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WORLD NEWS

â&#x20AC;&#x201C; a lesson in waste management &RQVXOWLQJ ZLWK ORFDO DUFKLWHFWV WKH JURXS GHVLJQHG WKUHH GLIIHUHQW PRGHOV WKDW KDYH VXI¿ FLHQW Ã&#x20AC; H[ WR EH HDUWKTXDNH UHVLVWDQW (DFK KRPH ZLOO EH GHOLYHUHG FRPSOHWH ZLWK SOXPELQJ DQG HOHFWULFLW\ DORQJ ZLWK VWDQGDUG GRRUV DQG ZLQGRZV 7KH UH XVH RI LWV FRUH PDWHULDOV DOORZV WKH 3ODVWLF %RWWOH 9LOODJH WR EXLOG KRPHV LQ D IUDFWLRQ RI WKH WLPH DQG DW D KXJH VDYLQJV LQ WKH FRVW RI UH FRQVWUXFWLRQ FRPSDUHG WR WKH

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One litre of light WHAT if something as simple as an ROG SODVWLF ERWWOH ¿ OOHG ZLWK ZDWHU FRXOG PHDQ WKH GLIIHUHQFH EHWZHHQ OLJKW DQG GDUNQHVV" 5XGLPHQWDU\ DV LW PD\ VRXQG WKH DOPRVW QR FRVW VROXWLRQ LV XSOLIWLQJ WKH TXDOLW\ RI OLIH RI WKRXVDQGV RI LPSRYHULVKHG IDPLOLHV DURXQG WKH ZRUOG ZKR KDYH QR DFFHVV WR HOHFWULFLW\ DQG XVH GDQJHURXV NHURVHQH ODPSV LQGRRUV 7KHVH PDNHVKLIW VRODU ODPSV EDVLFDOO\ DFW DV VN\OLJKWV DQG UHÃ&#x20AC; HFW DQG DPSOLI\ WKH UD\V RI WKH VXQ GXULQJ GD\OLJKW KRXUV ± HIIHFWLYHO\ SHUIRUPLQJ WKH ZRUN RI LQGRRU OLJKWEXOEV ± EXW ZLWKRXW XVLQJ DQ\ HOHFWULFLW\ DW DOO 7KH RUJDQL]DWLRQ behind the installation of the bottle OLJKWV ,VDQJ /LWURQJ /LZDQDJ RU /LWHU RI /LJKW ZDV VWDUWHG E\ )LOLSLQR VWXGHQW ,OODF 'LD] MXVW D IHZ \HDUV 7KH µOLJKW EXOE¶ LV PDGH E\ ¿ OOLQJ RQH OLWUH SODVWLF ERWWOHV ZLWK ZDWHU DQG EOHDFK 7KH

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2016/06/08 11:33

DuPontâ&#x20AC;&#x2122;s largest compounding plant to launch in China DUPONT Performance Materials will launch its newest and largest compounding plant globally in Shenzhen, China, at the end of June.

The plant will boast state-of-the-art compounding lines producing DuPontâ&#x20AC;&#x2122;s SRUWIROLR RI ULJLG DQG Ă&#x20AC; H[LEOH SRO\PHUV DQG elastomers, including Zytel and Zytel HTN nylons, Crastin polybutylene terephthalate, Delrin acetal, Bynel adhesives and Fusabond compatibilizers.

The company also has a 33,000m2 China research and development centre located alongside its Shanghai innovation centre, ZKLFK UHFHQWO\ DGGHG DQ LQMHFWLRQ PRXOGLQJ press with 450 tons of clamping force.

AROUND THE WORLD

INJECTION machine maker Engel Holding GmbH is investing $9.2 million to expand capacity at its Shanghai factory, saying it sees continued growth in the higher end of the market in China.

Engel announced a doubling of capacity at the Shanghai plant in 2012, and said this latest investment will enlarge machining FDSDFLW\ DQG SURYLGH PRUH RIÂż FH VSDFH DQG room for its training programs.

Construction has started and the new machining centre is scheduled to be Âż QLVKHG E\ $SULO $VLD DFFRXQWV IRU almost 25% of Engelâ&#x20AC;&#x2122;s $1.38 billion in total sales, or about $336.5 million.

Omnium to buy Faurecia exteriors unit FAURECIA group is to sell its automotive exteriors business worldwide to Compagnie Plastic Omnium. An MoU to this affect has been signed by the French groups. The exteriors business manufactures mainly bumpers and front end modules and had sale of over â&#x201A;Ź2-billion in 2014 and employs about 7700 people at 22 sites.

Plastic Omnium operates one business in 6RXWK $IULFD D MRLQW YHQWXUH ZLWK ,QHUJ\ LQ Brits, Inergy Automotive Systems.

Bag fee bill passed in New York SUPERMARKETS and most shops in New York City may soon be charging shoppers 5 cents for disposable bags. The New York City Council voted in favour to have stores charge 5c (equivalent to R0,75) for plastic and paper bags, with some exceptions. :KHQ VLJQHG E\ 0D\RU %LOO GH %ODVLR ZKR supports the measure, it will take effect on 1 October. Twenty council members stood to voice their thoughts on the bill before the vote, a rare occurrence at a council meeting. Opponents of the bill called it a tax, but also took issue with the fact that businesses will keep the fee revenue.

Bedazzling bottles FROM afar, these fountains at Londonâ&#x20AC;&#x2122;s Trafalgar Square may look like theyâ&#x20AC;&#x2122;re ringed by beautiful discs of light, but donâ&#x20AC;&#x2122;t be fooled. Take a step closer and youâ&#x20AC;&#x2122;ll see that these glowing rings are actually made up of thousands of plastic bottles. &RPPLVVLRQHG E\ WKH /XPLHUH /RQGRQ OLJKW IHVWLYDO /X]LQWHUUXSWXV Âż OOHG the Trafalgar fountains with 13,000 recycled plastic bottles held within doughnutshaped self-illuminated round structures. The installation was created to spread awareness on the global issue of plastic waste. Installations were put on show at Trafalgar Square from 14-17 January, after which the bottles were reused or turned over to the cityâ&#x20AC;&#x2122;s recycling plants.

Source: Inhabitat.com

www.inhabitat.com

Engel invests $9 million to expand Shanghai plant

WORLD NEWS

Rotomoulder uses â&#x20AC;&#x2DC;secret sauceâ&#x20AC;&#x2122; to develop new pallet material AFTER a 10-year materials development period, US Indiana-based Paxxal Inc has licensed a manufacturer in Saudi Arabia running a startup plant to rotationally mould its pallets â&#x20AC;&#x201C; using high density polyethylene and silica.

According to PlasticsNews, Paxxal developed the process, which uses automated rotomoulding equipment and Paxxalâ&#x20AC;&#x2122;s expertise in blending the materials, using a SURSULHWDU\ ÂľXQLÂż HUÂś 0LFKDHO /DLEOH VDOHV GLUHFWRU IRU WKH (DVWHUQ 8QLWHG 6WDWHV FDOOHG WKH XQLÂż HU ÂłRXU VHFUHW VDXFH´ Âł:HÂśUH QRW MXVW DQRWKHU SODVWLF SDOOHW FRPSDQ\ :HÂśUH EULQJLQJ D QHZ PDWHULDO WR WKH PDUNHW ´ /DLEOH VDLG 7KH 6DXGL $UDELD SODQW EHJDQ PDNLQJ FRPPHUFLDOO\ UHDG\ products late March.

The rotomoulded pallet has a solid core of a lightweight, but bone-like structure.

It works well in low-temperature environments such as freezers for food and pharmaceutical products, or chemicals that must be kept at a constant temperature.

One of the biggest hurdles of plastic pallets is when you put them in a freezer as the surface can get glossy and slippery. Because Paxxalâ&#x20AC;&#x2122;s pallet is Âż OOHG LW EHKDYHV differently in that environment.

Paxxal is using HDPE made by SABIC. The outer skin is virgin HDPE and the high-level silica produces a hardfoam core. www.inhabitat.com

80 JUNE / JULY 2016

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2016/06/08 11:33

Our O ur W Winning inning F Formula ormula S Sets et s U Us sA Apart part ELASTOMERS

PLASTICS & COMPOSITES

ACM CR EPDM Epichlorohydrin FKM HNBR HTV Silicone IR NBR NR PVC/NBR Blends SBR & BR

ABS Acetal Additives Composites CPE CSM EVA HIPS & GPPS Nylon PC PVC TPE & TPV TPU

FILLERS & ADDITIVES

AUXILIARIES & SERVICES

Aluminas Antimony Products Blowings Agents Carbon Blacks Flame Retardents Hydrocarbon Resins Magnesium Oxide Masterbatches MC & PE Waxes Mineral Fillers Peroxides Process Aids Rubber Chemicals Silanes Silica Sulfur Zinc Oxide

Curing Bladder Machinery Other Services Release Agents Release liners Spares

ANCHOR CHEMICALS Batch Off Bonding Systems Coated Powders Factice Masterbatching Process Aids Toll Mixing

P O LY M E R S D I V I S I O N

Johannesburg Jenny Warner Velogan Muthayan (T) 011 489 3600 (F) 011 489 3601

Durban Jaco Smith Paul Rose Ron Dunwoodie Prakash Kalipersad (T) 031 313 8500 (F) 031 313 8516

Cape Town Pieter Snyman (T) 021 506 4598 (F) 021 506 4561

www.carst.co.za

Port Elizabeth Kathy Garde (T) 041 3999 529 (F) 041 3999 401

DIARY

Graphene World Summit pioneering global use of graphene Ultra-fine miniature material reputed to be strongest compound ever discovered GRAPHENE is emerging as one of the most promising materials ever discovered â&#x20AC;&#x201C; one that has the potential to play a vital role in the development of advanced technologies in key industry segments, including computing, electronics, energy, defence, health care, telecommunications and transportation.

In simple terms, graphene is a thin layer of pure carbon; it is a single, tightly packed layer of carbon atoms that are bonded together in a hexagonal honeycomb lattice.

In more complex terms, it is an allotrope of carbon in the structure of a plane of sp2 Graphene has various applications, especially in emerging and small electronics, but researchers are still coming up with ways to produce high-quality graphene in large quantities

bonded atoms with a molecule bond length of 0.142 nanometres. Layers of graphene stacked on top of each other form graphite, with an interplanar spacing of 0.335 nanometres.

It is the thinnest compound known to man at one atom thick, the lightest material known (with 1 square metre coming in at around 0.77 milligrams), the strongest compound discovered (between 100-300 times stronger than steel and with a tensile stiffness of 150,000,000 psi), the best conductor of heat at room temperature (at (4.84Âą0.44) Ă&#x2014; 10^3 to (5.30Âą0.48) Ă&#x2014; 10^3 :Ä PĂ­ Ä .Ă­ DQG DOVR WKH EHVW FRQGXFWRU RI electricity known (studies have shown electron mobility at values of more than 15,000 FP Ä 9Ă­ Ä VĂ­

82 JUNE / JULY 2016

WasteCon to showcase the latest in waste management

A DECADE OF SERVICE TO THE

PLASTIC PIPE INDUSTRY SAPPMA proudly presents

PIPES X Date: One day conference: Tuesday 6 September 2016 Address: Bytes Conference Centre, Midrand Registration Fee: FEES UNCHANGED FOR THIRD YEAR RUNNING: Non-members: R1900 per person (excl VAT) Members: R1200 per person (excl VAT) Registered Engineers R1200 per person (excl VAT) E-mail: admin@sappma.co.za

CPD accredited event

WITH the recent waste management policy and legislative changes in South Africa, the Institute of Waste Management of Southern Africaâ&#x20AC;&#x2122;s (IWMSAâ&#x20AC;&#x2122;s) biennial conference, WasteCon, will set the stage for debate and knowledge sharing. The conference is set to take place from 17-21 October at Emperorâ&#x20AC;&#x2122;s Palace in Johannesburg. A wide range of exhibitors that will showcase their diverse waste management products and services. The theme is â&#x20AC;&#x2DC;The Changing Face of Waste Managementâ&#x20AC;&#x2122;.

7KH NH\QRWH VSHDNHU IRU WKH HYHQW LV 7RUEHQ .ULVWLDQVHQ 9LFH 3UHVLGHQW DW &2:, $ 6 EDVHG LQ 'HQPDUN .ULVWLDQVHQ will delve into the current status of the waste management industry, legislation and practice in Europe. He will review the consequences of the current European waste management OHJLVODWLRQ LQFOXGLQJ WKH UROH RI WKH SULYDWH VHFWRU .ULVWLDQVHQ will also discuss the South African waste landscape, the recent policy and legislative changes and the viability of European policy in South Africa.

Other thought-provoking topics that will be discussed at the conference include: e-waste; waste-to-energy; the role of industrial symbiosis in South Africa; the future of employees in the waste industry; leachate treatment; and the potential for new recycling industries from under-utilised waste streams. www.wastecon.co.za

COM I UP NG

Automotive hermoplastics

This remarkable new material is the subject of the Graphene World Summit, taking place 19-20 September in San Diego, California. With a focus on increasing the broad commercialized use of graphene and new applications, this yearâ&#x20AC;&#x2122;s agenda will provide insights to grow the business.

The show runs in parallel with the OLEDs World Summit (21-23 September). An OLED (organic light-emitting diode) is a light-emitting diode in which the emissive electroluminescent layer is D Âż OP RI RUJDQLF FRPSRXQG WKDW HPLWV light in response to an electric current.

This layer of organic semiconductor is situated between two electrodes; typically, at least one of these electrodes is transparent. OLEDs are used to create digital displays in devices such as television screens, computer monitors, portable systems such as mobile phones, handheld game consoles and PDAs. A major area of research is the development of white OLED devices for use in solid-state lighting applications.

Numerous other applications for this novel new technology are being researched, and will be covered at these future-oriented events. www.grapheneworldsummit.com

Plastics in Africa 2016 will provide a stimulating forum AUTOMOTIVE Thermoplastic Composites 2016 for anyone active in the African takes place from 5-6 July at the Renaissance plastics industry to get an up-to-date view on DĂźsseldorf Hotel, DĂźsseldorf, Germany. the latest market and technical developments Thermosets have been a mainstay of the and explore future growth opportunities. The composites sector for a long time. Development event will feature a diverse programme of of epoxy and polyurethane composites continues presentations by industry leaders covering apace. Adding to this wave of innovation is the trendsetting material and technology development of thermoplastic composites which developments, and valuable insights into market may offer advantages in terms of faster cycle times, trends and business opportunities. lower costs, greater recyclability and greater part In addition to a busy full-day programme, integration with other thermoplastic components.

Plastics in Africa 2016 will offer a high-level www.automotive-plastics-conference.com networking opportunity to meet with like minded professionals, get expert opinions and debate key issues in this booming industry.

The conference will bring together leading industry participants at all levels of the supply The Green Building Convention, South Africaâ&#x20AC;&#x2122;s chain, including top plastic African processors, Ă&#x20AC; DJVKLS HYHQW LQ HQHUJ\ HIÂż FLHQW EXLOGLQJ KDV international processing and converting groups, relocated to Johannesburg. This year the event global investors, suppliers and distributors mainly takes place at Sandton Convention Centre from Africa and the Middle East. from 26-29 July. Now in its 9th year, it is a Packaging is one of the most dynamic convention acting as a platform for new ideas and market segments in Africa accounting for 45% sustainability solutions. It is a convention which of polymer demand according to market data emphasises networking through a combination of

by AMI Consulting. Plastics in Africa 2016 keynotes, presentation, tours, and workshops. therefore is organised in combination with AMIâ&#x20AC;&#x2122;s 8th Flexible Packaging Middle East& Africa conference to help reduce travel and time expense for those interested in both FOLLOWING the success of AMIâ&#x20AC;&#x2122;s Plastics in events. Moreover, AMI offers special combo Africa conference launched in December 2015 in GLVFRXQWV WR HQFRXUDJH GHOHJDWHV WR EHQHÂż W London, AMI is organising its second Plastics in from an interdisciplinary approach to business Africa event in Dubai, United Arab Emirates which opportunities in the dynamic markets of Middle will take place on 5 December.

East and Africa. lr@amiplastics.com

Green Building Convention hits Jozi

Plastics in Africa 2016

JUNE / JULY 2016 83

Your local EREMA contact: Relloy S.A. (Pty) Ltd 27 Mopedi Road, Sebenza Edenvale, 1609, Gauteng dean@relloy.co.za www.relloy.co.za

The gentle way

RegrindProÂŽ

The gentle way to success in regrind recycling.

Are you looking for the ultimate way of producing top recycled pellets from thick-walled regrind? For end products with best performance properties and a particularly high recyclate content? The new INTAREMAÂŽ RegrindProÂŽ offers the ideal solution: extremely gentle processing in combination with high-performance filtration. A true material all-rounder so you remain as flexible as possible. RegrindProÂŽ. Go the gentle way.

CHOOSE THE NUMBER ONE.

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5HVHDUFK DQG LQGXVWU\ LQ GLDORJXH Science Campus at K2016 presents key themes for plastics, rubber industry +$9,1* PHW ZLWK D KXJH UHVSRQVH DW LWV premiere at K2013, the Science Campus at K2016 from 19-26 October ZLOO EH IXUWKHU LQWHQVLI\LQJ WKH GLDORJXH EHWZHHQ UHVHDUFK DQG LQGXVWU\ LQ DQ HQODUJHG DUHD DQG ZLWK DQ LQFUHDVHG QXPEHU RI SDUWLFLSDWLQJ VFLHQWL¿ F RUJDQLVDWLRQV 6XSSOHPHQWLQJ WKH SUHVHQWDWLRQV RI XQLYHUVLWLHV DQG FROOHJHV LQVWLWXWHV DQG VSRQVRULQJ RUJDQLVDWLRQV WKH Science Campus will focus on the four key WKHPHV GH¿ QHG E\ WKH . ,QQRYDWLRQ Circle â&#x20AC;&#x201C; a panel made up of experts IURP VFLHQFH DQG UHSUHVHQWDWLYHV RI .¶V ([KLELWRUV &RXQFLO 7KH 6FLHQFH &DPSXV HQDEOHV H[KLELWRUV DQG YLVLWRUV DW . WR JDLQ D FRQFHQWUDWHG RYHUYLHZ RI VFLHQWL¿ F

DFWLYLWLHV DQG ¿ QGLQJV LQ WKH SODVWLFV DQG UXEEHU VHFWRU DQG SURPRWHV DQ H[FKDQJH RI H[SHULHQFH EHWZHHQ FRPSDQLHV DQG XQLYHUVLWLHV $OO RI WKHP ZLOO EH SUHVHQWLQJ SLRQHHULQJ PDWHULDOV DQG WHFKQRORJLHV DQG UHVSRQGLQJ WR WKH FHQWUDO FKDOOHQJHV RI SODVWLFV DQG UXEEHU WHFKQRORJ\ $W WKH 6FLHQFH &DPSXV Center, the discussion and communication IRUXP DWWHQWLRQ ZLOO EH IRFXVHG RQ WKH IROORZLQJ NH\ WKHPHV LQQRYDWLRQ GULYHUV RI JOREDO FKDQJH y IRFXVLQJ RQ UHVRXUFH HI¿ FLHQF\ y Plastics Industry 4.0 y new materials, and y OLJKWZHLJKW HQJLQHHULQJ DV ZHOO DV RQ VFLHQWL¿ F WUDLQLQJ LQ

macromolecular chemistry and plastics WHFKQRORJ\ 6FLHQWLVWV RI . ¶V ,QQRYDWLRQ &LUFOH DQG WHDPV IURP WKHLU institutes will prepare the key themes and present them in different formats. Expected WR KDYH D ODVWLQJ LPSDFW RQ PDUNHW GHYHORSPHQW RI WKH VHFWRU LQ WKH FRPLQJ \HDUV WKHVH WKHPHV ZLOO QRW RQO\ EH WKH IRFXV RI WKH 6FLHQFH &DPSXV DW . EXW ZLOO DOVR EH UHÃ&#x20AC; HFWHG LQ WKH SUHVHQWDWLRQV RI WKH H[KLELWRUV WKH VSHFLDO VKRZ µ3ODVWLFV 6KDSH WKH )XWXUH¶ DQG WKH ,QQRYDWLRQ Compass.

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â&#x20AC;¢ 'LVWULEXWRU IRU :HLIDQJ RQ :HLSUHQ &3( â&#x20AC;¢ 6XSSOLHUV RI (36 9DULRXV *UDGHV â&#x20AC;¢ (QJLQHHULQJ 3RO\PHUV â&#x20AC;¢ 3RO\ROH¿QV â&#x20AC;¢ 5HZRUNHG DQG 5HSDOHWLVHG 0DWHULDOV ®

7+( QLQWK HGLWLRQ RI $0,¶V LQWHUQDWLRQDO 3RO\ROH¿ Q $GGLWLYHV Conference will take place in Vienna, Austria from 13-15 September 3RO\ROH¿ QV OHDG WKH JOREDO SODVWLFV PDUNHWV LQ WHUPV RI SURGXFWLRQ YROXPHV DQG WKH GLYHUVLW\ RI WKHLU DSSOLFDWLRQV )RU H[DPSOH SRO\HWK\OHQH SLSHV DUH JDLQLQJ VKDUH LQ FRQVWUXFWLRQ DJULFXOWXUDO ¿ OPV DUH WUDQVIRUPLQJ FURS \LHOGV LQ DULG UHJLRQV SRO\ROH¿ Q SDFNDJLQJ LV SUHVHUYLQJ IRRGVWXIIV DQG PLQLPLVLQJ ZDVWH ZKLOH WKH XVH RI SRO\SURS\OHQH DV D PHWDO UHSODFHPHQW LV UHGXFLQJ ZHLJKW LQ DXWRPRWLYH PDQXIDFWXULQJ The different properties of polyethylene and polypropylene PDWHULDOV DUH REWDLQHG E\ FDUHIXO VHOHFWLRQ RI UHVLQ DGGLWLYHV DQG SURFHVVLQJ PHWKRGV 3RO\ROH¿ Q $GGLWLYHV EULQJV WRJHWKHU LQGXVWU\ H[SHUWV WR GHEDWH WKH RSWLPDO UHVLQV DGGLWLYHV DQG FRPSRXQGV IRU D ZLGH UDQJH RI HQG XVHV IURP SDFNDJLQJ ¿ OPV WR DXWRPRWLYH components.

7KH WZR GD\ FRQIHUHQFH SURJUDPPH ZLOO FRPPHQFH ZLWK DQ H[SORUDWLRQ RI PDUNHW WUHQGV IURP D UDQJH RI SHUVSHFWLYHV www.amiplastics.com

COM I UP NG

Plastics caps & closures ONE of the largest global conferences for the plastics caps and closures industry, Plastics Caps & Closures, from 29-31 August in Chicago, USA, will showcase a myriad of new technologies and groundbreaking innovations shaping industry growth and opportunities in this fast-emerging packaging sector. The 2016 conference will broaden its focus to include tracks on major plastics packaging trends and issues while providing a world-class exhibition from top suppliers of packaging products and services that provide inspiration for future packaging development. www.cvent.com/events/plastics-caps-and-closures-2016

ness Expo, who are shining examples of effective entrepreneurship education. As a show of its commitment to the growth of small business, Eskom will also provide an opportunity for black-owned SMEs to exhibit at the expo.

Small Business Expo, in partnership with Eskom is devoted to the development and growth of small and medium enterprises by providing an opportunity

for these businesses to market themselves and interact with corporates and investors. www.smallbizexpo.co.za

Waste Management event in August THE 6th Annual Waste Management and Recycling Conference takes place at Emperors

Palace, Kempton Park, on 18-19 August. The conference seeks to convene experts in ZDVWH PDQDJHPHQW ÂżHOG WR share experiences, discuss critical challenges, innovative ground-breaking strategies and tools that help to achieve seamless recycling across a productâ&#x20AC;&#x2122;s entire â&#x20AC;&#x2DC;journeyâ&#x20AC;&#x2122;. www.mogorosicommunications.co.za

JUNE / JULY 2016 85

Eskom to give small business a boost at leading business expo ESKOM is set to recognise leading small businesses, showcase promising SMEs and give entrepreneurship education a boost during the upcoming Small Business Expo from 8-10 September at the Ticketpro Dome in Northriding, Johannesburg.

Through the Eskom Development Foundation, Eskom supports entrepreneurship and small business development at this leading small business event. At the Small Business Expo 2016, Eskom will announce the winners of the annual Eskom Business Investment Competition (BIC), in which substantial prizes aimed at building sustainable businesses are awarded to black-owned businesses in the manufacturing, engineering and construction, agriculture and agri-processing, services and trade industries.

In addition to hosting the BIC awards and showcasing the ÂżQDOLVWV DW WKH H[SR (VNRP will also feature leading Eskom Simama Ranta schools, in the new Blue Label Conference Centre during the Small Busi-

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After 3 years, weâ&#x20AC;&#x2122;re ready to go again. K 2016 presents you the best that engineers, chemists and researchers currently have on offer: machinery, technology, materials, tools, applications, and forward-looking products, processes and solutions. The best basis for global business, the perfect decision-making platform for investment. With some 3,200 exhibitors in 19 exhibition halls on more than 171,000 sqm of exhibition space, the worldâ&#x20AC;&#x2122;s premier trade fair for the plastics and rubber industry will once again be presenting the entire range of products and services that the industry has to offer.

Everything that will move the world in the future. Plan your visit now.

T i m e

k-online.com

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D e c i s i o n s

Southern African â&#x20AC;&#x201C; German Chamber of Commerce and Industry NPC 47 Oxford Road _ Forest Town, Johannesburg P.O. Box 87078 _ Houghton 2041 Tel. +27 (0)11 486 2775 _ Fax +27 (0)86 675 21 75 tradefairs@germanchamber.co.za www.germanchamber.co.za

DIARY PPP Expo Kenya: 16-18 June Nairobi, Kenya: www.expogr.com Manufacturing Indaba: 28-29 June Emperors Palace, Johnnesburg info@manufacturingindaba.co.za Automotive Thermoplastic Comp: 5-6 July Dusseldorf, Germany www.automotive-plastiics-conference.com PPP Expo Tanzania: 12-14 July Dar-es-Salaam, Tanzania: www.expogr.com Green Building Convention: 26-29 July Sandton Convention Centre www.greenbuildingconvention.org.za ExtruAfrica: 4-5 August: Potchefstroom, NW www.extruafrica.org.za ICIS African Polymers Conf: 10-11 August Nairobi, Kenya: www.icisconference.com Waste Management & Recycling: 18-19 August Emperors Palace, Kempton Park www.mogorosicommunications.co.za Plastics Caps & Closures 2016: 29-31 August Chicago, Illinois, USA: www.plasticsnews.com

EVENTS

SAPPMA Pipes X: 6 September Bytes Conference Centre, Midrand www.sappma.co.za Small Business Expo: 8-10 September Ticketpro Dome, Northriding, Johannesburg www.smallbizexpo.co.za 3RO\ROHÂż Q $GGLWLYHV 13-15 September Vienna, Austria: www.amiplastics.co.za Graphene World Summit: 19-20 September San Diego, California www.grapheneworldsummit.com OLEDs World Summit: 21-23 September San Diego, California: www.oledsworldsummit.com Propak West Africa: 20-22 September Landmark Centre, Lagos, Nigeria www.montex.co.uk Agrofood Plastpack Ethiopia: 4-6 October Millennium Hall, Addis Ababa, Ethiopia www.fairtrade-messe.de SA Automotive Week (SAAW): 11-13 October Tshwane Events Centre, Pretoria: www.saaw.co.za PE Industrial Technology Exhib: 19-20 October Sun International Boardwalk, PE www.pe-industrial.co.za K2016: 19-26 October DĂźsseldorf, Germany: www.k-online.de Waterproof Membranes 2016: 7-9 November Maritim Hotel, Cologne, Germany www.amiplastics.com/events PETnology Europe 2016: 7-10 November Nuremberg, Germany: www.petnology.com Feiplar Composites & Feipur 2016: 8-10 November Sao Paulo, Brazil: www.feiplar.com.br All4Pack 2016: 14-17 November Paris Nord Villepinte, France: www.all4pack.com International Composites Congress: 28-29 November CCD Congress Centre, DĂźsseldorf congress@avk-tv.de

BASF showcase sustainable strategy at conference BASF showcased how it is contributing to a sustainable future and how its Sustainable Solution SteeringÂŽ method is changing the companyâ&#x20AC;&#x2122;s business strategies at the recent Sustainable Brands Conference in Cape Town (SBâ&#x20AC;&#x2122;16) from 14 - 17 May. Sustainability is integral to BASFâ&#x20AC;&#x2122;s â&#x20AC;&#x2DC;We create chemistryâ&#x20AC;&#x2122; strategy and a major growth driver.

SBâ&#x20AC;&#x2122;16 Cape Town is an international gathering to evaluate the opportunities for brands to adapt and thrive in a fast changing world and display how inspirational BASF South Africaâ&#x20AC;&#x2122;s Petra Bezuidenhout and Juliet and active partnerships Mdluli, with Astrid Palmieri, Sustainability Coordinator can drive business sucfor Europe and Sustainability Manager at BASF Italy, at cess and activate posithe BASF stand at the Sustainable Brands Conference in tive social and environCape Town in May mental change. BASF was silver sponsor of the event. Astrid Palmieri, Sustainability Coordinator for (XURSH DQG 6XVWDLQDELOLW\ 0DQDJHU DW %$6) ,WDO\ SURYLGHG Âż UVW KDQG LQIRUPDWLRQ RQ KRZ VWHHULQJ WKH SRUWIROLR WRZDUG VXVWDLQDELOLW\ LV GULYLQJ SURÂż WDEOH JURZWK IRU BASF and sustainable value for its customers. www.basf.co.za

Milliken debuts new PP packing solution MILLIKEN exhibited its new UltraClear polypropylene (PP) packaging at Alimentaria 2016. The new sustainable packaging is believed to be both more functional and appealing. Lightweight and microwaveable, it also supports sustainability through its low carbon footprint during packaging production.

Finally, UltraClear is recyclable, meaning it is likely to become incorporated into existing recycling drives. MilladÂŽ NXâ&#x201E;˘ 8000 sets the new standard in clear polypropylene for packaging with a creative and sustainable touch.

2017 IOM National Rubber Conference: 9-12 March Khaya iBhubesi Lodge, Parys www.iom3.co.za MyBusiness Expo: 15-16 March Gallagher Estate, Midrand www.mybizexpo.co.za KZN Industrial Technology Expo: 26-28 July Durban Exhibition Centre, KZN www.kznindustrial.co.za

86 JUNE / JULY 2016

www.millikenchemical.com

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THERMOFORMING, SHEET EXTRUSION, AND MATERIALS THERMOFORMING TECHNOLOGY SAVE 90% of your electricity use with GN! â&#x20AC;¢ GN (Canada): machines for reduced waste and reduced energy â&#x20AC;¢ Thermoforming Moulds for GN and other thermoformers â&#x20AC;¢ ToolVu technology for productivity and NEW quality improvement on thermoforming machines â&#x20AC;¢ Complete lines for EPS foam trays and EPS cup moulding NEW

EXTRUSION TECHNOLOGY FROM AGRIPAK OF ITALY Mono & multi-layer extrusion lines for the production of: â&#x20AC;¢ â&#x20AC;&#x2DC;Cartonplastâ&#x20AC;&#x2122; (twinwall/hollow profile sheet) â&#x20AC;¢ Multilayer sheet for packaging â&#x20AC;¢ Semi-foamed sheet for thermoforming

MATERIALS FOR THERMOFORMED PACKAGING

â&#x20AC;¢ Sealing films for trays and top web for FFS machines â&#x20AC;¢ OPS, PP, PET sheet for general packaging â&#x20AC;¢ PP/EVOH/PP for high barrier containers

BRE INNOVATIONS Contact: Tim Forshaw (083 381 5253) or Phil Hopkinson (083 408 5253) or 021 671 5253 or mail to tim@bre.co.za

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Contact: Desirè Preston Ph: 011 894 3520 | Fax 086 673 9018 | Email: desire@jcl.co.za or visit us at www.jcl.co.za

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Interested in Vapour Phase Corrosion Inhibitor (VCI) masterbatches?

If you need advice, need to source, to evaluate and/or interested in making your own VCI-masterbatches, Please contact: Dr. Eino Vuorinen 0832592986 eino.vuorinen@gmail.com Website: www.vci-services.co.za

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7R SODFH D FODVVLÃ&#x20AC; HG DGYHUW SOHDVH Fax: 086 519 6089 or Tel: 021 712 1408 or E-mail: saplastics@iafrica.com ZZZ VDSODVWLFV FR ]D

JUNE / JULY 2016 87

Classifieds 2016.indd 87

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SPORTS

Resilient riding

fun for cool cruisers Longboard wheels of PU for stable running with high quality components OF course, in most cases itâ&#x20AC;&#x2122;s the kids who are cruising laid-back through the streets on their longboards. But why shouldnâ&#x20AC;&#x2122;t people who arenâ&#x20AC;&#x2122;t quite so young also use this climate friendly form of mobility? So pad your elbows and knees, put your helmet on and slowly get rolling.

High-quality longboard wheels of the kind produced by the Californian manufacturer AEND Industries, for example, are made from polyurethane cast elastomers. These plastic systems combine resilient elasticity, mechanical

load bearing capacity and high abrasion resistance in an almost ideal manner.

The MDI molecules commonly present in polyurethanes usually act as the hard segment in the plastic, while PolyTHFÂŽ from BASF is used by the Californian specialists as the soft segment for this ambitious application.

PolyTHF (known by its full name polytetrahydrofuran) is used in Spandex DQG HODVWDQH Âż EUHV ZKLFK IRU H[DPSOH make sportswear and leisurewear comfortable and elastic.

Processing of the high value

www.basf.com polyurethane cast elastomers is relatively uncomplicated for the user. At low processing temperatures of about 50 degree Celsius, the wheels are cast in metal moulds and can be reworked directly after cooling and hardening.

This naturally makes it much easier for the manufacturer to offer a broad range of longboard wheels of different sizes, widths and strengths.

The diameter of the longboard wheels is usually between 60 and 80mm, while the width of the running surface can measure from 25 to above 55mm.

Acclaimed Spot Rollik MTB frame now reinforced

by TeXtreme Spot Brand Bikes â&#x20AC;&#x201C; Rollik MTB frame reinforced by TeXtremeÂŽ

COLORADO-BASED US bicycle company Spot Brand has released the new Spot Rollik â&#x20AC;&#x201C; a lightweight MTB frame reinforced with TeXtremeÂŽ FDUERQ Âż EUH IDEULFV TeXtreme represents the next generation in state-ofWKH DUW FDUERQ Âż EUH PDWHULDO DQG LW LV QRZ EHLQJ DGRSWHG by the bicycle industry. Based on using Spread Tows instead of yarns, itâ&#x20AC;&#x2122;s used to create ultra-lightweight, high-performance products. Companies using TeXtreme WHFKQRORJ\ DFKLHYH VLJQLÂż FDQW UHVXOWV LQ PLQLPL]LQJ weight while increasing stiffness and strength, in FRPSDULVRQ WR RWKHU FDUERQ Âż EUH PDWHULDOV Spot Brand is a family-owned company located in the Colorado Rockies with a history of innovation and an unwavering commitment to top-level engineering and design. The company offers 16 models and counting across all major bicycle categories: mountain; street; cyclocross; road; geared; singlespeed; and fullsuspension.

88 JUNE / JULY 2016

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2016/06/08 11:35

The Protea Chemicals Team offers innovative solutions to industry with the backing of world class products, suppliers and industry professionals.

JOHANNESBURG 011 821 3300 jhbsales@ proteachemicals.co.za

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PORT ELIZABETH 041 403 1000 peorders@ proteachemicals.co.za

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