SA Plastics June-July 2017

www.saplastics.co.za

VOL 15 ISSUE 3 – JUNE / JULY 2017

SA’s recycling industry Polywrap jeopardized commissions by excessive high-tech Colines cast line filler use?

DPI

Userve commissions 5 Tederics at Blue Belt

S C I T S A L P

S NEW N O I S S I COMM ORY CT

FA HDPE PIPE

Master Plastics lists on JSE Run Clean, ZƵŶ ĸ ĐŝĞŶƚ͊ Ampa Plastics back in business 14

Sun Ace South Africa receive SANAS certification

16

SA’s oldest surviving Engel machine in good hands

30

We supply & maintain moulding machinery ĂŶĚ ĐĂƉŝƚĂů ĞƋƵŝƉŵĞŶƚ ĨŽƌ ƚŚĞ ƉůĂƐƟ Đ Θ metals industry

Technical Machine Suppliers is at the forefront ŽĨ ůĞĂĚŝŶŐ ŝŶŶŽǀĂƟ ŽŶƐ ŝŶ ŽƵƌ ŝŶĚƵƐƚƌLJ &ƌĞĞ ĐŽŶƐƵůƚĂƟ ŽŶƐ for new projects

HEAD OFFICE Landline: 031 701 0422 ŶŶĞƩ Ğ sĂƌƌŝĞ͗ Ϭϴϯ ϳϴϴ ϭϱϲϱ ŵĂŝů͗ ĂŶŶĞƩ ĞΛLJƚƐŵ͘ĐŽ͘njĂ

^ƚĂī ƚƌĂŝŶŝŶŐ ĨŽƌ ŵĂĐŚŝŶĞ ƐĞƫ ŶŐ

REGIONAL SALES REPS Johannesburg Clive Gooding sales@ytsm.co.za 083 310 3967

Machine maintenance contracts

Cape Town Sean Herholdt info@ytsm.co.za 071 155 0981

Free manuals for old Žƌ ĞdžŝƐƟ ŶŐ ŵĂĐŚŝŶĞƐ

Eastern Cape DĂƌŬ Θ ŶŶĞƩ Ğ sĂƌƌŝĞ ĂŶŶĞƩ ĞΛLJƚƐŵ͘ĐŽ͘njĂ 083 788 1565

Zimbabwe & Africa Raymond Marowa info@ytsm.co.za +263 7734 77740

BY THE WAY

Publisher: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Editorial assistant: Heather Peplow (heather@summitpub.co.za) Financial manager: Lisa Mulligan (lisa@summitpub.co.za) Designer: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za) Bronwen Moys Blinc Design (bronwen.clarke@gmail.com) Summit Publishing cc t: +27 (21) 712 1408 f: 086 519 6089 c: +27 (82) 822 8115 e: saplastics@iafrica.com Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa Unit 8, Bergvliet Village Centre, Cnr Hiddingh & Children’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

Plastics Institute of Southern Africa

Association of Rotational Moulders of South Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

Place your bets – The revellers ‌ err delegates at the Hosaf PET conference in May took a break from the technical sessions to try their hands at gambling at a Johannesburg casino.

The blackjack table drew a lot of interest from the suitably attired punters and some won and some didn’t. But it was all play-play stuff as real money didn’t change hands.

It has to be said, however, that only a few of the delegates appeared to have gambling experience, so the exercise may have been useful ‌ as operating in business these days certainly has a roll of the dice element to it

Back-up plan is absolutely necessary EXPECT the unexpected is a dictum often applied, not surprisingly, in advanced driving courses, but it could just as easily be applied to day-to-day business operation. One manufacturer recently received D WUDJLF VKRFN ZKHQ WKH FRPSDQ\œV ¿ QDQFLDO PDQDJHU SDVVHG DZD\ DW ZRUN ZKLFK ZDV D YHU\ GLI¿ FXOW H[SHULHQFH IRU DOO FRQFHUQHG %XW WKH WUDXPD GLGQœW HQG DW WKDW SRLQW DV DOO WKH FRPSDQ\œV ¿ QDQFLDO systems were password-controlled. It’s obviously necessary to have VWULFW ¿ QDQFLDO FRQWUROV LQ SODFH EXW EHDU LQ PLQG WKDW DQ\WKLQJ FRXOG happen at any time, and if you’re running a business you need to have it under control on a day-to-day basis, so make sure you have a back-up plan at all times.

Engineering Plastics apology THE article in our last issue about AK Engineering Plastics in Vereeniging was incorrect. The company’s name is simply Engineering Plastics and we understand it has absolutely nothing to do with its former parent/partner company AK Stone Guards, even though it operates from the same premises.

AK Stone Guards was for long one of the most successful converting RSHUDWLRQV LQ WKH FRXQWU\ DQG ZDV RQH RI WKH ¿ UVW WR EHFRPH LQYROYHG LQ the moulding of plastic automotive components – as its name suggests, producing stone guards for vehicles. But its location away from the main automotive assembly points may have made operation challenging.

What was confusing for us is that there are several companies using WKH QDPH (QJLQHHULQJ 3ODVWLFV EXW LQ HYHU\ FDVH ZLWK D SUHÂż [ WR WKH name. Be that as it may, we understand that the Vereeniging business is doing well and that effective operational systems have been put in place which is making it more and more competitive, rekindling hopes that the halcyon days of former years are returning to the site.

Is our market really different?

ANTON Hanekom of Plastics|SA, who has been caught in the Âż OOHU FRQWURYHUV\ FURVVÂż UH EHWZHHQ UHF\FOHUV DQG VKRSSLQJ EDJ manufacturers (see 6/7), advises that inquiries to trade associations LQ RWKHU FRXQWULHV UHYHDOHG WKDW QRQH KDG H[SHULHQFH RI Âż OOHU loadings in shopping bags becoming problematic. Are we really different here in South Africa? Probably not, but we may be one of the only Third World countries where such a high level of postFRQVXPHU PDWHULDO LV EHLQJ FROOHFWHG IURP ODQGÂż OO *LYHQ WKDW WKLV collection process is creating economic opportunities for many, it seems shortsighted for that operation to be stalled.

BACKGROUND PHOTO: Roof frame for Roding roadster produced by T-RTM (thermoplastic resin transfer moulding) process by Forward Engineering GmbH of Germany won a design award at the JEC Composites show in Paris in March

HAVE ‌ IF YOU G TO SAY IN H ET M SO de: if you si ht ig br e Look at th wisdom to of m ge e have som to us at ease write impart, pl com a. ic fr ia s@ saplastic

VOLUME 15 NR 3

REGLOPLAS

JUNE / JULY 2017

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

6 10 14 16 18 20 22 24 26

45

62

30 32

34

64

• Heating capacity 9 kW • Cooling capacity 24-90 kW

NEW

Temperature control units for oil up to 150°C • Controller RT61 PID

44

• Outlet temperature max 150°C • Heating capacity

58

70

80 82

at 400V 6 kW • Cooling capacity 28kW @ 140°C • Pump capacity 60 litres/min, 3.8 bar

• Simultaneous readout of temperature set-point and actual value

SPORT Fleece to keep you cool!

• Alarm buzzer

Type 150 Smart

WORLD NEWS Total silence at the Guggenheim Museum Specialised solutions for biggest solar plant in the world

• Solid-state relay (SSR)instead of

• Pump capacity 60 litres/min, 3.8 bar

MATERIALS & EQUIPMENT Latest updates on new materials & equipment

• RT 70 control system

changer for pump direction (clockwise)

DESIGN JEC Innovation Awards 2017

Temperature control units for water up to 90°C

heating contactor • Automatic phase-

ASSOCIATIONS Entries open for SAPRO’s 2017 Recycled Plastic Product of the Year Awards

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

New, more efficient Type 90 Smart

INDUSTRY NEWS SA’s recycling industry jeopardized by excessive CaCO3 use Polywrap commissions high-tech Colines cast line Ampa Plastics back in business Sun Ace 6RXWK $IULFD UHFHLYH 6$1$6 FHUWL¿ FDWLRQ Userve commissions 5 Tederics at Blue Belt…

DPI Plastics commissions new HDPE pipe factory Bag Safe, keeping luggage secure Ren-Flex installs sophisticated digital press for IML labels Nuvo study shows impact of rubber imports on SA co’s SA’s oldest surviving Engel machine in good hands SA public-private partnership in composites skills development

High-performance temperature control units

96

76

ON THE COVER In medical moulding, the stakes are high.

The cost savings of a smaller and more straightforward mould build, containing the part’s undercut details within a single component, ensures part accuracy, optimal cooling, greaseless moulding DQG GUDPDWLFDOO\ VLPSOL¿ HG PRXOG maintenance. Read more on page 68 about Mould & Die Solutions’ Roehr Tool Solutions’ range of collapsible cores and expandable cavities in South Africa. www.m-d-s.co.za

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

COMMENT Master Plastics launch – Manley Diedloff of Master Plastics (centre) showed off his drumming skills at the company’s listing on the JSE’s AltX board in May, ably assisted by colleagues Dieter Kriesel of 3HQLQVXOD 3ODVWLFV DQG 0DVWHU 3ODVWLFV¶ ¿ QDQFLDO RI¿ FHU 6DORPH 5DWOKDJDQH ,W¶V EHHQ TXLWH VRPH WLPH since a plastics, composites or rubber company has listed on the JSE, so hats off to Manley and company

Poor liaison with legislators,

THIS ISSUE

govt causes problems for convertors, recyclers ,QFUHDVHG ¿ OOHU OHYHOV FUHDWH XQH[SHFWHG SUREOHPV

T

HE fallout from the plastic bag levy of 2002 continues, and it’s not a good story.

has been heightened. The fact that ‘fear and loathing’ now stalks the bag recycling sector is no understatement.

What’s the point of this? The shopping bag There was optimism in some quarters at sector is highly visible (most consumers seem to the time, 15 years ago, when the bag levy believe that plastics are either bags or bottles) but legislation was passed and there were plans it’s a relatively small part of the overall tonnage for recycling and cleanups and job creation converted. No, the point is that a similar scenario and what knows else, but it all came to could so easily come to roost in your sector. practically naught. The bag manufacturers (IIHFWLYH OLDLVRQ ZLWK WKH 'HSDUWPHQW paid the levies, heard next to nothing from RI (QYLURQPHQWDO $IIDLUV DQG RWKHU the administrators of that ‘fund’ and, perhaps Malaise government departments, which preferring to be left alone, kept quiet and has so far proved elusive for the sets in after continued operating peacefully. But quite a Washed up – The industry, may go a long way towards recycling of number of the convertors hit on the idea of high levels of calcium improving communication and setting FDUERQDWH ¿ OOHU EHLQJ LQFUHDVLQJ ¿ OOHU OHYHOV VSHFL¿ FDOO\ WKDW RI shopping us on a course towards genuine used in HD shopping bag calcium carbonate (CaCO3), which had a economic recovery and development. bags grinds LV PDNLQJ LW GLI¿ FXOW WR YHU\ GH¿ QLWH EHQH¿ W WKH ¿ OOHU FRVW OHVV WKDQ Management of most companies recycle the bags, which to halt polymer, allowed extrusion and bag making in the industry seem reluctant the writer suggests is to continue as normal and, obviously, to engage with government a further unexpected reduced manufacturing costs. Over time departments and personnel, but there have FRQVHTXHQFH RI WKH OHYHOV RI ¿ OOHU FUHSW XS VWHDGLO\ WR WKH SRLQW plastic bag levy of over a been some success stories. Take the current where some of the convertors were running decade ago VXJDU WD[ SURSRVDO %R[PRUH¶V 'DYLG 'UHZ KDV YHU\ KLJK OHYHOV RI ¿ OOHU VRPH RYHU KDOI WKH engaged with various legislators in the process material content. Wouldn’t you too? and managed to achieve some real concessions. By default, 7KH RQO\ SUREOHP LV WKDW LW¶V GLI¿ FXOW WR UHF\FOH EDJV ZLWK D KLJK he became the unexpected spokesman for the industry, CaCO3 content. Well, it is possible, but not if the collected bags simply because no one else put their hand up – or even QHHG WR SDVV WKURXJK D UHF\FOHU¶V ZDVKSODQW ,Q WKDW HYHQW WKH ¿ OOHU reacted for that matter. There can be little doubt that a tax DQG FDUULHU PDWHULDO VLQN ZKHUHDV SRO\ROH¿ QV VXFK DV +' XVXDOO\ on sugar (for health reasons) is necessary, but for plastic À RDW 7KLV LV D YHU\ UHDO SUREOHP LQ 6RXWK $IULFD ZKHUH WKH EXON container manufacturers that posed a real threat for substantial RI UHF\FOHG VKRSSLQJ EDJV KDYH EHHQ UHWULHYHG IURP ODQG¿ OO VLWHV SULFH LQFUHDVHV RQ &6' SURGXFWV DQG PD\ KDYH HYHQ OHG WR DQG WKH ZDVK VWDJH LV QHFHVVDU\ 6R WKH UHF\FOLQJ RI SODVWLF consumer rejection – which is obviously unwelcome to them.

VKRSSLQJ EDJV VSHFL¿ FDOO\ +' EDJV KDV JURXQG WR D KDOW Perhaps one way forward is to either engage more %XW WKDW LV RQO\ KDOI WKH VWRU\ $ PDODLVH KDV VHW LQ WKH enthusiastically with legislators, or ¿ QG convertors do not want to concede, fearing that other bag someone in your company, or appoint manufacturers may not (and gain an advantage); relations someone who can and who is prepared between recyclers and convertors have deteriorated; to do so. Failure to do so may result in and relations among recyclers are also on edge. Like all burdensome legislation being foisted on us. manufacturing sectors, there is serious competition between recyclers too and, since the recycling of shopping bags was Martin Wells formerly an attractive market for some of the recyclers, that Publisher Martin Wells,

4

JUNE / JULY 2017

Publisher

75852B

WHY WE’VE BEEN TOP EMPLOYER FOR 9 YEARS IN A ROW. For 9 straight years in a row, 265 extraordinarily innovative people have helped us succeed, proving to us time and time again that when every employee is empowered with the same level of responsibility and importance, we can achieve great things together. Our people work with us, not for us. Thank you, SAFRIPOL people. 265 times.

NEWS

SA’s mechanical industry jeopardised À OOHU XVH In an attempt to reduce costs in the manufacturing of SODVWLFV SURGXFWV FRQYHUWRUV DUH DGGLQJ LQFUHDVHG DPRXQWV RI ¿ OOHUV OLNH &D&23 (calcium carbonate) WR PDWHULDO IRUPXODWLRQ 8QIRUWXQDWHO\ WKH ¿ OOHUV KDYH YHU\ KLJK UHODWLYH GHQVLWLHV HIIHFWLYHO\ PDNLQJ FRQYHQWLRQDO VLQN À RDW WHFKQRORJ\ UHGXQGDQW :RUNLQJ JURXS WR LQYHVWLJDWH LPSDFW RI ¿ OOHUV RQ UHF\FODELOLW\

6 JUNE / JULY 2017

THE South African Plastics Recycling Organisation (SAPRO) believes that South Africa’s mechanical recycling industry could be jeopardised E\ PDQXIDFWXUHUV RI SRO\ROH¿ Q SODVWLF products adding increasing levels of FDOFLXP FDUERQDWH ¿ OOHU to HD shopping bags.

This follows the public outcry in April after it was revealed that many of South African plastic shopping bag manufacturers – who claimed their bags were recyclable – were adding high FRQWHQWV RI ¿ OOHU WR +' EDJV PDNLQJ LW GLI¿ FXOW ± DQG LQ VRPH FDVHV HYHQ impossible – to effectively recycle.

And recently SAPRO said it had come to its attention that convertors are also considering increasing the addition levels of CaCO3 ¿ OOHU WR WKH PDWHULDO IRUPXODWLRQ RI SODVWLF IXUQLWXUH EXFNHWV SDLOV DQG chemical drums.

3ODVWLFV 6$¶V $QWRQ +DQHNRP FRQ¿ UPHG

WKDW D ZRUNLQJ JURXS HVWDEOLVKHG WR LQYHVWLJDWH WKH LPSDFW µ¿ OOHUV¶ DUH KDYLQJ RQ WKH UHF\FODELOLW\ RI SODVWLF VXSHUPDUNHW carrier bags is progressing well: it is researching possible solutions and is due WR UHSRUW EDFN WR WKH LQGXVWU\ WKLV PRQWK 7KH JURXS LQFOXGHV FRQYHUWRUV UHF\FOHUV UHWDLOHUV DQG SDFNDJLQJ VSHFLDOLVWV and has six months to investigate the impact and research possible solutions.

7KH ZRUNLQJ JURXS LV EHLQJ DVVLVWHG E\ %HUQDUG 5HHNVWLQJ DQ LQGHSHQGHQW external subject matter expert.

7KH PDLQ IRFXV RI WKH ZRUNLQJ JURXS LV threefold: • 7R SURYLGH FODUL¿ FDWLRQ RQ WKH GH¿ QLWLRQ RI UHF\FODELOLW\ YHUVXV QRW (currently) recycled. All polymers are by nature recyclable and can be UHF\FOHG +RZHYHU WKHUH DUH IDFWRUV that could affect certain processes ZKHQ UHF\FOLQJ SODVWLFV PDNLQJ LW OHVV HFRQRPLFDOO\ YLDEOH WR UHF\FOH H J KLJK OHYHOV RI ¿ OOHUV DQG GLUW FRQWDPLQDWLRQ can affect the washability of waste.

:LWKRXW DQ HQG XVH PDUNHW IRU WKH UHF\FOHG PDWHULDO RU DQ LQVXI¿ FLHQW VXSSO\ VWUHDP WKLV WRR ZLOO LPSDFW RQ the viability of recycling a particular material. • 7R FRQVLGHU WKH RSWLPXP OHYHO RI ¿ OOHU in various plastics products before WKH VSHFL¿ F JUDYLW\ RI WKH SURGXFW ZLOO change to a density that does not DOORZ HI¿ FLHQW UHF\FOLQJ DQG SURSRVH standardised methods and tests to assist recyclers. • To research technology and equipment available to deal with washing plastics ZLWK KLJK OHYHOV RI ¿ OOHUV “There are many challenges and differences in the approaches of the YDULRXV ZRUNLQJ JURXS PHPEHUV EXW WKH group is united in achieving the common JRDO WR ¿ QG ZRUNDEOH VROXWLRQV WR WKH recyclability of plastic products containing KLJK OHYHOV RI ¿ OOHUV :H DUH FRQ¿ GHQW and optimistic that we will achieve WKH REMHFWLYHV WKDW ZH KDYH VHW ´ VDLG +DQHNRP

Master Plastics lists on JSE

Listed! – Master Plastics’ CEO Manley Diedloff with Donna Nemer, director for capital markets at the JSE, and Salome Ratlhagane, CFO of Master Plastics

7+( QHZ YHQWXUH 0DVWHU 3ODVWLFV /WG ZKLFK LQFOXGHV WKH À H[LEOHV EXVLQHVVHV LQ WKH $VWUDSDN JURXS WKDW KDYH EHHQ µXQEXQGOHG¶ IURP $VWUDSDN OLVWHG RQ WKH -RKDQQHVEXUJ 6WRFN ([FKDQJH¶V $OW; ERDUG LQ WKH FRQWDLQHUV DQG SDFNDJLQJ VHFWRU RQ 0D\ 0DVWHU 3ODVWLFV FRPSULVHV %DUULHU )LOP &RQYHUWHUV EDVHG LQ 3URVSHFWRQ 'XUEDQ

3HQLQVXOD 3DFNDJLQJ %HOOYLOOH &DSH 7RZQ

DQG 3OXVQHW *HRWH[ 5DQGIRQWHLQ :HVW 5DQG $VWUDSDN UHPDLQV OLVWHG RQ WKH -6(¶V PDLQ ERDUG DQG LV H[SHFWHG WR GHOLVW ZKHQ LWV VDOH WR 53& RI (QJODQG WDNHV SODFH expected to be by mid-year.

0DVWHU 3ODVWLFV &(2 0DQOH\ 'LHGORII VDLG ³7KLV LV DQ H[FLWLQJ WLPH IRU 0DVWHU 3ODVWLFV DQG LWV SHRSOH DQG ZH DOO ORRN forward to delivering on and exceeding PDUNHW H[SHFWDWLRQV ´

JUST BRIEFLY

recycling by excessive 2QH RI WKH ¿ UVW OLWUH WDQNV WR UROO RII WKH OLQH DW $IULFD 7DQNV

Africa Tanks starts blow moulding water tanks

:K\ H[FHVVLYH DPRXQWV RI ¿ OOHU LV D SUREOHP Only mechanical recycling is currently commercially exercised in South Africa.

There are two or three small private incineration and diesel-from-waste plants on trial. At 20.3%, the country’s mechanical recycling rate is the highest in the world. By comparison, Europe’s mechanical recycling rate is between 9-11% and Australia averages 9.2%.

Almost all mechanical recycling in South Africa that is performed on dirty, SRVW FRQVXPHU SRO\ROH¿ QV XVH µVLQN À RDW¶ WHFKQRORJ\ DV WKHVH IDFLOLWLHV DUH reasonably accessible and facilitate economically viable recycling. Any threat to the ability of recyclers to recycle dirty plastics will therefore have an immediate detrimental effect on recycling in South Africa.

The majority of carrier bags manufactured in South Africa contain varying amounts from low to high SHUFHQWDJHV RI ¿ OOHUV 7KH FDUULHU bag industry alone is estimated at approximately 36 000 tons a year. This constitutes a massive source of raw PDWHULDOV IRU UHF\FOLQJ DQG FDQ VLJQL¿ FDQWO\ increase the sustainability of the industry. If 100% recycled, it could add a further 2.5% to the overall recycling rate.

In an attempt to reduce costs in the manufacturing of plastics products, convertors are adding increased amounts RI ¿ OOHUV OLNH &D&23 (calcium carbonate) to material formulation. Unfortunately, the ¿ OOHUV KDYH YHU\ KLJK UHODWLYH GHQVLWLHV &D&23 has a density between 2.7 and 2.8 g/cm³. Even at low addition levels, the

VSHFL¿ F JUDYLW\ RI WKH PL[WXUH ZLOO H[FHHG J cc. This means that the average density of the product is more than water, effectively PDNLQJ FRQYHQWLRQDO VLQN À RDW WHFKQRORJ\ redundant.

According to a *White Paper published E\ 6$352 ¿ OOHUV LQFUHDVH WKH VSHFL¿ F gravity of the product to more than one and WKHUHIRUH PDNHV LW XQ¿ W IRU XVH LQ WKH VLQN À RDW SURFHVVLQJ HTXLSPHQW ZLGHO\ XVHG E\ recyclers. SAPRO say that although these products are theoretically recyclable, with the current systems it is not possible to recycle dirty, post-consumer products where washing is an integral part of the recycling process.

2QO\ SRO\ROH¿ QV +' /' OLQHDU DQG 33

can be separated and washed in this manner as their relative densities are between 0.92 and 0.98 g/cm³. The other plastics such as 3(7 39& DQG SRO\VW\UHQH KDYH VSHFL¿ F JUDYLWLHV H[FHHGLQJ RQH DQG WKHUHIRUH VLQN with the dirt, also enabling the effective separation of these materials from the SRO\ROH¿ QV GXULQJ WKH ZDVKLQJ SURFHVV 6KRXOG WKH ¿ OOHG KLJK +' DOVR VLQN LW PDNHV the process of separation more complex.

(IIHFW RQ 6RXWK $IULFDQ UHF\FOLQJ LQGXVWU\ 7R 6$352¶V NQRZOHGJH WKHUH LV QR HFRQRPLFDOO\ YLDEOH DOWHUQDWLYH WR VLQN À RDW V\VWHPV WR EH XVHG LQ WKH PHFKDQLFDO UHF\FOLQJ RI GLUW\ SRVW FRQVXPHU SRO\ROH¿ Q SODVWLFV ZLWK D VSHFL¿ F JUDYLW\ JUHDWHU than one. To further complicate matters, WKH SURGXFWV FRQWDLQLQJ WKH ¿ OOHUV DUH indistinguishable from those without.

Entire batches are therefore contaminated, UHGXFLQJ WKH \LHOG IURP VLQN À RDW RSHUDWLRQV The prices recyclers are then willing to pay for collected material become too

$)5,&$ 7DQNV WKH QHZ YHQWXUH WR manufacture large-volume water WDQNV DW &XOOLQDQ LQ *DXWHQJ has commenced blow moulding RI OLWUH WDQNV LQ RQH RI the boldest steps by a plastics convertor in South Africa in recent \HDUV 8S WLOO QRZ WKH PDUNHW IRU ZDWHU WDQNV RI WKLV VL]H DQG ODUJHU has been virtually the exclusive domain of roto moulders. Blow PRXOGLQJ RI WKH WDQNV FDQ EH FDUULHG RXW DW D VLJQL¿ FDQWO\ IDVWHU rate, however, with an estimated cycle time of seven minutes as opposed to 45min for the roto process. But although the cycle time is vastly faster, the set-up costs are substantially higher too and the logistics involved are considerably more complicated too. $IULFD 7DQNV LV SDUWQHULQJ ZLWK WKH Build-It group of hardware outlets around southern Africa, where the WDQNV ZLOO EH PDUNHWHG LQLWLDOO\

Winhold group JW]OP\ Ja ?IÃ… UI

:,1+2/' WKH RZQHU RI *XQGOH Plastics and Inmins, has been ERXJKW E\ XQOLVWHG :D¿ PD Manufacturing & Distribution. :D¿ PD RIIHUHG WR EX\ :LQKROG DW R1.25 a share, which caused the Winhold share price to jump 30% to R1.17 on the day in late May. At R1.25 a share, the offer came out at R158-million.

Winhold said in a trading statement in mid-May that it expected to report an increase in headline earnings per share of 275% from the matching period in 2016.

JUNE / JULY 2017 7

NEWS low to cover the overheads of collection, forcing collectors to stop collecting the bags.

As more products start containing ¿OOHUV WKH UHF\FOLQJ UDWH RQ WKHVH products will continue to drop, having a detrimental effect on the future of the FRPSOHWH UHF\FOLQJ YDOXH FKDLQ LQ 6RXWK Africa. ,QWHUQDWLRQDOO\ D VLPLODU SUREOHP LV H[SHULHQFHG ZLWK PDQ\ SODVWLFV SURGXFWV WKDW FRQWDLQ ¿OOHUV EXW WKHVH DUH QRW PHFKDQLFDOO\ UHF\FOHG DQG WKH HQG RI OLIH SURGXFWV FDQ VWLOO EH XVHG IRU HQHUJ\ UHFRYHU\ 6$352 EHOLHYHV WKDW PDLQWDLQLQJ WKH VWDWXV TXR RQ ¿OOHG PDWHULDO IRUPXODWLRQV ZLOO PHDQ WKDW SURGXFWV DUH LQFRUUHFWO\ marked with the Mobius loop as well as FODLPV RI UHF\FODELOLW\ &RPSXOVRU\ VSHFL¿FDWLRQ IRU SODVWLF EDJV" Meanwhile, the Department of Environment Affairs said it would be OLDLVLQJ ZLWK WKH 1DWLRQDO 5HJXODWRU IRU &RPSXOVRU\ 6SHFL¿FDWLRQV 15&6 DQG WKH 6RXWK $IULFDQ %XUHDX RI 6WDQGDUGV 6$%6 WR HQVXUH WKDW PDQXIDFWXUHUV RI SODVWLF FDUULHU EDJV FRPSO\ ZLWK WKH UHJXODWRU\ UHTXLUHPHQWV DQG VWDQGDUGV of their products.

7KH '($ VDLG WKDW PRQH\ FROOHFWHG IURP WKH SODVWLF EDJ OHY\ WR VXSSRUW UHF\FOLQJ LQLWLDWLYHV WKURXJK WKH HVWDEOLVKPHQW RI QHFHVVDU\ LQIUDVWUXFWXUH IRU UHF\FOLQJ LQ WKH FRXQWU\ DQG WKH LPSOHPHQWDWLRQ RI WKH &RPSXOVRU\ 6SHFL¿FDWLRQ IRU 3ODVWLF %DJV 9& WKURXJK WKH 1DWLRQDO 5HJXODWRU IRU &RPSXOVRU\ 6SHFL¿FDWLRQV The DEA also claims that a FRQWULEXWLRQ RI 5 PLOOLRQ ZLOO EH DOORFDWHG WKH 15&6 IRU UHVHDUFK RQ SODVWLF EDJV RYHU WKH QH[W WKUHH ¿QDQFLDO \HDUV $V SDUW RI LWV PDQGDWH WKH 15&6 conducts compliance and enforcement RI WKH VSHFL¿FDWLRQV ,Q 6RXWK $IULFD LQWURGXFHG plastic bag regulations in a bold move

to address the challenge of plastic EDJ OLWWHU 7KH UHJXODWLRQV HVVHQWLDOO\ made the provision of thicker, more GXUDEOH SODVWLF EDJV FRPSXOVRU\ 7KH FRPSXOVRU\ VSHFL¿FDWLRQ ZDV VXEVHTXHQWO\ GHYHORSHG SUHVFULELQJ WKDW RQO\ SODVWLF FDUULHU EDJV DQG ÀDW bags of the minimum thickness of PLFURQV FDQ EH PDQXIDFWXUHG RU LPSRUWHG LQWR WKH FRXQWU\ DW D OHY\ RI FHQWV D EDJ QRZ F ,Q WHUPV RI WKH regulations, the plastic bags ought to EH UHF\FODEOH WKHUHE\ PDNLQJ WKHP PRUH µHQYLURQPHQWDOO\ IULHQGO\¶ 7KH new thickness also made them more reusable.

6LQFH WKH LQFHSWLRQ RI WKH OHY\ LQ WKH 1DWLRQDO 7UHDVXU\ KDV EHHQ FROOHFWLQJ WKH 3ODVWLF %DJ /HY\ 7KH PRQH\ FROOHFWHG JRHV LQWR WKH 1DWLRQDO 5HYHQXH )XQG DQG 1DWLRQDO 7UHDVXU\ allocates a portion of it to the DEA for regulation of the thickness of plastic EDJV 7KH FROOHFWHG OHY\ LV QRW ULQJ IHQFHG DQG FDQ RQO\ EH DOORFDWHG WR UHF\FOLQJ SURJUDPPHV IROORZLQJ VXEPLVVLRQ WR WKH 1DWLRQDO 7UHDVXU\ of an approved and clear business plan on the implementation of such programmes.

7KLV VHSDUDWLRQ WDQN VHUYHV PXOWLSOH IXQFWLRQV ,W WUDYHUVHV WKH SODVWLF WLPHV LWV OHQJWK SHUPLWWLQJ WKH SODVWLF WR VRDN LQ WKH ZDUP GHWHUJHQW ORRVHQLQJ ODEHOV DGKHVLYH DQG RWKHU FRQWDPLQDQWV 7R DFKLHYH D FU\VWDO FOHDU FRQWDPLQDQW IUHH SODVWLF SHOOHW GZHOO WLPH LQ GHWHUJHQW LV FULWLFDO 7KLV VHSDUDWRU WDQN SHUPLWV D PLQXWH GZHOO WLPH HYHQ ZKHQ ZDVKLQJ PRUH WKDQ WZR WRQV SHU KRXU ,W ZLOO QRW RQO\ UHPRYH DOO QRQ EXR\DQW FRQWDPLQDQWV IURP 3( 33 EXW DFKLHYH FOHDQ UHF\FOHG SODVWLF

'($ LPSOHPHQWLQJ LQLWLDWLYHV WR SURPRWH UHF\FOLQJ The DEA is implementing initiatives aimed at improving the regulation of the development and implementation RI ,QGXVWU\ :DVWH 0DQDJHPHQW 3ODQV LQ DQ HIIRUW WR IDVW WUDFN HIIHFWLYH LPSOHPHQWDWLRQ RI WKH 1DWLRQDO :DVWH 0DQDJHPHQW 6WUDWHJ\ ZKLFK SURPRWHV ZDVWH PLQLPLVDWLRQ UH XVH UHF\FOLQJ DQG UHFRYHU\ RI ZDVWH $V SDUW RI WKH VWUDWHJ\ DQG LQ WHUPV RI VHFWLRQ $ RI WKH National Environmental Management: :DVWH $PHQGPHQW $FW $FW 1R RI WKH 'HSDUWPHQW KDV HVWDEOLVKHG D :DVWH %XUHDX ZKLFK PRQLWRUV WKH LPSOHPHQWDWLRQ RI ,QGXVWU\ :DVWH 0DQDJHPHQW 3ODQV The Department has published a call for the development of among others ,QGXVWU\ :DVWH 0DQDJHPHQW 3ODQV IRU UHF\FOLQJ SXUSRVHV DQG GLYHUWLQJ ZDVWH IURP ODQG¿OOV 7KH 3DSHU DQG 3DFNDJLQJ ,QGXVWU\ :DVWH 0DQDJHPHQW 3ODQ LV RQH of these plans and comprises various waste streams, including plastic bags.

7KH 3DSHU DQG 3DFNDJLQJ ,QGXVWU\ :DVWH 0DQDJHPHQW 3ODQ SURYLGHV HIIHFWLYH DQG HI¿FLHQW ZD\V WKURXJK ZKLFK SODVWLF EDJV FDQ EH UHF\FOHG The DEA said that tt is for this reason WKDW WKH\ KDG DOORFDWHG D EXGJHW RI 5 PLOOLRQ WRZDUGV UHJXODWLRQ RI the thickness of plastic bags, and to VXSSRUW UHF\FOLQJ LQLWLDWLYHV IRU D SHULRG RI WKUHH ¿QDQFLDO \HDUV 7KH IXQGV DUH DGPLQLVWHUHG WKURXJK WKH :DVWH %XUHDX µ7KH UHF\FODELOLW\ RI ¿OOHG SRO\ROH¿QV¶ ± D 6$352 :KLWH 3DSHU

8 JUNE / JULY 2017

NEWS The new Colines ALLrollEX® 1000 line at Polywrap is one of the most sophisticated FDVW ¿ OP OLQHV LQVWDOOHG LQ 6RXWK $IULFD WR date; it can process up to 700kgs/hr and has a footprint of just 10x10m by 7m high; the line was recently installed at the plant in Saxenburg Industrial Park

Polywrap commissions

high-tech Colines cast &DSH VWUHWFK ¿ OP PDQXIDFWXUHU DFKLHYHV FRQVLGHUDEOH SURGXFWLRQ LQFUHDVH XVLQJ SURSRUWLRQDWHO\ OHVV HQHUJ\

10 JUNE / JULY 2017

POLYWRAP, the Cape Town pallet ZUDS DQG VKULQN ¿ OP PDQXIDFWXUHU KDV WDNHQ D PDMRU OHDS IRUZDUG ZLWK WKH LQVWDOODWLRQ UHFHQWO\ RI D VWDWH RI WKH DUW FDVW ¿ OP OLQH IURP &ROLQHV RI ,WDO\ 7KH $//UROO(;® PDFKLQH RIIHUV D KLJKO\ DXWRPDWHG VROXWLRQ DQG FDQ YLUWXDOO\ HIIRUWOHVVO\ SURGXFH VWUHWFK ¿ OP WKDW LV IDU FOHDUHU WKDQ WKH ¿ OPV SURGXFHG RQ WKH EORZQ ¿ OP OLQHV XVHG E\ WKH %ODFNKHDWK EDVHG FRPSDQ\ WR GDWH 3DUW RI D VXEVWDQWLDO LQYHVWPHQW E\ 3RO\ZUDS WKH $//UROO(; PDFKLQH KDV HQDEOHG 3RO\ZUDS WR FRQVLGHUDEO\ LQFUHDVH SURGXFWLRQ RI VWUHWFK ¿ OP SDOOHW ZUDS 7KH QHZ PDFKLQH H[HPSOL¿ HV WKH WHFKQRORJLFDO SURJUHVVLRQ LQ VWUHWFK ¿ OP SURGXFWLRQ DFKLHYHG E\ &ROLQHV 7KH

FR H[ OLQH SURGXFHV OD\HU ¿ OP XS WR P ZLGH DQG LQFOXGHV VHYHUDO IHDWXUHV VSHFL¿ FDOO\ UHGXFHG HQHUJ\ FRQVXPSWLRQ DQG D IDU VPDOOHU µIRRWSULQW¶ WKDQ KDV EHHQ FXVWRPDU\ ZLWK FDVW ¿ OP H[WUXVLRQ V\VWHPV XS WLOO QRZ ,W FDQ PDQXIDFWXUH ¿ OPV IURP PLFURQV SOXV ZLQGLQJ WHFKQRORJ\ KDV EHHQ LPSURYHG WR WKH SRLQW ZKHUH HYHQ YHU\ WKLQ ¿ OPV RI MXVW — FDQ EH FRQVLVWHQWO\ PDQXIDFWXUHG 3RO\ZUDS ZKLFK KDV EHHQ LQ RSHUDWLRQ VLQFH RULJLQDOO\ SURGXFHG PRQR ¿ OPV RQ EORZQ ¿ OP V\VWHPV DQG LQFUHDVHG FDSDELOLWLHV WR WKH SRLQW ZKHUH LW FRXOG PDQXIDFWXUH FR H[ ¿ OPV XS WR P ZLGH ,W KDV EHHQ ORRNLQJ DW WKH &ROLQHV WHFKQRORJ\ VLQFH DERXW EXW WKH VFDOH RI WKH

Polywrap directors Jan Rabie, Ben van der Touw and Johan Burger, the Polywrap sales & marketing manager; Polywrap operates in a partnership with Pelmanco Recycling, which is run by Rabie as well

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‘Colines system offers exceptional HI¿ FLHQFLHV reduces scrap to extremely low levels.’

Machine setter Reagan Swart at the neatly designed control panel of the new machine; Reagan joined Polywrap as a sweeper and has progressed to the point where he is now able to set the controls of the high-tech Colines system

REDISA disputes liquidation application

line

The ultimate test – The Polywrap cast ¿ OPV DFKLHYH H[FHSWLRQDO WHDU UHVLVWDQFH DOWKRXJK %HQ JDYH LW KLV EHVW VKRW KH IDLOHG WR SXQFWXUH HYHQ D UHODWLYHO\ WKLQ ¿ OP

project during 2015. The partners decided on using Italian technology: Van der Touw and Rabie liked Colines’ technical solutions. Colines has also succeeded in reducing production scrap to extremely low levels (the ALLrollEX system in fact ¾DXWR UHF\FOHVœ DOO WKH WULP ¿ OP

One of the features of the ALLrollEX V\VWHP ZKLFK LV SURYLQJ PRVW EHQH¿ FLDO is the automated thickness gauge control: Polywrap can now guarantee WKDW DOO ¿ OPV SURGXFHG RQ WKH PDFKLQH have a maximum variance of just fractions of a micron, which was unheard of until just recently. Running at throughputs of up to 700kgs an hour, that’s no mean feat.

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THE environmental affairs minister’s application for liquidation of REDISA has been described as a “hostile takeover� by REDISA director, Stacey Davidson.

Effective from 1 June, the liquidation order sought by Minister Edna Molewa, ordered REDISA to ceased all tyre collections and allow the Department of Environmental Affairs to liquidate the organisation and wind up its affairs.

Davidson said that REDISA denied all the allegations made by Molewa in support of the liquidation application and was shocked by the “gross misrepresentationsâ€? made by Molewa and the DEA. 'DYLGVRQ DOVR FRQÂż UPHG WKDW 5(',6$ was in the process of drafting papers to challenge the validity of the liquidation application and the provisional liquidation order that had been issued.

Molewa said in an almost 200-page af¿ GDYLW LQ VXSSRUW RI WKH OLTXLGDWLRQ DSSOLFDWLRQ that she suspected REDISA of grossly mismanaging the organisations’ public funding to the value of millions of Rands.

Davidson said REDISA were “dumbfoundHG´ E\ WKH DVVHUWLRQV PDGH LQ WKH DIÂż GDYLW and claimed the DEA had all the documentation that clearly showed how the funds were Ă€ RZLQJ DQG WKH FRPSDQ\ ZDV PDQDJHG Meanwhile, in a statement on 31 May

by REDISA CEO, Hermann Erdmann, said that REDISA had no choice but to, for the time being, cease collections with immediate effect. REDISA will no longer collect waste tyres from registered collection points, including micro-collectors. However, REDISA depots will remain open, but will not be accepting any deliveries. Deliveries to processors will continue as scheduled until further notice.

Erdmann said that REDISA was taking steps to secure the funding necessary to reinstate its collections.

Manufacturing grants to \IZOM\ [MK\WZ[ VW\ Ă… ZU[

www.polywrap.co.za

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JUST BRIEFLY

%OHQGHUV IURP 'RWHFR DOVR RI ,WDO\ DOORZ IRU KLJKO\ DXWRPDWHG EOHQGLQJ DQG GRVLQJ

THE Department of Trade and Industry has redesigned its manufacturing competitiveness enhancement programme so the extension of grants will target strategic sectors rather than individual manufacturers on a Âż UVW FRPH Âż UVW VHUYHG EDVLV DV LQ WKH SDVW The programme took effect on 1 April and will prioritise the labour-intensive sectors of agro-processing and agriculture, as well as downstream manufacturers exposed to the metals sector. The department will offer low-interest loans in addition to grants to manufacturers for them to use for competitiveness-enhancing investments.

The re-engineering is in line with the World Bank’s recommendation in its economic update on SA that the government direct income tax incentives towards sectors that attract investment and create jobs.

JUNE / JULY 2017 11

ASSOCIATION NEWS

‘Turnaround’ process

battle, and more ‘TURNAROUND’ is a word often used in times of crisis and quite frequently – very frequently of late – in the manufacturing environment. And although the goals of the turnaround may be clear, what is not so clear is the major psychological battle that can play out in the process, for both management and staff.

Several converting businesses have been facing this tough scenario of late, chartering through troubled waters with all the hallmarks of such a situation – high scrap rates, high product reject

Observation quickly revealed some unwanted surprises

levels, low staff morale and so on – being all too present.

Years go by and, while trading conditions are favourable, businesses can put on weight in the form of additional equipment and, more relevantly, personnel. Easy trading conditions can create lethargy within an organisation and the dreaded V\PSWRPV RI RYHU FRQÂżGHQFH DQG unrealistic expectations. Then, when conditions change and trading becomes challenging, the reaction of people at PRVW EXVLQHVVHV LV WR DW ÂżUVW H[SHFW the unfavourable conditions to be a temporary situation that will pass and

for life to return to ‘normal’. But, when tough trading conditions continue and intensify, low levels of panic start setting in and spread insidiously throughout the business. Such a scenario has effected many companies in our industry and a large number have paid the ultimate price, namely closure and liquidation.

A business’s balance sheet is the main focus of attention when this phenomenon prevails, with remedial action an obvious priority. But what to do, and how to do it?

Here we look at the recent experience of a South African convertor, aimed at achieving a successful turnaround.

Step One was to bring in consultants to

Sugar tax poses serious obstacle for container manufacturers, others Complicated matter of implementing tax on sugar 7+( SURSRVHG VXJDU WD[ ZKLFK ZDV ¿UVW PRRWHG LQ WKH ¿UVW KDOI RI 2016, received virtually no reaction from container manufacturers, HYHQ WKRXJK LI LPSOHPHQWHG DV DW ¿UVW RXWOLQHG LW ZRXOG KDYH OHG WR a substantial increase in the cost of carbonated softdrinks – and almost certainly had a negative effect on sales. David Drew, commercial director at Boxmore, took up the issue on behalf of his company in the apparent absence of any other reaction.

As a result, he became the de facto representative of the entire PET container manufacturing sector in South Africa.

What started out quite innocuously with the suggestion that a 20% increase on the sugar content of ‘sugary drinks’ be introduced would have resulted (at the current sugar bulk price of about R11/kg) in an increase of R23 per kilogram of sugar ‌ and led to a cost increase of 209% on the sugar content of the CSD alone. That sounded bad enough, but David’s calculations showed that on a one-litre drink that would have incurred an additional tax of R3.59 – in other words, a major price increase of the drink’s cost.

For drinks with a higher sugar content, the tax component would increase proportionately more, an example being Oros: a 2-litre container of this beverage would have increased from R34,99 to close to R60, which would almost certainly have led to consumer rejection.

Various interactions with the Health Department and Treasury have ensued, with Boxmore’s Drew being literally the industry’s only representative. Common sense appears to have prevailed.

Drew and other interested parties argued that “the tax as previously conceived was far too high and was going to move retail prices far more than the 20% that government and NGOs believed was necessary to change behaviour, both of consumers and producers�. “We indicated that as industry must adapt to survive (by 12

JUNE / JULY 2017

Sugar tax not so sweet – David Drew has been the industry’s only representative at the consultations between government and stakeholders in the softdrinks market with regard to the proposed sugar tax. He gave a presentation on the topic at the Hosaf PET conference in Johannesburg in May (see pages 28-29

protecting volume) some of the consequences of the tax would be an increase in the use of sweeteners and the reduction of pack sizes to mask the impact of the tax on shelf and limit the price increases,� said Drew.

The response from treasury was the reduction to 2.1c/g, making WKH ÂżUVW J PO ÂľWD[ IUHHÂś DQG FRQFHGLQJ WKDW FRQFHQWUDWH SURGXFWV only be taxed at half the rate of ready-to-drink products. Âł7KLV LV REYLRXVO\ D VLJQLÂżFDQW LPSURYHPHQW EXW OLWUH ÂľYDOXHÂś brands would still see around 30% price increase on the shelf without reformulation or pack size reduction,â€? added Drew. “Lastly, because we believe implementing the tax will be H[WUHPHO\ FRPSOLFDWHG DQG GLIÂżFXOW WR DXGLW WKDW LV WR GHWHUPLQH just how much sugar is actually in each product and how much of each is sold, we think that it would be much simpler to apply D WD[ WR DOO LQGXVWULDO VXJDU DW WKH UHÂżQHU\ JDWH “This approach would ensure that excess sugar in many other products (not just soft drinks) would also be taxed and as a result reduced/replaced, whilst making tax avoidance H[WUHPHO\ GLIÂżFXOW ´ VDLG 'UHZ The legislation drafting process has now been delayed, with further bargaining taking place, and implementation is planned for March 2018.

Thanks to Drew for holding the torch for convertors around the country.

presents serious psychological department’s complement manage the process, shrunk to just three, with but that didn’t achieve Low levels of most of the mixing team the desired rescue – panic set in and redeployed elsewhere, at and cost a bit too. So spread insidiously least temporarily. the next step was to And the high rate of product go it alone, with a fairly throughout the return from customers did obvious need being to business not require any discovery, analysis all aspects of the problem was abundantly the operation. obvious to everyone, from production to “A surprising number of discoveries sales to accounts. Analysis showed the rate came to light within a short while,â€? said of return was unhealthily high, to the point the GM. where it was suspected that this could have Âł,WÂśV DOVR VXUSULVLQJ ZKDW \RX FDQ ÂżQG been caused by on-line sabotage. That out by just walking around the plant too was probably consistent with low staff and tidying things up,â€? he added. The morale and disgruntlement, and hence also QH[W VWHS ZDV WR LPSOHPHQW VSHFLÂżF not surprising. housekeeping rules with several plant The presence of the owner, GM or layout changes being made, improved VSHFLÂżFDOO\ DSSRLQWHG WUXVWHG LQGLYLGXDO RQ safety measures and zero tolerance for WKH VKRSĂ€RRU DW DOO WLPHV LV D FKDUDFWHULVWLF littering introduced. of most of the successful converting 2QH RI WKH ÂżUVW ÂľGLVFRYHULHVÂś ZDV WKDW operations around the country. What was the previous management had decided surprising was that the previous managers to mothball a sophisticated material did not see the need for this. mixing/blending plant. Rather than The next discovery was that virtually use the gravimetric systems to feed every operator in the plant had a full-time WKH ÂżOP OLQHV WKH PL[LQJ GHSDUWPHQW assistant. This led to the next step in the had swollen and was employing over turnaround, that of cutting staff numbers 40 individuals. Once the automated and by mid-2016 that was extremely OLQH ZDV ÂľUHFRPPLVVLRQHG Âś WKH PL[LQJ

necessary. This was the phase where the psychological challenge really set in, where emotional considerations had to EH SXW DVLGH $UJXDEO\ WKH PRVW GLI¿FXOW aspect of the entire process, retrenching staff was a huge challenge ‌ but failure to do so could have undermined the process entirely and led to the demise of the business. There was no alternative: the hankies had to be packed away. &DOFXODWLQJ DFFHSWDEOH WHUPV E\ ¿UVW ¾LQYLWLQJœ YROXQWDU\ UHWUHQFKPHQW DQG ZKHQ WKDW ZDV QRW VXI¿FLHQW WR WULP numbers forcibly, yet doing so in a manner that retrenched individuals who had a realistic chance to rehabilitate themselves afterwards, was a daunting step.

Although the process is not complete, the business has retrenched over 100 of its staff, about 40% of its complement, on amicable terms. And the surprise is that tonnage turnover has fallen by a far lesser percentage – an estimated 20% – plus the scrap rate has come down and product returns have shrunk WR DFFHSWDEOH ¿JXUHV PHDQLQJ WKDW the operation has a far more realistic opportunity to survive – and maybe even thrive again.

FCB CAPE TOWN 10014153CT/E

JUNE / JULY 2017 13

PROFESSIONAL PROFICIENT PROACTIVE PROGRESSIVE PROCESS OILS

Engen is a member of the PETRONAS Group

At Engen, we have reaffirmed our commitment to the Process Oils market. We supply high quality virgin Group I and II base oils and Naphthenic grades under the Parprol brand. These are available in a variety of packs, including true bulk and mini bulk.

Our dynamic, new management team is ready to take your business into the future with a strong focus on supply assurance, and a reliable network that takes advantage of our distribution centres in all major cities and a number of outlying areas.

We supply a wide range of industries, including: Adhesives, Pesticides, Cable Compounds, Ink Oils, Plasticisers, Rope Dressing, Rubber, Textiles, Coatings, Paints, Sealants, Detergents and Wood Oils.

To find out more on how we can take your business forward, contact us at Engen.ProcessOils@engenoil.com

NEWS

Ampa Plastics

back in business Rescue plan involving IDC sees Ampa back on track THERE’S usually no escape for a business when the liquidation notice goes out and it’s game over when the auction is advertised, no doubt, but that hasn’t been the case at Ampa Plastics Group.

A virtually iconic name in the local plastics industry, originally known as Ampaglas, the company has been extruding sheet since 1973 and was the standard for extruded plastic sheet in Africa for over four decades. But it all came to a grinding halt in October last year when the doors at the $PSD KHDG RIÂż FH LQ -RKDQQHVEXUJ ZHUH shut.

The problem, as it invariably is in these VLWXDWLRQV ZDV ¿ QDQFLDO VSHFL¿ FDOO\ WKDW $PSDœV ¿ QDQFLDO SDUWQHUV GLG QRW ZDQW WR proceed further. Ampa CEO Trevor Zulberg UHTXHVWHG DGGLWLRQDO FDVK À RZ FDSLWDO IURP the shareholders to see it through a tough trading period. Unfortunately the shareholdHUV ¿ QDQFLHUV IHOW WKH EXVLQHVV ZDV EHWWHU off going into liquidation and the doors were shut soon after.

All staff were barred from the premises in Elandsfontein the following day and were out on the street. Operating from various coffee shops in the Bedfordview area over the recent festive season, making very necessary use of his mobile, Trevor somehow managed to cobble a rescue solution together. Balancing on the tightrope with liquidators on the one hand and other major obligations such as staff considerations on the other, Zulberg was in a tight spot.

The problems were formidable: Ampa was literally in the dwang, with debts exceeding 100 bar, plus it had been employing over 280 people.

There were some positives though, if the business could get going again. These included the fact that the plant and equipment were in good condition and the core of the company’s staff remained committed, 14 JUNE / JULY 2017

and who at that stage were just hoping the business could be saved, but at the end of 2016 and early this year that looked extremely unlikely.

Zulberg, the ex-Stallion Security, Tetrathene businessman, didn’t allow the obstacles to stall the recovery plan. Amazingly, he put together a rescue plan involving a large percentage of his personal funding, and some additional IDC work in progress funding. With this backing he was able to put in an offer to the liquidators in order to repurchase all the machinery that had been advertised in the local media. Then a new lease had to be negotiated with the landlord for the property in Tunney, Elandsfontein, and a settlement agreement needed to be reached with the majority union. Part of the offer to purchase was the continuation of the Ampa name so as to keep the usage of the brands that have become so well entrenched in the industry over the years.

Thankfully this was all negotiated and accepted successfully and therefore it was literally a case of a new beginning and a new entity was formed.

Huge legacy issues existed in the business, which was no surprise as it had been operating steadily for over four decades and had established itself as the preferred supplier for a range of plastic sheet types.

But although Zulberg and some of the NH\ VWDII KDG EHHQ WKURXJK ³¿ YH PRQWKV RI hell,â€? some positives began to emerge. “We have been able to cherry pick what we see as the best options,â€? said Zulberg, &(2 RI WKH 1HZFR VSHFLÂż FDOO\ ZLWK UH gard to the product lines which offer most potential. It has gone back virtually to its

roots and is now manufacturing polycarERQDWH À DW DQG SUR¿ OHG VKHHW SRO\SURS WZLQ ZDOO VKHHW ¾&RURSODVœ DV ZHOO DV $%6 +' 33 DQG 367 À DW VKHHW And the bottom line is a lot less challenging too: break-even has dropped to less than a third of what it was when it was shut down last year.

Staff numbers have reduced dramatically as well: in its heyday prior to 2014, Ampa employed over 400 people, but had fallen to 280 by 2016. Now, after restarting, Ampa is employing approximately 70 people, the most obvious result of ‘rightsizing’ the operation.

The Ampa branch ofÂż FHV DURXQG WKH FRXQWU\ have also gone. The company is now supplying via distributors or direct to clients. “The process has been very challenging,â€? said Zulberg. “We’ve all personally changed ( hopefully for WKH EHWWHU DV ZHOO DV VWUD tegically and have learnt a lot during this process and as a result it’s made us more adamant to prove what we can achieve.â€?

There is now a tangible sense of relief amongst the staff, particularly so after the barren festive season, and that looks like it’s being channelled into a new, driven market focus. That sense of relief was boosted at the time the doors reopened RQ $SULO DQG ZRUN À RRGHG LQ DJDLQ 7KDW momentum from the earlier years may prove to be the most useful of the legacy issues that have built up around Ampa over the past 44 years.

Ampa is working again with its network of distributors across Southern and West Africa and is also due to start working with distributors within SA.

“We’ve all changed a bit, and it’s made us want to prove that we can achieve our goals.�

www.ampa.co.za

After restarting, Ampa is employing approximately 70 people – led by management team Munya Mihlolo, Brett Goldberg, Andries 3UHWRULXV ¿ QDQFLDO director) and Trevor Zulberg (CEO of the Newco)

FdB CONSULTING Engineering Design

www.rapidgranulator.com

Phone: +27 (0)82-651 3315 Email: frank@fdbconsulting.co.za

NEWS

6XQ $FH 6RXWK $IULFD UHFHLYH ,02 FHUWLĂ€ FDWLRQ

16 JUNE / JULY 2017

2QH RI WKH Âż UVW FRPSDQLHV WR EH FRPSOLDQW SUN ACE South Africa (SASA) is a subsidiary of a global polymer additive business and exports approximately half of its production into 15 African countries.

As of 1 July 2016, the International Maritime Organisation (IMO) amended the Safety of Life at Sea Convention (SOLAS) to require, as a condition for loading a packed container onto a ship for export, WKDW WKH FRQWDLQHU KDV D YHULÂż HG JURVV weight. The shipper is responsible for YHULÂż FDWLRQ RI WKH SDFNHG FRQWDLQHUÂśV JURVV weight. After 1 July, it would be a violation of SOLAS to load a packed container onto a vessel if the vessel and marine terminal RSHUDWRUV GR QRW KDYH YHULÂż HG FRQWDLQHU weights. Furthermore, it is illegal to collect packed containers for shipment without

the correct documentation.

On becoming aware of the requirement, SASA immediately put a programme into place to become accredited by 1 July. SASA used the services of SGS, an approved SANAS auditor, to perform the required audit and YHULÂż FDWLRQV GXULQJ -XQH “Sun Ace is proud in that we achieved WKH YHULÂż FDWLRQ DIWHU D VLQJOH DXGLW ´ says MD Terence Hobson. “SGS FRQÂż UPHG 6$6$ WR EH RQH RI WKH Âż UVW companies to be compliant. This is testament to the entrenched quality systems, consistency in processes, and accuracy in measurement, that SASA customers have become DFFXVWRPHG WR´ KH DGGHG

Sun Ace South Africa (SASA) complies with the following processes and documentation: 1. $ 9HULÂż FDWLRQ &HUWLÂż FDWH 6*6 DFFUHGLWHG 9HULÂż FDWLRQ /DERUDWRULHV

2. Safe packing of the container, by even distribution 3. $SSRLQWHG DQG FRPSHWHQW 9HULÂż FDWLRQ 2IÂż FHUV 4. &DOLEUDWLRQ DQG YHULÂż FDWLRQ FHUWLÂż FDWHV 5. Training records of operators of weighing equipment 6. Servicing and maintenance records of weighing equipment 7. Records of weight tickets issued www.sunace.co.za

Rotomoulding from

MBT South Africa Distributors of Plastic Raw Materials Unit 16 (DVWZRRG 2IÂżFH 3DUN Unit 16, Eastwood Office Park, E 5LOH\ 5RDG %HGIRUGYLHZ 11b+27-11-455 Riley Road, Tel: 2889Bedfordview: Tel:

011 455 2889

&DSH 7RZQ 2IÂżFH &ROOHJH +RXVH Cape Town Office, 4 College 9LOODJH :DON 3DUNODQGV Village Walk, Parklands: Tel: +27-21-5567787

We sell natural pellets, natural powder and colour compound powder as well as a full range of HDPE LDPE LLDPE PVC PET PS ABS PP & Wax

For all your of Polymer Distributors Plastic Raw Raw Material Materials Requirements &DSH 7RZQ 2IÂżFH &ROOHJH +RXVH

Unit 16 (DVWZRRG 2IÂżFH 3DUN

hĹśĹ?Ćš ϭϲ͕ Ä‚Ć?ĆšÇ Ĺ˝Ĺ˝Äš Kĸ Ä?Äž WÄ‚ĆŒĹŹ Ď­Ď­Ä? ZĹ?ůĞLJ ZŽĂĚ͕ ÄžÄšÄ¨Ĺ˝ĆŒÄšÇ€Ĺ?ÄžÇ Tel: +27-11-455 2889

ĂƉĞ dĹ˝Ç Ĺś Kĸ Ä?Äž Ď° ŽůůĞĹ?Äž ,ŽƾĆ?Ğ͕ sĹ?ĹŻĹŻÄ‚Ĺ?Äž tÄ‚ĹŻĹŹÍ• WÄ‚ĆŒĹŹĹŻÄ‚ĹśÄšĆ?

Tel: +27-21-556 7787

www.mbtsa.co.za >Ä‚ĹśÄ?Äž ǀĚ DÄžĆŒÇ Äž ĎŹĎ´ĎŽ ϾϏϭ Ϗϰϳϳ WĂƾů 'ĆŒĹ?Ć‰Ć‰ÄžĆŒ ĎŹĎ´ĎŽ ϰϹϲ ϲϲϹϾ dĹ?Ä‚Ĺ?Ĺ˝ ĚŽĆ? ZĂžŽĆ? ĎŹĎ´ĎŽ ϳϳϹ Ϲϯϰϰ

Ä‚ĆŒĹŻĹ˝ĆŠ Ä‚ ^ƚĂč Ĺ˝ĆŒÄš ĎŹĎ´ĎŽ ϲϏϏ ϳϰϏϯ ,ĞůĹ?Ä‚ &ÄžĆŒĆŒÄžĹ?ĆŒÄ‚ ĎŹĎ´ĎŻ ϳϲϾ ϰϹϰϯ ^ƚĞǀĞŜ ŽĂƚĞĆ? Ϗϲϯ ϲϾϾ ϹϭϏϹ

erda.co.za

NEWS

The new Tederic injection moulding machines supplied by Userve to Blue Belt - Darron Kensley and Tom Modlen of Blue Belt hold a section RI WKH %OXH %HOW FRQYH\RU À DQNHG E\ &HVDUH DQG 8PEHUWR )DYLQL IURP 8VHUYH RQ WKH OHIW DQG 7DOGRQQ &RQQ DOVR RI 8VHUYH RQ WKH ULJKW

Userve commissions Tederics at Blue Belt

5

Reliable, affordable machines with exemplary back-up service USERVE Plastic Machinery recently comPLVVLRQHG ¿ YH QHZ 7HGHULF LQMHFWLRQ PRXOG LQJ PDFKLQHV DW WKHUPRSODVWLF FRQYH\RU EHOW PDQXIDFWXUHU %OXH %HOW 7KH 7HGHULF PDFKLQHV DUH DOO ' VHULHV ' [ ' ' ' VHUYR K\GUDXOLF XQLWV HTXLSSHG ZLWK EL PHWDOOLF EDUUHO DQG VFUHZ V\VWHPV WR UXQ HQJLQHHULQJ SODVWLFV (VWDEOLVKHG \HDUV DJR 1RUWKULGLQJ EDVHG %OXH %HOW PDQXIDFWXUHV WKH µDOO LQ RQH¶ K\EULG SODVWLF EHOW FDSDEOH RI FRPELQLQJ VWUDLJKW KRUL]RQWDO DQG YHUWLFDO UDGLL VHFWLRQV LQWR RQH VPRRWK FRQWLQXRXV FRQYH\RU 7KH DOO SXUSRVH K\EULG WKHUPRSODVWLF FKDLQ GHYHORSHG ZLWK GRXEOH VKHHU DQG

WHQVLOH VWUHQJWK FKDUDFWHULVWLFV LV VXLWDEOH IRU XVH LQ KLJK VSHHG RSHUDWLRQV KDV QR PRYLQJ SDUWV DQG UHTXLUHV QR OXEULFDWLRQ 7KH UHVXOW LV ORZ IULFWLRQ DQG VPRRWK TXLHW RSHUDWLRQ ± WKH V\VWHPV LV RI WKH ZHLJKW RI FRPSDUDEOH VWHHO FRPSRQHQWV DQG DFKLHYHV MXVW RQH WKLUG RI WKH IULFWLRQ IDFWRU ³:H ¿ QG WKH 7HGHULF PDFKLQHV WR EH UHOLDEOH DQG DIIRUGDEOH DQG WKHLU EDFN XS VHUYLFH VSDUHV DQG IULHQGOLQHVV RI 8VHUYH WKH 7HGHULF DJHQW LQ 6RXWK $IULFD WR EH RI D KLJK VWDQGDUG 7KLV LV ZKDW PDNHV 7HG HULF DQ HDV\ FKRLFH WR PDNH ´ VDLG 'DUURQ .HQVOH\ RI %OXH %HOW 8VHUYH 3ODVWLF 0DFKLQHU\ EDVHG LQ 6WU\GRP 3DUN LQ *DXWHQJ VSHFLDOLVHV LQ

DOO DVSHFWV RI SODVWLF PDFKLQHU\ ZLWK RYHU \HDUV¶ H[SHULHQFH VXSSO\LQJ VHUYLFLQJ DQG UHIXUELVKLQJ LQMHFWLRQ PRXOGHUV EORZ PRXOGHUV H[WUXVLRQ OLQHV EDJ PDNHUV SULQWHUV DV ZHOO DV DOO DQFLOODU\ HTXLSPHQW 7KH FRPSDQ\ LQWURGXFHG WKH 7HGHULF LQMHFWLRQ PRXOGLQJ PDFKLQH D &( FHUWL¿ HG PDFKLQH WR 6RXWK $IULFD LQ 8VHUYH EHOLHYHV LW LV LPSRUWDQW DQG WKDW WKH FXVWRPHU ZLOO EHQH¿ W LI WKH\ VWD\ ZLWK RQH HTXLSPHQW EUDQG DV WKLV HQVXUHV FRQVLVWHQF\ LQ PDQXIDFWXULQJ DV ZHOO DV JXDUDQWHHG EDFN XS DQG JRRG VHUYLFH www.userve.co.za www.bluebelt.co.za

Michelin introduces airless golf cart tyre 0,&+(/,1 7ZHHO 7HFKQRORJLHV LV UROOLQJ RXW WKH ; 7ZHHO 7XUI DQ DLUOHVV UDGLDO JROI FDUW W\UH GHVLJQHG WR UHSODFH WKH VWDQGDUG ; 1 IURQW DQG UHDU W\UH RQ JROI FDUWV %HFDXVH WKH W\UH LV DLUOHVV LW FDQQRW JR À DW RU ORVH SUHVVXUH 7KH SRO\XUHWKDQH W\UH IHDWXUHV D IRXU EROW SDWWHUQ DQG LV FRQVWUXFWHG ZLWK KLJK VWUHQJWK SRO\ UHVLQ VSRNHV WKDW KHOS FDUU\ WKH ORDG DQG FUHDWH VXVSHQVLRQ OLNH FKDUDFWHULVWLFV 7KH PXOWL GLUHFWLRQDO WUHDG SURYLGHV IRU ORQJHU ZHDU DQG EHWWHU WUDFWLRQ DFFRUGLQJ WR 0LFKHOLQ 18 JUNE / JULY 2017

Plastic Machinery Injection moulding machines and ancillaries for the plastic converting industry and suppliers of and

robotics fom Italy

robots from China

Professional >> Precise>> Power-Saving >> Short Cycle >> Stable

• • • •

Toggle system injection moulding machines Clamping force 60 - 4000 ton Two-platen clamping injection moulding machines Clamping force 850 - 7000 ton

Applications Automobile parts, IT, construction industry, civilian and industrial goods, transportation and logistics, home appliances Visit us at our new showroom: Unit A6, Strydom Industrial Park, No 13 Hammer Avenue, Strydom Park.

OFFICE: +27 11 791 3145 Mobile: +27 82 075 7192 Email: umberto@userve.co.za info@userve.co.za

Website: www.userve.co.za

NEWS

DPI Plastics commissions

new HDPE pipe factory

20 JUNE / JULY 2017

14 extrusion lines and an installed capacity of 2 200 tons a month A NEW factory with 14 extrusion lines, and an installed capacity of 2 200 tons a month, was commissioned by DPI Plastics in March. Located adjacent to the existing Roodekop facility in Johannesburg, the new factory will produce HDPE pipe up to 1 000mm in diameter, and up to PN25 pressure class.

The new factory is operational and consists of an entirely separate site that required new infrastructure such as cabling, power, water, stockyard, a laboratory and a raw-material store. Using only approved PE 100 raw material, the pipe will be manufactured in accordance with SANS 4427 (HDPE for water) and SANS 4437 (HDPE for gas).

The new HDPE factory has 14 extrusion lines and an installed capacity of 2 200 tons a month

“Our production capability has tripled with the acquisition of these new machines,” said DPI Plastics Technical and Product Manager, Renier Snyman.

The Durothene-branded size range that will be produced ranges from 16mm up to 1 000mm, in pressure classes from 3 to 25. Smaller pipes up to a diameter of 110mm are coiled in up to 100m lengths. ³2XU ODERUDWRU\ KDV PHOW À RZ LQGH[LQJ (MFI) and oxidation induction time (OIT) testers to perform critical quality tests on our HDPE pipes,” Snyman explained. DPI Plastics also has a recycling facility where internal scrap is reworked into pellets that are tested and reused.

The latest addition enhances the

manufacturing capabilities of DPI Plastics, which already boasts the largest PVC pipe production capability in Africa.

Commissioned in 1980, the Roodekop factory has 15 extrusion lines and an installed capacity of 2 700 tons a month.

It produces PVC pipe in diameters from 50mm up to 630mm, and pressure classes from four to 25 bar - the only factory in Africa that produces 630-mmdiameter PVC-m pipe.

DPI Plastics also has an injectionmoulding factory, with 18 injection moulders from 50 tons to 575 tons, and an installed capacity of 250 tons a PRQWK 7KH IDFWRU\ SURGXFHV 39& ¿ WWLQJV from 40mm to 160mm, which are also

DPI Plastics Technical and Product Manager Renier Snyman

The new factory enhances the manufacturing capabilities of DPI Plastics and can produce HDPE pipe up 1 000mm in diameter and up to PN25 pressure class

trimmed, assembled, and packed on-site.

Mould and machine maintenance are taken care of by a fully functional tool room, with lathes, milling machines and a VSDUN HURGHU &HUWDLQ ¿ WWLQJ FRQ¿ JXUDWLRQV

are fabricated separately by means of cutting and welding, while two 30 ton SUHVVHV ¿ W VWHHO 9LFWDXOLF VKRXOGHUV RQWR 39& KLJK LPSDFW DQG PLQLQJ SLSHV www.dpiplastics.co.za

Top: DPI Plastics’ new HDPE factory is adjacent to the existing Roodekop facility in Johannesburg Above: The Durothene-branded pipes range from 16mm to 1 000mm

JUNE / JULY 2017 21

NEWS

Bag Safe Keeping luggage tamper evident and safe A NEW product being launched in South Africa is the Bag Safe – a cheaper alternative to plastic ‘wrapping’ – made from polyethylene.

Jan Visser, who is considered the ‘father of the plastic envelope in South Africa’ and founder of Plaslope, is also the MD of Tamper Evident Security Solutions. Jan, who together with his business partner Kevin du Preez, developed the product and will be marketing the Bag Safe.

Jan explained that the Bag Safe is a cheaper and simpler alternative to having luggage stretch-wrapped or shrinkwrapped at an airport.

Jan and Kevin’s tamper-evident Bag Safe’s are made Locally developed, the Bag Safe is a cheaper using 120 micron PE and can accommodate printing on both and simpler alternative sides for branding purposes. Currently three different sizes to having luggage DUH SURGXFHG WR Âż W D PHGLXP DQG ODUJH VXLWFDVH DV ZHOO DV stretch-wrapped or D WUROOH\ GXIĂ€ H EDJ shrink-wrapped at an “When travelling by air, the risk of items being stolen airport from luggage, as well as the risk that luggage is used for the piggy-backing of drugs from one country to another, is a very real danger,â€? said Jan. “Travelers then also have the hassle of standing in the queue at an airport to have luggage either stretch-wrapped or shrink-wrapped. This not only takes time but is expensive and adds to the anxiety of having to get to the check-in on time so that they do not PLVV WKH Ă€ LJKW ´ H[SODLQHG -DQ “The Bag Safe is a DIY operation that can be performed at home or in your accommodation, prior to leaving for the airport. It is also a lot easier to remove than the stretch wrap. “We also include sequentially numbered sets of tamperevident security seals in the pack. This enables visual detection of any tampering that may have taken place at the time the luggage is removed from the airports ‘arrivals’ carousel. This will allow a traveler to report the matter before you even leave the arrivals hall,â€? he added.

Contact Jan or Kevin on email at Jan@thebagsafe.co.za or Kevin@thebagsafe.co.za www.thebagsafe.co.za Currently the Bag Safe is available online at

Jan Visser, who is considered the ‘father of the plastic envelope in South Africa’ and founder of Plaslope, is also the MD of Tamper Evident Security Solutions

Incledon supplies 6km sewer pipe for Nelspruit project INCLEDON is supplying 6km of PE100 800mm steel-reinforced spirally-wound HDPE pipe for the Tekwane South integrated human settlement project in the Nelspruit area. The project will accommodate 722 Breaking New Ground (BNG) houses and walk-up units for 500 households.

The sewer pipe forms part of the bulk infrastructure to be provided and will run from Tekwane South Extension 2 to the wastewater treatment. The pipe is made from reinforced polyethylene, formed by integrating HDPE with steel strips. The pipe itself is being manufactured by Amanzi Stairway of East London. The expected lifespan of the PE100 800mm pipe is 50 to 100 years, far in excess of any traditional sewer pipe. Due to its high ring-stiffness-to-weight ratio, the pipe is also much lighter than any comparable plastic pipe with equal ring stiffness.

22

JUNE / JULY 2017

www.dpiplastics.co.za

INNOVATE ADVANCE EXCEED NUVO™ Rubber Compounders is a bespoke rubber compounding company situated in Kwa-Zulu Natal, South Africa and servicing both the local and global market. Equipped with a research and testing laboratory that far exceeds conventional standards together with the most advanced mixing equipment, innovation is at the company’s core. NUVO’s customer focused ethos and unabated pursuit of technological advancement has placed them amongst the world’s leaders in compounding science. With a personalised approach and decades of experience NUVO™ offer a rubber compounding solution of distinction.

NUVO™ RUBBER COMPOUNDERS Tel: 033 387 1330 35 Willowton Road, Willowton, Pietermaritzburg, 3201 Kwa-Zulu Natal, South Africa info@nuvorubber.com www.nuvorubber.com NUVO™ LV D OHYHO %(( FRQWULEXWRU KDV ,62 FHUWLˉFDWLRQ

NEWS Donal Ryan of Nuvo Rubber Compounders of Pietermaritzburg conducted the study

Nuvo study shows

how rubber imports hammered SA co’s Non-tyre sector missed opportunity to grow, lost jobs during 15-yr period THE SCALE of the impact of imports from China on the South African rubber manufacturing industry has been far more severe than even the most skeptical of analysts may have originally believed.

According to a study commissioned

by Nuvo Rubber Compounders of Pietermaritzburg, the effect of Chinese rubber imports on the local sector over a 15-year period, from 1999-2014, resulted in WKH VHFWRUÂśV ÂľWUDGH GHÂż FLWÂś MXPSLQJ IURP 5 ELOOLRQ LQ WR 5 ELOOLRQ LQ Âą WKLV equates to imports growing from 9000 to 40,000 tonnes tons per year. ,Q ZKDW ZDV WKH Âż UVW VWXG\ RI LWV NLQG in South Africa in which the analysis split the rubber industry into tyre and ‘non-tyre’ sectors, a far clearer picture of the plight of manufacturers in the ‘non-tyre’ sector emerged. Non-tyre refers to technical rubber component manufacturers.

Prior to the study, the non-tyre component manufacturers had been lumped with the far larger tonnage tyre sector and been almost completely overlooked.

Dr Donal Ryan of Nuvo handled the comprehensive study. His analysis separated the direct effect of Chinese imports on domestic production and employment.

Trade data from SARS and StatsSA and data from several rubber industry sources were used. A questionnaire survey of rubber component manufacturing companies who are members of the Institute of Materials

(IOM3) was also carried out. A number of the non-tyre rubber manufacturers also compound rubber material and supply this to the local market and in some cases export too, adding a slight further complication to the research process. $FFRUGLQJ WR 5\DQÂśV Âż QGLQJV LPSRUWV of non-tyre rubber components (usually mouldings such belting, hose, mining, transport and other sectors) climbed far more steeply during the period than that of tyres.

In the year 1999, imports were minimal but had grown to over 30,000 tons/year by 2013 Âą ZKLFK LQFLGHQWDOO\ ZDV DOVR WKH Âż UVW \HDU when imports began to decline slightly.

Figure 1 – Imports of rubber products from China

The tyre sector also suffered due to the high rate of tyre imports during the period, but imports were sourced from other origins besides China. ³,PSRUWV LQWR 6$ KDG D VLJQL¿ FDQW DQG negative effect on growth in domestic production in the non-tyre sector and on employment growth in the overall industry,� said Ryan (see Table 1).

Overall Domestic Production

Non-Tyre

Tyre

+25

-3

+36

+5

Contributing factors: • Domestic Market • Export Market

+19

-1

• Imports from entire world

-30

-7

Table 1 – Change in annual output (in thousand tonnes) of rubber products manufactured in SA between 1999-2014

The table refers to the overall change in annual output in the tyre and non-tyre sectors between 1999 and 2014. For example, the annual domestic production in South Africa in 2014 was 25,000 tonnes higher than it was in 1999. This increase ZDV FDXVHG E\ DQ LQFUHDVH RI tonnes due to the domestic market demand and 19,000 tonnes due to export market demand. But imports had a negative effect of 30,000 tonnes meaning that imports effectively reduced domestic production by this amount.

Note that the ‘imports effect’ outlined in 7DEOH LV IRU LPSRUWV IURP WKH ZKROH ZRUOG Âą QRW MXVW &KLQD Âł)XUWKHU DQDO\VLV RI WKH HIIHFW of imports showed that Chinese imports DORQH GLUHFWO\ GHWUDFWHG RYHU WRQQHV from domestic production in the non-tyre sector between 1999 and 2014,â€? said Ryan.

24 JUNE / JULY 2017

100t of PET-G ‌ and nowhere to go A RECENT inquiry from a local recycling concern queried how to sell or dispose of hundreds of tons of PET-G in the form of trays. No-one is buying it and no-one is recycling it. Tons of PET-G are being dumped as businesses do not know where to go with it. &KDQGUX :DGKZDQL MRLQW 0' RI ([WUX

pet, explained that it is important to make a distinction between PET-G and thermoformed trays (as described above) as PET-G is also used in the manufacture of bottles sometimes.

Currently there is no collection and therefore no recycling of any thermoformed

products in South Africa, whether PET or PET-G. “The systemic problem highlighted here is the approach to the problem in that awareness has only been drawn to the issue after the pack has been produced (be it a tray or bottle). Conventional PET trays are more

from China )RU WKH W\UH VHFWRU WKH ¿ JXUH ZDV ORZHU EXW DW DQ HVWLPDWHG WRQQHV QRQHWKHOHVV KDG DQ DGYHUVH HIIHFW RQ WKDW VHFWRU 7KH ¿ QGLQJV SUHVHQWHG LQ )LJXUH UHODWH VSHFL¿ FDOO\ WR WKH &KLQHVH LPSRUWV HIIHFW DQG VXJJHVW WKDW WKH QRQ W\UH VHFWRU FRXOG KDYH JURZQ E\ DV PXFK DV RYHU WKH \HDUV ZKHUHDV LW DFWXDOO\ DFKLHYHG D IDU ORZHU 7\UH SURGXFWLRQ DOVR VXIIHUHG GXH WR LPSRUWV IURP &KLQD EXW ZKDW ZDV HYHQ PRUH WHOOLQJ ZDV WKDW WRWDO HPSOR\PHQW LQ WKH LQGXVWU\ IHOO E\ DV PXFK DV

ZKHUHDV DERXW KDOI WKRVH MREV FRXOG SRWHQWLDOO\ KDYH EHHQ VDYHG LI D SURSHU VWUDWHJ\ WR FRPEDW WKH KLJK UDWH RI LPSRUWV KDG EHHQ DGRSWHG ³(YHQ ZLWKRXW WKHVH LPSRUWV WKH W\UH LQGXVWU\ ZRXOG RQO\ KDYH JURZQ E\ GXH WR D GUDVWLF GURS LQ WKH GHPDQG IURP WKH GRPHVWLF PDUNHW VLQFH ´ KH DGGHG ³$OPRVW MREV ZHUH ORVW LQ WKH UXEEHU LQGXVWU\ EHWZHHQ DQG ± DOPRVW KDOI RI ZKLFK ZHUH GLUHFWO\ GXH WR WKH ULVH LQ &KLQHVH LPSRUWV ´

Figure 2 – Effect of Chinese imports on growth in the rubber industry between 1999-2014

Survey Ryan then conducted a survey of rubber manufacturers and interviewed with 26 companies, yielding some interesting replies, including that felt the industry was in decline and 100% felt rising imports • 100% were a factor in this; • VXJJHVWHG ODERXU XQUHVW DQG SRRU HI¿ FLHQF\ ZHUH DOVR IDFWRUV of companies have experienced increased output – over 80% • of38% who cited exports as a contributing factor; • 73% felt import duties should be increased; • 47% felt workforce skill level needs to be improved; and • 33% felt technology needs to be improved

www.nuvorubber.com

OLNHO\ WR HQG XS EHLQJ UHF\FOHG LQ WLPH ZKLFK FDQQRW EH VDLG IRU 3(7 * DQG DV VXFK VKRXOG QRW EH PXGGOHG XS LQ WKDW GHEDWH ´ VDLG &KDQGUX ³%UDQG RZQHUV QHHG WR EH DVNLQJ WKH TXHVWLRQ DV WR WKH VXLWDELOLW\ RI D PDWHULDO RU SDFN WR UHF\FOLQJ EHIRUH LW¶V HYHU PDQXIDFWXUHG 7KH IXQGDPHQWDO

FKDOOHQJH ZLWK 3(7 * JOREDOO\ LV WKDW LW KDV D GLIIHUHQW PHOWLQJ WHPSHUDWXUH WR FRQYHQWLRQDO 3(7 DQG DV VXFK DFWV DV D FRQWDPLQDQW LQ 3(7 UHF\FOLQJ SODQWV 7KH RQO\ UHDOLVWLF VROXWLRQ LV WKDW 3(7 * VKRXOG QRW EH WKH FKRVHQ PHGLXP IRU DQ\ SDFNDJ LQJ DW WKLV MXQFWXUH LI VXVWDLQDELO LW\ LV WUXO\ D FRQFHUQ ´ KH DGGHG JUNE / JULY 2017 25

NEWS

Ren-Flex installs sophisticated

digital press for IML

26 JUNE / JULY 2017

Only digital printer in Africa used for IML labels REN-FLEX of Johannesburg, the label manufacturing business in the Ren-Form group, has installed a highly advanced digital press for the printing of IML labels, taking it one step further towards its goal of becoming one of Africa’s top label manufacturers.

The HP Smartstream Digital press for labels and packaging is the only digital printer in Africa being used for the production of IML (in-mould labelling) labels – and Ren-Flex JRW RII WR D À \LQJ VWDUW ZLWK WKH QHZ WHFKQRO ogy, achieving fantastic quality virtually from WKH ¿ UVW SURGXFWLRQ UXQ The SmartStream printer, powered by Esko, can print at speeds up to 42m a minute, run a maximum web width of 740mm and print on media thickness from 10-250

PLFURQV RQ D ZLGH YDULHW\ RI ¿ OPV ± LQFOXGLQJ DOO WKH PDLQ ¿ OPV XVHG IRU ,0/ ODEHOV FXU UHQWO\ %233 ¿ OPV DUH WKH PRVW SRSXODU IRU IML products currently, with 5-layer BOPP ¿ OPV EHLQJ WKH FKRLFH RI EUDQG RZQHUV LQ some cases. Varnishes used to coat the labels are being imported.

The system was introduced to customers at a ‘Fire & Ice’ open house event held at Ren-Flex’s new premises in Booysens in April.

Besides the fact that it’s digital, the new system offers considerably faster set-up WLPHV DQG LV OLWHUDOO\ PRUH À H[LEOH WKDQ V\V tems used to date. Several of SA’s top bottle and containers manufacturers attended the event, in some cases conveniently being

1 Ren-Flex marketing manager Erika Hearnshaw is very happy with the IML results from the new HP press 2 Ren-Flex FKLHI RSHUDWLQJ RI¿ FHU $OEH 1DXGp 3 *XHVWV KDG RSSRUWXQLW\ WR VHH WKH SULQWLQJ SURFHVV LQ DFWLRQ ZLWK WKH GLIIHUHQW FRORXUV EHLQJ ODLG GRZQ VHTXHQWLDOO\ 4 7KH ¿ UVW GLJLWDOO\ SULQWHG ,0/ MREV UROOHG RII WKH PDFKLQH VKRUWO\ DIWHU LQVWDOODWLRQ DQG VRPH JXHVWV DW WKH ODXQFK IXQFWLRQ LQ %RR\VHQV ZHUH HYHQ DEOH WR VHH WKHLU ODEHOV EHLQJ SULQWHG 5 5HQIRUP &(2 7RPP\ GX 6DUW FHQWUH ZDV KDSS\ WR KRVW FXVWRPHUV VXSSOLHUV DQG VWDII DW WKH µ)LUH ,FH¶ SDUW\ DW WKH FRPSDQ\¶V QHZ SUHPLVHV LQ $SULO 1

3

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able to inspect the quality and progress of jobs being run on the new system.

The new HP printer also offers the major advantage of being suited for short-run label print orders, which has opened a whole new market. Previously food and beverage manufacturers, or for that matter suppliers of any product in which thin-wall containers are used (where IML is feasible) were reluctant to print as large orders were required ± DQG WKHVH ZHUH GLI¿ FXOW WR MXVWLI\ ZLWK product introductions. The new machine has hence opened the door for a number of new medium-sized food and beverage manufacturers who have recently entered the market.

According to Ren-Form chief operating

4

The main print hall at Ren-Flex’s new premises in Booysens, where it has extensively renovated and modernised an existing factory, houses its other presses, including the Drent-Goebel UV offset press which it has used to print IML products since 2012. The new HP digital press is housed in an adjacent hall

labels RIÂż FHU $OEH 1DXGp WKH GLJLWDO SURM HFW KDV OHG WR VLJQLÂż FDQW FKDQJHV DW WKH JURXS ,W PRYHG LWV ODEHO SULQWLQJ EXVLQHVV IURP QHDUE\ 6HOE\ WR LPSUHVVLYHO\ UHQRYDWHG SUHPLVHV LQ QHDUE\ %RR\VHQV DQG VHW XS D VWDWH RI WKH DUW SODQW ZLWK

WKH DLP RI PHHWLQJ JOREDO SULQW VWDQGDUGV • Ren-Form started in 1989 as a computer forms supplier and expanded its abilities in continuous specialty forms, offering litho and web print. It started Ren-Flex, the label manufacturing subsidiary business in 2011.

Little Green Beverages bought by Ethos Capital Time to Refreshhh! /,77/( *5((1 %HYHUDJHV WKH FDUERQDWHG VRIWGULQN PDQXIDFWXUHU KDV EHHQ SXUFKDVHG E\ (WKRV &DSLWDO D SULYDWH HTXLW\ EXVLQHVV (WKRV UHFHQWO\ FRQ¿ UPHG WKDW LW KDG DFTXLUHG D PDMRULW\ VKDUHKROGLQJ LQ /*% LQ SDUWQHUVKLS ZLWK WKH EXVLQHVVœV PDQDJHPHQW DQG 1HGEDQN 3ULYDWH (TXLW\ /*% KDV D QDWLRQDO IRRWSULQW ZLWK SURGXFWLRQ IDFLOLWLHV LQ (DVW /RQGRQ DQG -RKDQQHVEXUJ DV ZHOO DV GHSRWV LQ %ORHPIRQWHLQ .ZD =XOX 1DWDO DQG WKH :HVWHUQ &DSH /*% SURGXFHV D ZLGH YDULHW\ RI EHYHUDJHV LQFOXGLQJ &6' PLQHUDO ZDWHU PL[HUV DQG HQHUJ\ GULQNV DOO YDULDQWV RI WKH 5HIUHVKKK EUDQG DQG SULYDWH ODEHO SURGXFWV IRU OHDGLQJ UHWDLOHUV (WKRV SDUWQHU -RQDWKDQ 0DWWKHZV VDLG /*%œV EXVLQHVV SURFHVVHV SHRSOH DQG EUDQGV ZRXOG UHFHLYH HQKDQFHG IRFXV DQG LQYHVWPHQW WR IXUWKHU LPSURYH SURGXFWV DQG GHOLYHU YDOXH 0LFKDHO %HQMDPLQ H[ 6$%0LOOHU KDV EHHQ DSSRLQWHG &(2 RI /LWWOH *UHHQ &R IRXQGHU /DQFH 6KHSSDUG ZLOO IXO¿ O WKH NH\ UROH RI FRPPHUFLDO GLUHFWRU ZKLOH IHOORZ FR IRXQGHU 9LPDO *RZDQ KDV VROG KLV LQWHUHVW LQ WKH FRPSDQ\ (WKRV LV RQH RI 6RXWK $IULFDœV ODUJHVW SULYDWH HTXLW\ IXQG PDQDJHUV ZLWK D \HDU WUDFN UHFRUG 7KH 5HIUHVKKK UDQJH FRPSULVHV FDUERQDWHG VRIWGULQN À DYRXUV ZLWK ¿ YH DGGLWLRQDO VXJDU IUHH À DYRXUV DYDLODEOH LQ OLWUH OLWUH PO DQG PO 3(7 ERWWOHV ,W PDQXIDF WXUHV LWV RZQ FRQWDLQHUV DW WKH SODQWV LQ ,VDQGR DQG :LOVRQLD

www.renform.co.za

JUNE / JULY 2017 27

͞ϯ DŽƾůĚ ĹśĹ?Ĺ?ĹśÄžÄžĆŒĹ?ĹśĹ? ŽĨ ƚŚĞ “Base for Symba Peadiatric Hospital Bedâ€?)

0DXV – A A winner’s choice!

Maus GmbH designs, engineers and manufactures aluminium moulds, suitable for your projects, using the latest available technology. This allows us to achieve the quality Maus is known for - as well as keeping the agreed deadlines. Depending on your ideas and requirements, we can choose from a variety of technologies for the production of your rotational mould.

(CNC Aluminium mould half for “Base for Symba Peadiatric Hospital Bed�)

We at are very proud that the Íž^LJžÄ?Ä‚ Peadiatric Hospital ĞĚÍ&#x;Í• a product made from our mould, has won the prestigious ARMSA 2017 Product of the Year Award.

Special thanks to Pioneer Plastics for giving us the chance to become involved in this project, but also for the very professional co-operation during the project realization. /Ĩ LJŽƾ͛Ě ĹŻĹ?ĹŹÄž ƚŽ ÄšĹ?Ć?Ä?ĆľĆ?Ć? Ç‡Ĺ˝ĆľĆŒ Ä¨ĆľĆšĆľĆŒÄž žŽƾůĚ Ć‰ĆŒĹ˝ĹŠÄžÄ?ĆšĆ? Ç Ĺ?ƚŚ ĆľĆ?Í• Ç ÄžÍ›ĆŒÄž ĹŠĆľĆ?Ćš Ä‚ Click away!

www.maus-gmbh.de

info@maus-gmbh.de

+49 (0) 721 94874-0

HOSAF PET CONFERENCE ‘017

Hosaf PET conference bolsters

Presentations from across value chain at PET pow-wow WITH Hosaf’s PET output about to undergo an exponential increase, the timing of the company’s PET Conference in May was opportune ‌ but the focus was on developing understanding of the market dynamics and future technologies, rather than on sales.

The new energy at Hosaf, now that the PET manufacturer’s group has been expanded by parent company KAP’s recent purchase of Safripol, was evident at the conference at the Hyatt Hotel in Johannesburg. Hosaf and Safripol, who until recently had relatively little to do with one another, are now on the same team as part of the KAP Chemicals group – which has virtually overnight become one of the biggest polymer manufacturing businesses in Africa, if not the outright leader. Besides Hosaf’s soon to be commissioned additional PET volumes which will see it increase output from 160,000 to 210,000 tons per annum, KAP Chemicals has capacities of 160,000 of HDPE and 120,000 tpa of polyprop from the Safripol plant at Sasolburg.

PET is one of the success stories of the South African plastics sector, as a result of which it’s probably not surprising that between 60,000 and 80,000 tpa of the material has been LPSRUWHG DQQXDOO\ HVWLPDWHV RI WKH DFWXDO ¿JXUH GLIIHU

The large and increasing capacity for PET in China and

SE Asia is a major feature of this market, according to the opening statement by Hosaf GM Daniel Schoeman: China is manufacturing about 7,3 million tons per annum and SE Asia about 6,1 million tpa, with material exports from this zone dominating the market internationally. The other main importers RI 3(7 LQ $IULFD LQFOXGH 1LJHULD WSD (J\SW WSD DQG 7XQLVLD WSD

Dr Roeloff Botha, the comic ‌ err economic forecaster, then provided an analysis of the regional economic scene.

Besides the many lighthearted moments, the fact that manufacturing as a share of GRP in South Africa has declined from over 20% in the 1990s, to less than 15% today, is VHULRXV 5HFHQW VWDWV LQGLFDWH WKDW WKH ÂżJXUH PD\ EH HYHQ lower and closer to just 12%. According to Botha, the main cause for this decline is imports from China (which is a problem that most countries around the world have had to FRQWHQG ZLWK RYHU WKH SDVW \HDUV

Matt Tudball of ICIS, the polymer sector global analyst and forecaster, said the international PET market is characterised by excess capacity, and there’s more capacity coming onstream – particularly in China. Six new plants are under construction in China. South Africa is arguably a safe distance from China to After day one, delegates were bussed over to Katy’s Palace Bar in Sandton for an evening of gambling and entertainment. Most seemed unfamiliar with the process, so it was just as well that real money wasn’t involved

28

JUNE / JULY 2017

Daniel Schoeman, GM of Hosaf, presented a summary of the company’s plant expansion in Durban

Keynote speaker, Dr Roelof Botha gave an economic outlook, ‘Better Future for South Africa,’ which was packed with anecdotes about the local political scenario

Neelin Naidoo of Mpact, Lyle Batchelor of Little Green Beverages and Johnny Magalo of Mpact were in good spirits Lorita Diem of Novara/REPI Colours and Alta Ingram of Coca Cola-Sabco Francois Agenbach and David Putterill of Quality Beverages 2000; Mohamed Darsot of Tin Can Man and Bernd Sass of Bowler PET

Matt Tudball of ICIS (the industry analysts/forecaster) gave a breakdown of the global PET market; Matt is based in London

Hosaf HR manager Avista Ramkissoon and Daniel Schoeman Cheri Scholtz of PETCO, in her presentation ‘Are we going to prevent Government Intervention,’ looked at how the PET container manufacturing industry has initiated collection and recycling programmes and created employment and opportunities in the sector, which may go a long way to gaining approval from government departments 3DFNDJLQJ6$ÂśV &KDUOHV 0XOOHU KDG D PLOG ERXW RI ¾ÀX which may have resulted in a somewhat more subtle SUHVHQWDWLRQ &KDUOHV ÂżQGV KLPVHOI LQ DQ XQXVXDO situation at the Packaging body: previously he was competing with glass, metal and other packaging materials, now he’s having to defend them – all of them

local sector mitigate the threat of imports, but it has nevertheless up to now been the Chinese manufacturers’ seventh largest PET customer (accounting for 3,5% of China’s PET exports). With the new Hosaf plant in Durban due to be commissioned later this year, the potential for imports will almost certainly decline, while the opportunity for Hosaf to export material to convertors in Southern Africa will increase.

The fact that the amount of time spent by women on domestic activities on average has fallen from four-and-a-half hours a day as recently as 1965 to just 45 minutes now is obviously a huge change, but it’s just one of several factors affecting the packaging sector, said Tom McLaughlin of Woolworths. Now a global player with something like 400 stores, Woolworths is committed to sustainability, but it’s not that easy to achieve. Woolies uses about 26,000 tons of packaging a year and it’s estimated that only about one-third of that is recycled, said Tom. And it’s still not clear who is actually responsible for the sustainable management of all this packaging. Woolies does ‘tracking studies’ of its products involving about 6000 customers every three months and some interesting observations have been made: 33% felt it’s the packaging manufacturers’ responsibility to deal with the materials; 23% felt the food or product manufacturers should; 21% felt the retailers should be responsible and 15% felt the municipalities should do so.

According to Tom, however, there is still too much packaging which is not designed for recycling.

Tom McLaughlin of Woolworths outlined how much the consumer landscape has changed, not least due to the fact that the average woman’s housekeeping ‘duties’ have been slashed from four-and-a-half hours a day to just 45 minutes – make you think hey?

Ashley Henry of Husky outlined some of the recent developments by the Canadian PET systems manufacturer, including a new barrier system and an offset neck proposal

Gambling winner – Victor Gomes of VM Bottle Printers & Fillers (right) received a prize for being the ‘best gambler’ during the diversion to Katy’s Palace, for which he won a weekend trip to a game lodge for two, presented by Hosaf business development manager Stephen Woolven. The ‘contest’ did not involve actual winnings, however,it was all play-play stuff, but Victor’s style won on the night

Henry Attias of Sidel talked about new technology from the French PET systems maker. Sidel is strong in the modular area: some of its systems offer up to 200 SRVVLEOH FRQ¿ JXUDWLRQV JUNE / JULY 2017 29

NEWS

The smaller of the vintage PDFKLQHV ZDV Âż WWHG ZLWK a lock and key, which incredibly is still attached

The 250 ton and ES 5/10 12 ton Engel machines were both manufactured 49 years ago in 1968 and until recently, both were still operational. Operator, Isaac Mahlatsi, has been with Enterprise Plastics since 1985

SA’s oldest surviving

Engel machine in good hands 30 JUNE / JULY 2017

In operation for 49 years POSSIBLY the oldest Engel injection moulding machines in South Africa can be found at Enterprise Plastics in Robertville, Gauteng.

The 12 ton and 250 ton Engel machines were both manufactured in 1968 (49 years old) and until recently, both machines were still operational and only recently taken ofÀ LQH WR PDNH ZD\ IRU PRGHUQ PDFKLQHU\ WR LPSURYH HI¿ FLHQF\ FDSDFLW\ DQG LPSURYH power saving. The 12 ton machine was

used to manufacture plugs, electrical connectors, etc, while the larger 250 ton machine was used to manufacture arm pads, piling spacers and larger components up to 400g shot weight.

Enterprise Plastics has been supplying FRPSRQHQWV WR WKH RIÂż FH FKDLU LQGXVWU\ since 1984, as well as products for the construction and mining industry and safety products for the industrial building sector. Over this time the company has developed a number of new products in conjunction with its customers. Because Enterprise Plastics manufacture locally, they are able to ensure a reliable and HIÂż FLHQW VXSSO\ RI WKHVH LWHPV The company was originally started by Terry Crowe, well-known for his engineering technical knowledge and a senior member of the Plastics Institute of South

Africa (PISA). The company is now run by his daughter Jackie and son-in-law Bruce Barkhuizen.

Enterprise’s other main products include the ‘Globrite’ lightweight demarcation safety barrier system, which it designed and developed. The barrier system was developed as a result of more stringent health and safety requirements in the construction and mining industries. The barriers components are lightweight and can be erected by a single person, that is obviously more cost effective and seen as a value-added feature in this application. Transport costs are also drastically reduced because of the compactness of the barrier in its knock-down form.

Most importantly, the Globrite demarcation safety barrier is highly visible.

Jackie and Bruce Barkhuizen with one of the chair handles that Enterprise Plastics manufactures locally. This is just one example of the larger arm chair handles which Enterprise manufacture, and which used to be solely imported

www.enterpriseplastics.co.za

www.greentechmachinery.co.za

A new generation takes shape.

Take the proven and tested, make it even better and explore something new – that is what makes ENGEL and their customers so successful.

Following our claim be the first, we present a new generation of injection moulding machines setting new standards. For now, we will entice you with this: We do not compromise on energy efficiency, ergonomics or precision. Do you want to know more?

www.engelglobal.com www.greentechmachinery.co.za sales@greentechmachinery.co.za

NEWS

Joint venture between

Boxmore & PETCO creates jobs, drives recycling Critical to minimise the environmental impact of post-consumer PET DURING April, Boxmore Packaging and PETCO, the organization responsible for IXO¿ OOLQJ WKH 6RXWK $IULFDQ 3(7 SODVWLF industry’s role of Extended Producer Responsibility, partnered to sponsor and KDQGRYHU ZDVWH UHF\FOLQJ WUROOH\V WR ¿ YH local PET (polyethylene terephthalate) collectors in the Harrismith community.

In collaboration with Vans Buy Back Centre, PETCO and Boxmore have

LGHQWL¿ HG ¿ YH EHQH¿ FLDULHV IRU WKH WUROOH\V who will sell their PET to Vans Buy Back Centre. This arrangement will allow the waste pickers’ progress to be tracked and their need for assistance to be monitored.

Those involved in this initiative are committed to helping these individuals reach their full earning potential, and to stimulate awareness around the importance of recycling.

“Our company is one of the biggest employers in Harrismith and therefore we are, both directly and indirectly, at least partly responsible for the socio-economic wellbeing of the community,� said Boxmore Harrismith factory manager, Neil Bresendale. “Also, as a leading provider of rigid plastic packaging, it’s critical for our business to minimise the environmental impact of post-consumer

First public-private partnership in composites

32 JUNE / JULY 2017

Composites Training Academy and SARETEC sign agreement THE Composites Training Academy has VLJQHG DQ DJUHHPHQW ZLWK WKH 6RXWK $IULFDQ Renewable Energy Technology Centre 6$5(7(& DQG ZLOO XVH WKHLU VWDWH RI WKH art facility as a base for the Academy. “We are extremely encouraged by this GHYHORSPHQW DV LW LV D Âż UVW DV IDU DV D public-private partnership is concerned in the composites skills development arena,â€? says Oliver Dawson who heads up the Composites Training Academy (CTA).

The CTA is launching various Recognition of Prior Learning (RPL) Assessment programmes that will assist currently employed people in the industry who have years of experience, but no formal recognition for the skills and knowledge they have gained. The programmes, and support WKHUHRI ZLOO EH UXQ RQ 6DWXUGD\V WR DVVLVW learners that are working full time.

Naim Rassool, Managing Director of

6$5(7(& VD\V Âł6$5(7(& LV H[FLWHG LQ partnering with the Composites Training Academy and welcomes the use of our advanced composites laboratory trainLQJ IDFLOLWLHV WR WKH EURDGHU 6RXWK $IULFDQ industry.â€? Âł$QRWKHU Âż UVW IRU XV LV WKDW WKH &7$ ZLOO be delivering skills interventions in Lagos, Nigeria from August 2017,â€? says Dawson. “The academy has delivered noncomposite related services in Nigeria for the past six years and there is a growing demand for us to invest further and to support the development of their composites aspirations as well. The composites industry in Lagos is developing quickly and our clients want to learn more, are open to advice and are welcoming of new technology and opportunities.â€?

7KH &7$ÂśV 6KRS )ORRU 0DQDJHPHQW training programme, like the RPL project,

www.compositesafrica.co.za

will commence in the third quarter of 2017.

7KH SURJUDPPH LV DLPHG DW )LUVW /LQH 0DQ agement in composites environments, and the purpose is to assist department heads and supervisors to develop understanding and capacity in productivity, and how and why to control the quality, costs and scheduling objectives of the business.

About CTA CTA is fully accredited with the Merseta (The Manufacturing, Engineering and 5HODWHG 6HUYLFHV 6(7$ DQG DEOH WR WUDLQ nationally across various application sectors. Our focus at present is on supporting industry to stabilize and standardize operations and then ultimately to grow off a solid base. Understanding WKH WHFKQRORJ\ JDSV EHWZHHQ WKH 6RXWK African and International markets, and the need to “bridge these gaps�, CTA is actively

www.saretec.org.za

PET. Driving recycling through job creation in this community is a win–win scenario that I’m proud to be associated with.�

PETCO CEO Cheri Scholtz, said the project was an important one as PETCO believes small and micro-collectors play a crucial role in growing recycling tonnages in South Africa. “Thanks to their hard work, alongside

that of the remarkable network of dedicated people and companies we work with, 2 billion PET bottles were collected for recycling across South Africa during the course of 2016, growing the annual recycling rate from 52% of post-consumer bottle PET in 2015 to 55%,� she added.

Boxmore is a founding member of PETCO, and last year Chief Commercial 2IÂż FHU 'DYLG 'UHZ ZDV DSSRLQWHG WR WKH board of directors. “Apart from this investment being the right thing to do, our industry cannot ignore the mounting necessity to encourage and educate South Africans about recycling. We DUH FRQÂż GHQW WKDW WKHVH EHQHÂż FLDULHV KDYH all the support to further develop this small business opportunity into something that will both grow in size and income,â€? said David.

An additional 10 trolleys will be donated across two other communities where Boxmore branches are based.

ZZZ ER[PRUH FR ]D

skills development engaging various international entities to gain international accreditation with in strategic growth sectors. $ERXW 6$5(7(& The South African Renewable Energy 7HFKQRORJ\ &HQWUH LV WKH ¿ UVW QDWLRQDO UH newable energy technology centre in South Africa, and is located at the Cape Peninsula University of Technology’s (CPUT) campus in Bellville. SARETEC expedites specialised industry-related and accredited

training, short courses and workshops for the renewable energy industry.

The centre is funded by the Department of Higher Education and Training (DHET) through the National Skills Fund (NSF).

It receives substantial support from the German Ministry for Economic Cooperation and Development through the South African-German energy programme (SAGEN), and is implemented by the GIZ, the South African National Energy Development Institute (SANEDI) and Green Cape.

7KH 6RXWK $IULFDQ 5HQHZDEOH (QHUJ\ 7HFKQRORJ\ &HQWUH LV WKH Âż UVW QDWLRQDO UHQHZDEOH HQHUJ\ WHFKQRORJ\ FHQWUH LQ 6RXWK $IULFD DW WKH &DSH 3HQLQVXOD 8QLYHUVLW\ RI 7HFKQRORJ\ÂśV &387 %HOOYLOOH FDPSXV

DTI implementing tangible initiatives to boost advanced manufacturing in SA SOUTH Africa’s discussions with France on co-operation around the development of composites has been hailed by the burgeoning composites sector in South Africa.

The Mandela Bay Composites Cluster, supported by the Department of Trade and Industry (DTI), and tasked with representing and advancing the interests of and commercial opportunities in the composites sector in South Africa, said the development showed serious intent from South Africa to H[WUDFW HFRQRPLF EHQHÂż WV WKURXJK the development of composites in manufacturing. “What is clear and highly satisfying is that the DTI is implementing tangible initiatives to boost advanced manufacturing in the country, which has pockets of excellence, but on the whole requires development and support,’’ said Mandela Bay Composites Cluster Director, Dr Kjelt van Rijswijk.

Van Rijswijk said the agreement with France to cooperate on composite technology was the latest outcome of the joint efforts of the DTI and the Mandela Bay Composites Cluster (MBCC) in support of the local composites industry. “This effort has previously resulted in the inclusion of composites in the Industrial Policy Action Plan (IPAP), international trade promotion activities and the establishment of the MBCC itself,�

Van Rijswijk added. “The MBCC and its cluster participants will continue to work together with the DTI and the French Embassy to turn the recent agreement into a portfolio of composite relevant activities, which will include attending the JEC composites trade show in France in 2018,� van Rijswijk said. “The MBCC applauds local and overseas Government representatives for their efforts in supporting the composites industry.�

JUNE / JULY 2017 33

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3(7&2 DQG %R[PRUH KDYH LGHQWLÂż HG Âż YH EHQHÂż FLDULHV IRU ZDVWH UHF\FOLQJ WUROOH\V ZKR ZLOO VHOO WKHLU 3(7 WR 9DQV %X\ %DFN &HQWUH 3LFWXUHG KHUH DUH -DPHV YDQ 9XXUHQ 9DQV 6FUDS <DUG DQG 1HLO %UHVHQGDOH IDFWRU\ PDQDJHU RI %R[PRUH +DUULVPLWK Ă&#x20AC; DQNHG E\ ZDVWH SLFNHUV IURP OHIW )DQD 0RIRNHQJ 7KDELVR 0DVHQJHQL %HQHWK 2OLIDQW -RVHSK 0VLEL DQG 6LSKR 6LEHNR

South Africa, France co-operation on composites hailed

ASSOCIATION NEWS

Entries open for SAPROâ&#x20AC;&#x2122;s 2017

Recycled Plastic Product of THE South African Plastics Recycling Organisation (SAPRO) is inviting entries to this yearâ&#x20AC;&#x2122;s Recycled Plastic Product of the Year Awards. The closing date for entries is Thursday, 10 August 2017.

This is SAPROâ&#x20AC;&#x2122;s sixth prestigious competition, with the aim of acknowledging the wide variety of products that are locally manufactured using recycled materials.

The Recycled Plastic Product of the Year $ZDUGV ZDV KHOG IRU WKH Âż UVW WLPH LQ DQG has been dubbed â&#x20AC;&#x2DC;The Oscars of the plastics recycling industryâ&#x20AC;&#x2122;. This biennial competition showcases the tremendous amount of ingenuity and creativity our local product designers have, and aims to encourage brand owners to seriously consider recycled plastics as a material of choice. Whether they are designing packaging or pallets, shoes or shopping bags, this competition has demonstrated that there is no limitation to where and how recycled plastics can be used.

Winners of this yearâ&#x20AC;&#x2122;s competition will be announced at a gala dinner in Gauteng during Clean-Up and Recycle SA Week from 11-17 September.

To encourage even greater participation and entries by local converters and innovators, this yearâ&#x20AC;&#x2122;s competition will have WKH IROORZLQJ Âż YH SURGXFW FDWHJRULHV ZLWK the overall winning entry will walk away with the SAPRO trophy for The Best Recycled Product for 2017.

Products made from 100% post-consumer recyclate Products containing a percentage postconsumer recyclate Products made from recycled mixed materials Novel and Artistic products (articles made from discarded plastics products) $QG IRU WKH Âż UVW WLPH WKHUH LV DOVR D Âľ1HZ Ideasâ&#x20AC;&#x2122; category - anything that can be made from recycled materials. â&#x20AC;&#x153;It does not have to be a product as yet, just the idea clearly explained on a poster, mock-ups or a good explanation,â&#x20AC;? $QQDEp FODULÂż HG Entry forms and competition rules can be obtained online from SAPROâ&#x20AC;&#x2122;s website. www.plasticrecyclingsa.co.za

Plastics|SA clean-up collects 39 tonsâ&#x20AC;&#x2122; waste MORE than 39 000 kg of waste was collected by the Plastics|SA Clean-Up Crews along the routes used by athletes during the recent Old Mutual Two Oceans Marathon.

According to Douw Steyn, Director of Sustainability at Plastics|SA, the majority of the waste collected during these annual events is made up of plastic, which has a high recycling value. â&#x20AC;&#x153;We work hard to ensure that this packaging is kept out of the environment and off the streets by employing a clean-up crew of cleaners from Masiphumelele, Ocean View and 34

JUNE / JULY 2017

Athlone. Many of the members of these clean-up crews have been working with us for the past 10 years on race days and are trained to quickly and effectively sweep the areas,â&#x20AC;? he explained. â&#x20AC;&#x153;The organizers of this yearâ&#x20AC;&#x2122;s Old Mutual Two Oceans Marathon in particular did an excellent job with their #GOGREEN campaign that was launched prior to the race. This is antilittering movement which, coupled with our waste management plan, offered a sustainable way to collect and process the non-organic waste which was generated during race week. All event waste will be recycled and transformed into approximately 500 Green Desks for needy schools in www.plasticsinfo.co.za

and around Cape Town, thanks to a partnership between the Wildlands Trust DQG 32/<&2 3RO\ROHÂż Q 5HF\FOLQJ Company),â&#x20AC;? Steyn added.

The Plastics|SA Clean-Up crews were also responsible for collecting the waste generated by spectators attending the SA Navy Festival and the Cape Town Cycle Tour in March.

To view the documentary about this yearâ&#x20AC;&#x2122;s clean-up crews, click on https:// youtu.be/3vwTwDLbBFI

the Year Awards

JUNE / JULY 2017 35

Previous overall winners include the City of Cape Town and MPACT Plastic Containers with their Fifty/50 Wheelie Bin (2015), Unilever with their Sunlight Dishwashing bottle (2013), Lasher Tools with their Eco-Wheelbarrow (2012), Woolworths and Polypet with their 1.5 litre juice bottle (2011) and 7XIÀH[ 0DWHULDOV ZLWK WKHLU LQQRYDWLYH UDLOZD\ VOHHSHU PDGH IURP PL[HG materials (2010)

WE CLOSE THE LOOP. (5(0$ (ˈ FLHQF\ LQ SODVWLF UHF\FOLQJ

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

CHOOSE THE NUMBER ONE.

ASSOCIATION NEWS

Transitioning to a circular economy: What does this mean for SA? A new way to design products, services, businesses

Keynote speaker, Joachim Quoden, Managing Director of EXPRA, an international alliance of packaging recovery organisations, clearly presented the case for a Circular Economy and the key role Extended Producer Responsibility (EPR) has in transitioning to a Circular Economy

SO MANY of humanityâ&#x20AC;&#x2122;s most acute challenges â&#x20AC;&#x201C; from economic inequality to climate change to water scarcity â&#x20AC;&#x201C; seem to be getting worse instead of better. But what if we had a new way to design products, services and businesses that were good for people, the planet, and business?

Thatâ&#x20AC;&#x2122;s the promise of the Circular Economy: moving from our traditional take-makedispose economy, to one where materials are continuously repurposed, creating new value and delivering long-term economic, social and ecological prosperity.

To unpack what the drivers and levers are to shift towards this new economic model and what this means for South Africa, PETCO and GreenCape hosted a workshop in Cape Town in May entitled â&#x20AC;&#x2DC;Transitioning to a Circular Economyâ&#x20AC;&#x2122;.

Keynote speaker, Joachim Quoden, Managing Director of EXPRA, an international alliance of packaging recovery organisations,

clearly presented the case for a Circular Economy and the key role Extended Producer Responsibility (EPR) has in transitioning to a Circular Economy.

This was followed by Sam Smout of GreenCape, interrogating how designers, manufacturers and users of packaging can effectively collaborate to optimise the performance of packaging, while minimising WKH ULVNV RI VXSSO\ FKDLQ LQHIÂż FLHQFLHV /DVWO\ Dr Philippa Notten, Managing Director for The Green House, gave an overview of how Life Cycle Assessments can be used to support the Circular Economy. The presentations were followed by a panel discussion by the speakers alongside PETCO CEO, Cheri Scholtz. â&#x20AC;&#x153;Transitioning the Circular Economy into the mainstream will be one of the biggest creative challenges of our time. Now more than ever, we need to explore new ways to create sustainable, resilient, long-lasting value â&#x20AC;&#x201C; redesigning the world around us,â&#x20AC;? said Cheri.

SAPPMA & PPCAâ&#x20AC;&#x2122;S PIPES XI conference More than 35 world leaders in water infrastructure, engineering MORE than 35 of South Africa and the worldâ&#x20AC;&#x2122;s top experts on issues relating to plastic piping, water infrastructure and engineering will be presenting at this yearâ&#x20AC;&#x2122;s PIPES XI Conference â&#x20AC;&#x201C; an annual event hosted by the Southern African Plastic Pipe Manufacturers Association (SAPPMA).

This yearâ&#x20AC;&#x2122;s event, however, will be unlike any other event the association has ever hosted and promises to be an unforgettable experience. â&#x20AC;&#x153;We are extremely privileged to be hosting our conference this year in conjunction with the Plastic Pipe Conference Association (PPCA). It will be a two-day event taking place on the 4th and 5th of September at Emperorâ&#x20AC;&#x2122;s Palace Convention Centre.

In addition to the line-up of top national and international speakers, this yearâ&#x20AC;&#x2122;s PIPES XI also sees at least 10 of the best papers which were presented at PIPES XVIII in Berlin last year, delivered to our local audience,â&#x20AC;? said 36

JUNE / JULY 2017

Jan Venter, CEO of SAPPMA. Every two years, the PPCA plays host to the worldâ&#x20AC;&#x2122;s biggest international pipe conference which takes place either in Europe or the USA. Venter H[SODLQV WKDW LW LV WKH Âż UVW WLPH LQ KLVWRU\ that their spin-off conference, which is organised every alternate year, will be coming to South Africa.

Topics that will be covered at this yearâ&#x20AC;&#x2122;s event are varied, ranging from raw materials and additives to the life cycle and material design of plastic pipes. Installations, applications and rehabilitations as well as standards, WHVWLQJ DQG FHUWLÂż FDWLRQ DQG YDULRXV case studies will also be covered.

The opening keynote address will be delivered by Dr Roelof Botha, a local economist of the GOPA Group, after which delegates can select to listen to presentations in two break-away sessions.

International speakers presenting include:

Zoran Davidovski of Pipelife International (presenting on behalf of TEPPFA in Austria) on â&#x20AC;&#x2DC;Main barriers to plastic pipesâ&#x20AC;&#x2122; Tony Radoszewski of PPI in the USA, on â&#x20AC;&#x2DC;Manufacturing and Infrastructure in the Age of Trump Bruce Hollands of the PVC Pipe Association in the USA on â&#x20AC;&#x2DC;Life Cycle assessment of PVC Water and Sewer pipe and comparative sustainability analysis of pipe materialsâ&#x20AC;&#x2122; Jean-Pierre De Grève of PVC4Pipes LQ %HOJLXP RQ Âľ(YROXWLRQ DQG EHQHÂż WV of PVC pipesâ&#x20AC;&#x2122; Dane Tallen of Baerlocher in Germany Dr Predrag Micic of Qenos, Australia, Rob SpekreĂżse of Rollepaal in the Netherlands Robin Bresser representing Borealis in Austria www.sappma.co.za www.pipesxiconference.co.za

New ISO 9001:2015 standard explained simply ISO operator breaks it down to make it more accessible the man, the introduction of ISO 90012015 has â&#x20AC;&#x153;changed the perception of quality and its meaning foreverâ&#x20AC;?. â&#x20AC;&#x153;This is an evolution of the existing ISO systems to incorporate business principles and provide organizations with an overall tool to manage quality and business in an effective, combined system,â&#x20AC;? said Loga, who referred to SODVWLFV VSHFLÂż FDOO\ LQ KLV SUHVHQWDWLRQ which covered areas such as quality (obviously), customer satisfaction, risk, resource management, operational planning and control, design and development, control of externally sourced products and services and others.

One area of special interest was that of improvements: in a situation where corrective action is taken, businesses should then factor in a review of the risk associated with the change.

This is important in so far as continuous improvement is concerned: it requires the manager and team to â&#x20AC;&#x153;use the strategic plan to plan, measure,

Loga Govender (centre), the standards presenter, with PISA KZN chairman Bruce Naidoo, of Skyland, and Gan Naicker of Idwala, who is the branchâ&#x20AC;&#x2122;s functions organiser

review and re-set objectives,â&#x20AC;? said Loga.

According to Bruce Naidoo, chairman of PISA in KZN, the Durban branch has adopted a new strategy which is to â&#x20AC;&#x153;assist companies to mitigate internal and external factors that could have an adverse effect on our economy and business performance,â&#x20AC;? in which respect Logaâ&#x20AC;&#x2122;s presentation was a positive step.

About 40 delegates attended, from both the plastics and rubber sectors.

Refreshments and snacks were sponsored by PISA KZN. www.pisa.org.za

JUNE / JULY 2017 37

A PRESENTATION on the â&#x20AC;&#x2DC;New ISO Standard: Its Incorporation and Relevance in the Business Environmentâ&#x20AC;&#x2122; proved of interest to PISA members and guests in Durban recently.

The presentation by Loga Govender paid particular attention to the plastics and rubber industries. Loga consults as lead auditor for ISO systems and product specialist for plastics.

Prior to getting involved with ISO, Loga worked as a polymer chemist at British Industrial Plastics (BIP), which in the 1980s and early 90s was a strong business in South Africa. After that he worked as a tyre technologist at Dunlop Tyres; then as a laboratory manager at Sasol Fibres Division and most recently at the SABS, where he was the lead auditor for 14 years, specialising in the plastics DQG UXEEHU WHVWLQJ +H LV LV DIÂż OLDWHG with SAATCA (South African Auditor 7UDLQLQJ DQG &HUWLÂż FDWLRQ $XWKRULW\

Loga discussed the difference between the old and new standards and what the system demands. According to

6DIHW\ LV Ă&#x20AC; UVW DW Management takes the lead when it comes to safety

A LEADING proponent of health, safety and the wellbeing of its employees, DPI Plastics has maintained a Disabling Injury Frequency Rate (DIFR) of <1 for the past year, in accordance with OHSAS 18001â&#x20AC;&#x2122;s standard AS NOSA Five Star principles.

As a recognised leading manufacturer RI SODVWLF SLSHV DQG Âż WWLQJV '3, 3ODVWLFV KDV EHHQ 2+6$6 FHUWLÂż HG E\ DEKRA, a leading global provider of DXGLWLQJ DQG FHUWLÂż FDWLRQ VHUYLFHV VSHFLDOLVLQJ LQ WKH Âż HOGV RI VDIHW\ environment and health. â&#x20AC;&#x153;During our last surveillance audit held on 2 June 2016, we had only one minor non-conformance, which emanated from the previous audit. This was closed immediately during the DXGLW DQG FHUWLÂż HG DV VXFK RQ WKH VDPH day,â&#x20AC;? said Khanyiso Sihawu, Safety 2IÂż FHU DW '3, 3ODVWLFVÂś 5RRGHNRS Johannesburg manufacturing facility.

All new employees undergo safety training during their induction. â&#x20AC;&#x153;It is also very important that visitors to our manufacturing facilities

Khanyiso Sihawu, Safety 2IÂż FHU DW '3, 3ODVWLFV 5RRGHNRS '3, KDV LQWURGXFHG QHDU PLVV VDIHW\ REVHUYDWLRQ UHSRUWLQJ DW LWV 5RRGHNRS PDQXIDFWXULQJ IDFLOLW\ WR HQKDQFH VDIHW\ DZDUHQHVV

familiarise themselves with our safety procedures, which is done by means RI D FRPSUHKHQVLYH VDIHW\ OHDĂ&#x20AC; HW DQG animation video,â&#x20AC;? Sihawu adds.

All departments hold Safety Toolbox 7DONV RQ D ZHHNO\ EDVLV DV SDUW RI WKH safety drive at the manufacturer. â&#x20AC;&#x153;This

1HZ VDOHV UHS IRU '\QDPLF 3ODVWLFV

initiative helps us educate employees on various safety issues, especially the relevant legislation. We have also LQWURGXFHG VSHFLÂż F ZRUNSODFH FKDOOHQJH initiatives.â&#x20AC;?

DPI Plastics has introduced a system of near miss/safety observation reporting,

Winners of Plastomark â&#x20AC;&#x2DC;Openâ&#x20AC;&#x2122;

TASCHA Gerber recently joined Dynamic Plastics as VDOHV UHSUHVHQWDWLYH '\QDPLF 3ODVWLFV LV NQRZQ IRU LWV ,QMHFWLRQ PRXOGHG SODVWLF EXFNHWV Âą SODLQ SULQWHG RU ,0/ 7DVFKD KDV ZRUNHG LQ WKH SODVWLFV LQGXVWU\ IRU VHYHUDO years, gaining invaluable experience at Safripol (now KAP Holdings) as sales consultant for raw materials, Dow Plastics as sales consultant for all raw material chemicals, DV ZHOO DV DW EORZ PRXOGLQJ FRPSDQLHV 3RO\RDN DQG 0 6 Plastics selling blow moulded products 7DVFKD *HUEHU UHFHQWO\ MRLQHG '\QDPLF 3ODVWLFV DV VDOHV UHSUHVHQWDWLYH

High scoring team â&#x20AC;&#x201C; 7KH HYHU SRSXODU 3ODVWRPDUN JROI WRXUQDPHQW WKH VR FDOOHG Âľ WK PDMRUÂś DW -RKDQQHVEXUJÂśV 5LYHU &OXE LQ 0D\ VDZ VRPH VHULRXVO\ JRRG DFWLRQ +HUH 3ODVWRPDUNÂśV =HOGD 9LNRV SRVHV ZLWK WKH ZLQQLQJ WHDP 0DUN :KLWH 0DUN :KLWH 1LVVDQ -DSLH %UHLWHQEDFK %OXH %HOW *XVWDY 0HUW] ,PSHULDO 0RWRUV DQG )UHG 2XGPD\HU $IFRP DQG 3ODVWRPDUN 0' :ROIJDQJ 5DIIDOVN\ 7KH FKDPSV HDFK ZRQ DQ LPSUHVVLYH GULYHU IRU WKHLU GHHGV RQ WKH GD\

38 JUNE / JULY 2017

PEOPLE

'3, 3ODVWLFV which involved training all employees on the correct procedure to report unsafe workplace conditions or actions. â&#x20AC;&#x153;Our near-miss reporting card system serves as a means to encourage workers to report any deviations from safety best practice,â&#x20AC;? Sihawu explains.

Other safety-related initiatives include the introduction of reverse parking as mandatory at Roodekop.

The manufacturer has also introduced a 5S system as means of improving safety in the warehouse environment.

This system encourages proper housekeeping, which Sihawu stresses is the basis of an effective safety strategy, including the factory. â&#x20AC;&#x153;At DPI Plastics, management takes the lead when it comes to safety, in order to stress that this is not only the responsibility of employees,â&#x20AC;? Sihawu elaborates. This is reinforced by company-wide slogans such as â&#x20AC;&#x2DC;Safety

is Everyoneâ&#x20AC;&#x2122;s Responsibilityâ&#x20AC;&#x2122;.

DPI Plastics has a daily on-site FOLQLF DV ZHOO DV SURYLGLQJ \HDUO\ Ă&#x20AC; X vaccinations for all employees. â&#x20AC;&#x153;Safety is an ongoing priority, as evidenced by the fact that safety meetings are held on a monthly basis as a means of continuous communication about safety issues,â&#x20AC;? Sihawu notes.

These vital meetings are chaired by the Operations Director as a sign of commitment to the process by top management. â&#x20AC;&#x153;This means that any serious underlying safety issues can EH LGHQWLÂż HG LPPHGLDWHO\ 2XU 0' DOVR drives the process by commencing all Exco meetings with safety as the initial topic.â&#x20AC;?

In addition, DPI Plasticsâ&#x20AC;&#x2122; manufacturing facilities in the rest of Africa have also adopted company-wide safety principles such as emergency procedures, the 5S system, reverse

parking, compliance with local legislation, and screening workers for early indications of non-occupational diseases. â&#x20AC;&#x153;As a company, we have a vision of improving the safety and wellness of our employees continuously. Our vision of zero incidents is communicated constantly. In this way, we not only EHQHÂż W RXU HPSOR\HHV EXW DOVR ERRVW our productivity and staff morale,â&#x20AC;?

Sihawu concludes.

www.dpiplastics.co.za

JUNE / JULY 2017 39

People on the move Alistair Calder has joined the Sun Ace South Africa Board of Directors

40 JUNE / JULY 2017

Sun Ace board appointment â&#x20AC;&#x201C; Alistair Calder has been appointed to the board of directors of Sun Ace South Africa, effective April. Sun Ace is a global supplier RI 39& DGGLWLYHV ZLWK LWV KHDG RI¿ FH LQ -DSDQ DQG RI¿ FHV LQ 6RXWK $IULFD .HQ\D South America, Europe, India, China, SE Asia and Australia. Alistair, who is based at the Sun Ace SA plant in Jet Park, is also the groupâ&#x20AC;&#x2122;s business development director.

Benito Piccoli, IRUPHUO\ RI (%) 3ODVWLFV a sheet extrusion operation which closed, has joined Ampa Plastics Group in Elandsfontein.

Harry Havenga has joined Extrupetâ&#x20AC;&#x2122;s marketing department where he has been appointed national sales & marketing manager responsible for all PET sales, including PhoenixPET® +DUU\ EULQJV ZLWK KLP VHYHUDO \HDUV RI H[SHULHQFH

Harry Havenga has joined Extrupet

Brent Grant has joined Prima Corporation in Lagos

LQ WKH SODVWLF LQGXVWU\ DQG ZLOO OHQG KLV knowledge to this new role.

Brent Grant has joined Prima Corporation in Lagos. Prima is the leading manufacturer of preforms and caps in West $IULFD IRFXVHG RQ WKH EHYHUDJH LQGXVWU\ Established in 1965, Prima repositioned its business in 2005 to focus on the manufacture of preforms and closures.

It has since established a position as the market leader in the sector with manufacturing sites in Nigeria and Ghana. Coke, 3HSVL DQG 6$% DUH PDLQ FOLHQWV 6$% LV QRZ FDOOHG $% ,Q %HY %UHQW ZDV ODVW LQ packaging in 2015 as divisional managing GLUHFWRU RI WKH $VWUDSDN )RUPLQJ 'LYLVLRQ Paul Nkunzi has joined Plastics|SA as D 7HFKQLFDO 7UDLQHU ZLWK WKH .ZD=XOX Natal team in Pinetown. Paul was born in Pretoria, but completed his schooling LQ 0SXPDODQJD EHIRUH JRLQJ RQ WR VWXG\

Paul Nkunzi has joined Plastics|SA as a Technical Trainer with the KwaZuluNatal team

Sipho Zwane has joined 3RO\Ã&#x20AC; RU 6$ as a sales consultant based at its Gauteng RI¿ FH

SODVWLFV WHFKQRORJ\ DW 787 +H KROGV D % 7HFK LQ SRO\PHU WHFKQRORJ\ DQG KDV PRUH WKDQ \HDUV¶ ORFDO DQG LQWHUQDWLRQDO H[SHULHQFH ZRUNLQJ ZLWK GLIIHUHQW SRO\PHU PDWHULDOV LQ WKH SODVWLF H[WUXVLRQ LQGXVWU\ Sipho Zwane KDV MRLQHG 3RO\Ã&#x20AC; RU 6$ as a new sales consultant based at its *DXWHQJ KHDG RI¿ FH =ZDQH JUHZ XS in Orlando West, Soweto and attended ERWK KLV SULPDU\ DQG VHFRQGDU\ VFKRRO LQ (OGRUDGR 3DUN +H FRPSOHWHG KLV %DFKHORU RI %XVLQHVV $GPLQLVWUDWLRQ DW &,'$ &LW\ &DPSXV PDMRULQJ LQ 0DUNHWLQJ 6WUDWHJ\ and Human Resources. Prior to joining WKH 3RO\Ã&#x20AC; RU WHDP 6LSKR ZDV HPSOR\HG DV D VDOHV FRQVXOWDQW IRU %DUORZRUOG Equipment in Polokwane. In his new SRVLWLRQ 6LSKR VD\V KH ZLOO EH UHVSRQVLEOH IRU HVWDEOLVKLQJ DQG PDLQWDLQLQJ PXWXDOO\ EHQH¿ FLDO UHODWLRQVKLSV ZLWK FOLHQWV LQ RUGHU to achieve and exceed targets - for both 3RO\Ã&#x20AC; RU DQG WKH FOLHQW

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

STANDARD FEATURES â&#x20AC;¢ High speed injection without accumulator â&#x20AC;¢ High rigidity clamping unit â&#x20AC;¢ Low power consumption per Kg conversion rate â&#x20AC;¢ Yizumi offers professional in-house mould making for thin walled product and all standard PET preforms. â&#x20AC;¢ We can supply full electric, large two platen, high speed packing and preform machines.

Contact Dave for a brochure pack to be sent to you.

Click on the QR code on the right to watch a video of a PAC 300 operating.

MOULD BASE SA Dave Moore: 083 675 8325 | www.mouldbasesa.co.za

PEOPLE

SABIC group engages with convertors in region

The impressive venue for the SABIC dinner, the Rotunda at the Bay Hotel in Camps Bay, with customer guests from around the country attending

Gala dinner an opportunity to meet with one RI ZRUOG¶V WRS SRO\ROH¿ QV PDQXIDFWXUHUV SABIC group, as pointed out in Niall Marshall’s column this issue (page 56), is a massive Saudi manufacturing operation that LV RQH RI WKH OHDGHUV LQ WKH JOREDO SRO\ROH¿ QV market, with equally major shares of the world agrichemicals and steel sectors. But with all that might, it has built up its business through engagement with customers around the world. That certainly was the

case recently when SABIC hosted a gala dinner in Cape Town, with many of its key customers in the region invited. $OWKRXJK D VLJQL¿ FDQW QXPEHU RI WKH guests were from other industries, it was still a ‘Who’s Who’ of the local plastic converting market. The speeches were kept short and, after presentations from Kaapse Klopse and Zulu drummer bands, the rest of the

Dr Abraham Brink (second from right) of Karbochem with SABIC’s Anas Kentab, Uwaidh Al-Harethi, vice-president for innovation and business development; and Mr Al-Fageeh

evening was spent chatting and getting to know one another.

The Saudi contingent comprised Abdulrahman Al-Fageeh, vice president for petrochemicals; Uwaidh Al-Harethi, vicepresident for innovation and business development; and Anas Kentab, vice-president for agri-nutrients. These gentlemen made a clear effort to engage with customers.

Abdulrahman Al-Fageeh (centre), vice president of SABIC’s petrochemicals business, with Anas Kentab, vice-president of its agri-nutrients division, Paul Gripper and Ivan Horowitz of MBT, its local polymers distributor, and Iyad Al-Garawi, GM of SABIC South Africa JUNE / JULY 2017 41

Proudly South African synthetic rubbers for every step of your journey www.karbochem.co.za SALES AND MARKETING

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

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

TRAINING

JJ Precision Plastics aiming to JHW LW ULJKW Ã&#x20AC; UVW WLPH HYHU\ WLPH Routsis Training offers easily accessible online interactive training JJ Precision Plastics (JJ PP), an Astrapak company and a world-class injection moulding operation, knows that skills development is part of creating and implementing a continuous improvement culture, which they believe is core to maintaining their world-class status. This meant becoming a learning organisation, a process rife with challenges, most of which have now become opportunities with the range of online interactive training from USAâ&#x20AC;&#x2122;s Routsis Training.

For most organisations one of the biggest barriers to training is getting staff out of the workplace and into the training rooms, simply because resources are so limited.

Added to this is the growing need for businesses to retain and uplift employees through consistent improvement and investment initiatives.

7UDLQLQJ QHHGV WR VXSSRUW WKLV E\ ¿ WWLQJ in with the individualâ&#x20AC;&#x2122;s training time and allowing them to progress at their own pace, while not negatively impacting the RUJDQLVDWLRQ¶V ZRUNÃ&#x20AC; RZ DQG QHHGV Employee availability, production ZRUNÃ&#x20AC; RZ PDQDJHPHQW DQG FRQWLQXRXV development and training that supports these elements are just a few of the reasons why JJPP, part of the Astrapak group, started using world-renowned interactive online training by Routsis Training. â&#x20AC;&#x153;Routsis Training offered easily accessible online interactive training that is internationally accredited and GHDOV ZLWK D VFLHQWL¿ F PRXOGLQJ DSSURDFK ´ VDLG --33 $VVHW Care Manager, Hardus Burger. â&#x20AC;&#x153;Employees could train GXULQJ ZRUNLQJ WLPH DQG ZH FRXOG VWLOO EHQH¿ W IURP KDYLQJ WKHP LQ KRXVH ZKHQ WKH QHHG DURVH ´ Routsis Training provides easily accessible online training DQG HQVXUHV WKDW OHDUQHUV JHW PD[LPXP EHQH¿ W E\ IXOO\ engaging them in a hands-on and interactive method, using superior graphics, clear audio and in-depth footage of plastics manufacturing processes.

Burger describes the scenario at JJPP: â&#x20AC;&#x153;Setters seemed to UHO\ RQ WKH µVKRWJXQ DSSURDFK¶ WR IDXOW ¿ QGLQJ DQG VHWWLQJ XS new moulds or even repeat moulds. We wanted to see that the VHWWHUV JR EDFN WR JHWWLQJ WKH EDVLFV GRQH ULJKW DQG XVH VFLHQWL¿ F PRXOGLQJ SURFHGXUHV LQ VHWWLQJ XS PRXOGV DQG GRLQJ IDXOW ¿ QGLQJ :H DOVR ZDQWHG WR FUHDWH RQH VWDQGDUG LQ WKH RSHUDWLRQ ´ 42

JUNE / JULY 2017

â&#x20AC;&#x153;Routsis Training offered easily accessible online interactive training that is internationally accredited and deals with a VFLHQWL¿ F PRXOGLQJ DSSURDFK ´ VDLG --33 DVVHW FDUH PDQDJHU +DUGXV %XUJHU ³(PSOR\HHV FRXOG WUDLQ GXULQJ ZRUNLQJ WLPH DQG ZH FRXOG VWLOO EHQH¿ W IURP KDYLQJ WKHP LQ KRXVH ZKHQ WKH QHHG DURVH´

Not only are common issues during mould commissioning highlighted early on, but there is D EHQH¿ FLDO LPSDFW RQ HPSOR\HH morale too. â&#x20AC;&#x153;Setters are talking the same language and are able to assist each other. The candidates are very positive and discuss WKHLU OHDUQLQJ RSHQO\ ZLWK HDFK RWKHU ´ Burger added. â&#x20AC;&#x153;They could quite easily go WR D PDFKLQH WR FRQ¿ UP VRPHWKLQJ WKDW ZDV learned and get back to the course without ORVLQJ DQ\ WLPH ´ More about Routis Training in South Africa Routsis Training is at the forefront of technical plastics training worldwide and is represented and supported in Africa by Productive Services who have specialised LQ SURYLGLQJ IDFH WR IDFH DQG VKRSÃ&#x20AC; RRU training for more than 20 years.

Jorge Silva, Managing Director at Productive Services, notes that the success that JJPP has seen from the online interactive training is really only the start of the journey: â&#x20AC;&#x153;I am certain that their workforce will continue to achieve much more effective production through this training method, and we intend to HQVXUH WKDW E\ VXSSRUWLQJ WKHP DOO WKH ZD\ ´ â&#x20AC;&#x153;The situation at JJPP is not unique: this solution can EHQH¿ W DQ\ RUJDQLVDWLRQ ZLOOLQJ WR VWHS DZD\ IURP WUDGLWLRQDO solutions and into the world of Online Interactive plastics WUDLQLQJ ´ VDLG -RUJH ³,W FDQ VHHP GDXQWLQJ DW ¿ UVW EXW RXU IRFXV LV RQ VXSSRUWLQJ our clients each step of the process from needs assessment to employee selection, course selection and technical support. In Africa, this online training has already helped people acquire skills in plastics in Uganda, Zambia, Sierra Leone and others, so there is absolutely no reason why that FDQ¶W EH GRQH DQ\ZKHUH LQ 6RXWK $IULFD ´ KH DGGHG There is no doubt that the impact of effective training on the ZRUNSODFH WKH ZRUNÃ&#x20AC; RZ DQG RQ HPSOR\HH PRUDOH LV DOZD\V positive, and now this can be easily achieved without the risk and cost of removing a vital employee from the production environment.

ZZZ SURGXFWLYHVHUYLFHV FR ]D

JEC Innovation Manufacturing processes for large series are growing in importance integration of automotive suppliers and the downstream THE JEC Innovation Awards for 2017 rewarded the best integration of raw materials producers,â&#x20AC;? said FrĂŠdĂŠrique Mutel, composite breakthroughs based on their technical -(& *URXS 3UHVLGHQW &(2 LQWHUHVW PDUNHW SRWHQWLDO SDUWQHUVKLSV Âż QDQFLDO Just as last year, a high number of submissions environmental impact and originality. came from the automotive industry, perfectly This year, the submissions for the Innovation illustrating the current market trends.

Awards programme were impressive, both in Manufacturing Process improvement was also one of the quantity and diversity, and more importantly in most represented themes, highlighting the quality. processes for large importance of cycle time reduction. â&#x20AC;&#x153;Manufacturing processes for large series series are growing With 13 categories ranging from raw are growing in importance this year. This in importance materials to process, to applications in movement is expected to trigger a more YDULRXV Âż HOGV VXFK DV DHURQDXWLFV DXWRPRWLYH massive use of composites. Therefore, we could construction, marine and better living, the winning see a change of scale in our industry, particularly projects offer a complete overview of the composite in certain mass production sectors such as the value chain, and the many future opportunities that are automotive sector, for example, where the supply chain VWLOO WR EH WDNHQ LQ WKH Âż HOG RI FRPSRVLWHV LV UHFRQÂż JXULQJ WKURXJK PHUJHUV DQG DFTXLVLWLRQV WKH XSVWUHDP

Innovative composite fan system for aero-engines

44 JUNE / JULY 2017

IHI Corp., together with its partners, developed an innovative lightweight comSRVLWH V\VWHP IRU IDQ FDVHV DQG WKH Âż UVW thermoplastic composite structural guide vane (SGV).

7R LQFUHDVH IXHO HIÂż FLHQF\ LQ DLUFUDIW engines, the bypass ratio (ratio between WKH PDVV Ă&#x20AC; RZ UDWH DW WKH HQWUDQFH RI WKH HQJLQH WR WKH PDVV Ă&#x20AC; RZ UDWH HQWHULQJ the core) has to be increased. But this requires a larger fan case, which, if it was made with traditional materials, would greatly increase the weight of the engine DQG QHJDWH VRPH RI WKH JDLQ HIÂż FLHQF\

Using composites for the primary structural fan case and SGV was the route IHI chose to achieve the required bypass ratio. Using its own developed materials, a thermoset for the fan case and a thermoplastic for the SGV, along with carbon Âż EUHV LQ ERWK FDVHV ,+, PDQDJHG RYHU 20% weight savings over previous-generation aircraft engines, thus contributing to further fuel consumption reductions. :LWK WKLV SURMHFW LW LV WKH Âż UVW WLPH WKDW thermoplastic composites are selected for primary structure parts in aircraft engines. The thermoplastic SGV are

Aeronautics IHI Corporation (Japan)

manufactured by prepreg cutting and layup at IHIâ&#x20AC;&#x2122;s Soma factory, and the main advantage is that they show low delamination after high-velocity impact. The thermoset used for the fan case was also developed to show superior impact energy absorption against high-velocity impact, which is one of the main criteria for both these engine parts.

This innovation was successfully applied to the Airbus A320neo, powered by the PW1100G-JM engine. This engine was FHUWLÂż HG E\ )$$ LQ 'HFHPEHU ZKLOH WKH $LUEXV $ QHR ZDV FHUWLÂż HG LQ 'HFHPEHU 2015.

DESIGN

Awards 2017 Automotive, Structural

Forward Engineering GmbH (Germany)

T-RTM The aim of this project is to develop the near-net-shape T-RTM (thermoplastic resin transfer moulding) process for high-volume production. This innovative process combines the advantages of thermoplastic resin and the design freedom offered by HP-RTM technology for complex parts.

To demonstrate the process potential, a roof frame for the Roding roadster was re-designed, having in mind that the roof frame is a structural element for the car.

The roof structure is made of a complex multi-preform part with hybrid textiles and integrated metal inserts, impregnated with a low-viscosity polyamide 6 (PA6)

by HP-RTM. This low viscosity allows EHWWHU LPSUHJQDWLRQ RI WKH Âż EUHV D KLJKHU Âż EUH YROXPH IUDFWLRQ DQG WKXV LPSURYHG mechanical properties and an overall reduced wall thickness, which reduces material cost.

To further reduce cost, the expensive FDUERQ Âż EUH ZDV SDUWO\ UHSODFHG ZLWK JODVV Âż EUH WKDQNV WR LQ SO\ K\EULGLVDWLRQ within a non-crimp fabric (NCF). As VXFK D ORZ DPRXQW RI FDUERQ Âż EUHV LV

HQRXJK WR DGG VWLIIQHVV WR WKH JODVV Âż EUH layers. All these optimisations lead to a 16% material saving for the roof frame compared to epoxy resin RTM. To ensure a cost as low as possible, Forward Engineering also focused on the integration of metal inserts in order to ensure optimised load transfer and to minimise roof assembly costs in mass production. Two types of inserts are used in the demonstrator: Al-casted inserts treated for ideal matrix adhesion applied directly on the dry preforms, and steel-threaded inserts applied by river nuts.

During the RTM process, an additional form locking due to overmoulding with pure resin occurs, and the resin also prevents galvanic corrosion.

One-piece roof rack

LG Hausys (South Korea)

LG Hausys developed a manufacturing process where the CFT, made of SRO\SURS\OHQH DQG JODVV Âż EUHV LV Âż UVW SUH IRUPHG WR WKH GHVLUHG VKDSH and then overmoulded to form the ribs that will add rigidity to the rack. In WKH Âż QDO VWHS WKH IRUPHG URRI UDFN LV painted using a new surface treatment technology.

The advantage of this project is that the technology was developed for high design freedom, enabling better

adaptation of the rack on the roof, which will help reduce the part cost for mass production across a broad range of vehicles. This innovation reduced the partâ&#x20AC;&#x2122;s weight from 3.8 kg to 2.76 kg, which represents a 28% reduction, while maintaining the required performance. This CFT roof rack is also EHQHÂż FLDO IURP DQ DVVHPEO\ SRLQW RI YLHZ DV the number of parts is reduced to 1 from 5 in existing aluminium roof racks.

Overall, compared to an aluminium roof rack, the cost is reduced by â&#x201A;Ź5.2/part.

JUNE / JULY 2017 45

With increasing pressure on automobile manufacturers to reduce the carbon footprint of their vehicles, weight reduction is becoming a major prerequisite.

The goal of this project is to reduce the weight and cost of a part that is traditionally made of aluminium and largely unnoticed in the composite industry.

This innovation aims to reduce the weight and cost of a roof rack through the XVH RI D FRQWLQXRXV Âż EUH WKHUPRSODVWLF (CFT) composite. To achieve this goal,

Automotive, Exterior

DESIGN ACCIONA ConstrucciĂłn SA (Spain)

Construction

Innovative composite panels for high-speed railway tunnel construction When the two 24km-long Pajares highspeed railway tunnels met the problem RI FRQWLQXRXV ZDWHU LQÂż OWUDWLRQ RQ DURXQG 30% of the total tunnel length, few of the available solutions in the market were able to solve the issue.

The innovative composite panels developed by Acciona proved to be the best solution in this demanding construction work because they managed to meet all the technical challenges ZKLOH FRPSO\LQJ ZLWK WKH Ă&#x20AC; DPH UHWDUGDQW requirements associated with this type of application.

The challenges of this innovation were diverse because of the many criteria that had to be met. From a mechanical point of view, the use of composites made it

Process

possible to meet the structural requirements while being thin enough not to change the tunnelâ&#x20AC;&#x2122;s diameter and being compatible with catenary systems. The GHVLJQ Ă&#x20AC; H[LELOLW\ RIIHUHG E\ FRPSRVLWHV also enabled Acciona to develop a system with leak-proof joints and an anchorage system. The 9.2-metre-long panels ZHUH DOVR Ă&#x20AC; H[LEOH HQRXJK WR DGDSW WR WKH shape of the tunnel and its irregularities.

Another concern in this project was the need to produce as many as 15,000 panels within the delivery schedule and to keep the cost of the composite panels as low as possible. To achieve this, Acciona opted for a pultrusion process and developed a low-cost resin injection V\VWHP DQG Âż EUH LPSUHJQDWLRQ FKDPEHU

that were adapted to the viscosity of the Ă&#x20AC; DPH UHWDUGDQW UHVLQ IRUPXODWHG IRU WKH project. This new system made it possible to produce one composite panel in 34 minutes on a continuous basis.

The other advantages of composites in this application were their low maintenance and high corrosion resistance compared to traditional construction materials. Finally, the handling and installation of the panels in the tunnel were easy and fast thanks to the lightweight nature of the composite panels.

To sum up and illustrate the size of the project: more than 15,000 panels were produced, covering about 200,000 square metres of tunnel for a total of 1,700 tonnes of composites.

IRT M2P (France)

46 JUNE / JULY 2017

Fast RTM The â&#x20AC;&#x153;Fast RTMâ&#x20AC;? project unveiled by the M2P research institute in June 2013 is the fruit of a collaborative initiative between Faurecia and key stakeholders in the French automotive industry.

Pinette P.E.I. (compact press and loading/unloading system), Compose (innovative tooling for mesh FRPSRQHQWV 6,6( HIÂż FLHQW KHDW regulation system), Chomarat (optimal UHLQIRUFLQJ PDWHULDOV +H[LRQ $UNHPD (reactive resins), and Renault, Faurecia +XWFKLQVRQ LQWHJUDWLRQ DQG GHVLJQ

worked together to deliver solutions DQG GHYHORS D SURFHVV WR VLJQLÂż FDQWO\ reduce production time for mass manufacturing.

With its automated environment and state-of-the-art equipment, the Fast RTM platform can create composite parts in a record cycle time of just two minutes.

The goal of the project was to develop a pilot line for mass production of automotive parts that could be scaled to other industries, such as aerospace, maritime, rail and even leisure.

To ensure the traceability and quality of manufactured components, the platform is fully equipped to automate data collection,

measure energy consumption and integrate control systems. As a result, the process could easily be adopted by other industries that need higher production rates, such as aerospace, rail transport and all other transport sectors.

TEL: +27 (0) 11 462 2990

SOLUTION

MACHINERY (PTY) LTD

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

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DESIGN Voith Composites GmbH & Co. KG (Germany)

Manufacturing

Voith Roving Applicator This innovation is a fully-automated direct ¿ EUH SODFHPHQW PDFKLQH FDOOHG WKH 9RLWK 5RYLQJ $SSOLFDWRU 95$

7KH 95$ XVHV XQWUHDWHG URYLQJ DQG ELQGHU SRZGHU WR JHQHUDWH D QHW VKDSH GU\ VWDFN 7KH VWDFN LV SURGXFHG LQ IRXU GLIIHUHQW VWHSV ¿ UVW WKH URYLQJ LV VSUHDG DQG DVVHPEOHG LQ D PP ZLGH WDSH D ELQGHU LV DSSOLHG RQ WKH WDSHV RQ OLQH WKHQ WKH WDSH ZLGWK LV FKHFNHG E\ RQ OLQH TXDOLW\ FRQWURO DQG ¿ QDOO\ WKH ELQGHUHG WDSHV DUH SODFHG RQ D URWDWDEOH PRYDEOH WDEOH E\ VHYHUDO SDLUV RI JULSSHUV 7KLV UHVXOWV LQ WKH DVVHPEO\ RI D QHDU QHW VKDSH SUHIRUP VWDFN VWHS E\ VWHS ZLWK ORFDO UHLQIRUFHPHQWV RU OD\HUV WKDW FDQ EH SODFHG DW DQ\ DQJOH LQ DQ\ DUHD The main advantage of this manufacturLQJ SURFHVV LV WKDW WKH UHVXOWLQJ SUHIRUP LV IXOO\ DGDSWHG WR WKH PHFKDQLFDO UHTXLUH

Sustainability

PHQWV DQG ORDGV RI WKH ¿ QDO SDUW ZLWK JUHDW Ã&#x20AC; H[LELOLW\ DQG IDVW DGDSWDWLRQ 7KH 95$ EHLQJ OLQNHG ZLWK DQ DXWRPDWHG SURGXFWLRQ line already used for an automotive highYROXPH VHULHV &)53 PDWHULDO LW SURYLGHV LQFUHDVHG HI¿ FLHQF\ DQG EHWWHU LQWHJUDWLRQ 0RUHRYHU HYHQ WKRXJK WKH LQGLYLGXDO JULSSHUV DUH TXLWH VWDQGDUG WKH 95$ LV VFDODEOH WKH OD\ XS UDWH FDQ EH LQFUHDVHG E\ D IDFWRU RI WZR E\ GRXEOLQJ WKH QXPEHU RI JULSSHUV $QG VHYHUDO XQLWV FDQ EH SODFHG LQ SDUDOOHO XSVWUHDP WDSH PDQX IDFWXULQJ OLQHV ZKLFK SUHVHQWV D VWURQJ

DGYDQWDJH FRPSDUHG WR VWDQGDUG GU\ ¿ EUH SODFHPHQW PDFKLQHV ,Q DGGLWLRQ WR WKLV LQFUHDVHG SURGXFWLRQ UDWH WKLV LQQRYDWLRQ KDV D VWURQJ JRDO RI UHGXFLQJ SURGXFWLRQ FRVWV 8QWUHDWHG URYLQJ DQG ELQGHU DUH XVHG GXH WR WKHLU FRVW HIIHFWLYHQHVV EXW DOVR EHFDXVH WKDQNV WR WKH 95$ WKHVH UDZ PDWHULDOV FDQ EH SURFHVVHG LQWR D XVHDEOH SUHIRUP GLUHFWO\ IURP WKH ¿ EUH LQ RQH VWHS ± ZLWKRXW KDYLQJ WR XVH FRVWO\ LQWHUPHGLDWH VWHSV RU VHPL ¿ QLVKHG SURGXFWV DQG ZLWK DOPRVW QR ZDVWH

Faurecia (France)

48 JUNE / JULY 2017

NAFILiteâ&#x201E;¢, a microcellular foamed material for automotive weight saving $V DQ DXWRPRWLYH HTXLSPHQW VXSSOLHU SLRQHHULQJ LQQRYDWLYH VROXWLRQV IRU WKH DXWRPRWLYH LQGXVWU\ )DXUHFLD LV FRQ VWDQWO\ VWULYLQJ WR GHYHORS VROXWLRQV WKDW PHHW QHZ PRELOLW\ QHHGV DQG RYHUFRPH HQYLURQPHQWDO FKDOOHQJHV 7KH -(& :RUOG $ZDUGV FURZQHG WKLV FRPPLWPHQW E\ FRPPHQGLQJ )DXUHFLD¶V LQQRYDWLYH XVH RI FRPSRVLWH PDWHULDOV ZLWK D 6XVWDLQDELOLW\ DZDUG IRU WKH 1$),/LWHÂ&#x152; SURMHFW DQG D 3URFHVV DZDUG IRU WKH )DVW 570 SURMHFW :HLJKW UHGXFWLRQ LV FUXFLDO WR HTXLSPHQW VXSSOLHUV DQG DXWRPDNHUV ZKR DUH VHHNLQJ WR FXUE HPLVVLRQV $ NJ UHGXFWLRQ LQ YHKLFOH ZHLJKW LV HQRXJK WR FXW &2 HPLV VLRQV E\ JUDP SHU NLORPHWHU )DXUHFLD GHVLJQHG DQG GHYHORSHG LWV KHPS ¿ EUH EDVHG 1$),/HDQÂ&#x152; DQG 1$), /LWHÂ&#x152; PDWHULDOV WR KHOS DFKLHYH WKHVH JRDOV +HPS LV DQ HFR IULHQGO\ QRQ IRRG FURS WKDW UHTXLUHV QR SHVWLFLGHV

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7KHVH SDUWV DUH WKHQ FRYHUHG ZLWK OHDWKHU RU IDEULF XSKROVWHU\ ³:H DUH GHOLJKWHG WR EH FKRVHQ IRU WKLV LQQRYDWLRQ LQ WKH -(& $ZDUGV ,W LV DQ RXWVWDQGLQJ RSSRUWXQLW\ WR SURPRWH RXU PDWHULDO DQG VKLIW WKH JRDOSRVWV ´ VD\V /DX UHQFH 'XIUDQFDWHO ,QQRYDWLRQ 0DWHULDOV *OREDO 'RPDLQ 0DQDJHU DW )DXUHFLD ³:LWK WKLV LQQRYDWLRQ ZH FDQ VLJQL¿ FDQWO\ UHGXFH WKH HQYLURQPHQWDO LPSDFW RI DXWRPRELOHV :H KDYH DFKLHYHG ZHLJKW VDYLQJV RI FRPSDUHG ZLWK FRQYHQWLRQDO PDWHULDOV ,W¶V D UHDO UHYROXWLRQ IRU WKH DXWRPRWLYH LQGXVWU\ ´ 7KH DOO )UHQFK SURMHFW LV D UHVXOW RI WKH $30 MRLQW YHQWXUH EHWZHHQ )DXUHFLD DQG ,QWHUYDO D PDMRU )UHQFK DJULFXOWXUDO FRRS HUDWLYH 7KLV FRPPLWPHQW WR WKH HQYLURQ PHQW KDV QRZ EHHQ HQVKULQHG E\ WKH -(& $ZDUGV FRQ¿ UPLQJ WKH FRPSD Q\¶V GHWHUPLQDWLRQ WR VKDSH WKH IXWXUH RI PRELOLW\

DESIGN VABO Composites (The Netherlands)

Marine

â&#x20AC;&#x153;Plug-and-playâ&#x20AC;? composite ship door Traditionally, ship doors are made of steel or aluminium, which is detrimental to weight but also to corrosion resistance.

Corrosion being a threat and involving huge costs, it was only natural that some alternative would eventually make it to production.

This innovation offers such an alternative, as VABO Composites developed a â&#x20AC;&#x153;plug-and-playâ&#x20AC;? composite ship door and hatches designed to replace the existing metal solution.

The door and hatches are produced by RTM in a modular moulding system, which allows the production of several door dimensions at a lower cost. The core and post-production processing is done by CNC milling and all the other parts are assembled and checked in VABOâ&#x20AC;&#x2122;s workshop to ensure that the products can be used directly in yachts, cruise ships, commercial ships, etc.

The advantages of this innovative ship door are obviously the fact that composite materials have great corrosion resistance and are lighter than metal â&#x20AC;&#x201C; a fully-equipped door with dimensions 1800 x 800 mm weighs less than 45 kg, i.e. approximately 60% weight saved versus the steel YHUVLRQ Âą WKXV LPSURYLQJ WKH EDODQFH DQG IXHO HIÂż FLHQF\ RI ships. But composite doors also require low maintenance as no lubrication is needed and they include some additional functions.

7KH GRRUV VXFFHVVIXOO\ SDVVHG Âż UH UHVLVWDQFH WHVWV DQG have excellent acoustic damping and insulation properties, meaning there is no need to add insulation as it is the case for aluminium and steel doors.

50 JUNE / JULY 2017

3D Printing

+LAB - Politecnico di Milano University (Italy)

Smart manufacturing RI FRQWLQXRXV Ă&#x20AC; EUH composites: Atropos $WURSRV LV WKH QDPH RI WKH Âż UVW D[LV URERWLF DUP DEOH WR ' SULQW FRQWLQXRXV Âż EUH FRPSRVLWHV XVLQJ WKHUPRVHWWLQJ resins. ,Q WKH SURFHVV VXSSRUWLQJ $WURSRV WKH Âż EUHV DUH impregnated and drawn to the head of a numericallycontrolled machine that can place them in a precise and repeatable manner. Once extruded by the printing head, the material is irradiated by a dedicated UV lamp to quickly cure the resin.

The choice of focusing on thermosetting resins with curing times shorter than one second makes it possible WR SODFH FRQWLQXRXV Âż EUHV DW VSHHGV RI DERXW PP V IRU now, thereby rapidly generating products characterised E\ VLJQLÂż FDQWO\ KLJKHU ZRUNLQJ WHPSHUDWXUHV FRPSDUHG WR conventional thermoplastic resins.

To optimise the internal and external shape of the object, +LAB developed a slicing algorithm that can predictively plan the machine movements to place the reinforcing material where the maximum stresses appear LQ WKH Âż QDO REMHFW )XUWKHUPRUH WKH DOJRULWKP FDQ DOVR YDU\ WKH Âż EUH PDWUL[ UDWLR XS WR LQ YROXPH :LWK ERWK these characteristics, it is possible to obtain a lightweight and customisable part with optimised performance according to its use.

The main strength of this project is the ability to control WKH Âż EUH GLUHFWLRQ DV WKH SDUW LV SURGXFHG WR JHW WKH EHVW RI WKH Âż EUHVÂś DQLVRWURSLF QDWXUH WKDQNV WR WKH DOJRULWKP developed by +LAB. Thus, different parts with the same shapes can be produced and customised according to their in-service loads.

Better Living Brødrene AA (Norway)

Vision of the Fjords, Ship of the Year 2016 in Norway When Brødrene AA was commissioned to develop a ship for use on tourist excursions in the UNESCO World Heritage-listed fjord of NÌrøyfjord, it faced the challenge of combining mass tourism and the need to preserve the environment with an impact as low as possible. The solution Brødrene AA came up with was a ship with lots of external open spaces for sightseeing as well DV YDVW ZLQGRZ DUHDV DQG DQ HI¿ FLHQW catamaran design to reduce waves and wash on the shores of the fjord.

Sports

The only solution that provided the required stiffness to realise the GHVLJQHUVÂś LQWHQWLRQ ZDV FDUERQ Âż EUH reinforced polymers and carbon sandwich materials. All of the shipâ&#x20AC;&#x2122;s structural elements are made out of carbon sandwich laminates (decks, walls, stairs, ceilingsâ&#x20AC;Ś), including the 42-metre-long and 5-metre-high hulls of the catamaran structure, which are produced in a one-shot vacuum infusion process, thus making the Vision of the Fjord the largest commercial passenger

ERDW WR EH EXLOW LQ FDUERQ Âż EUH 6DHUWH[ provided the fabrics, Diab the low-weight core for the sandwich composite and 5HLFKKROG WKH UXEEHU PRGLÂż HG YLQ\OHVWHU The low weight of the sandwich laminates also enabled the ship to be propelled by electric motors with lower power, making it clean and silent. In this project, the use of composite materials was mandatory to be able to provide the required design while making the ship environmentally friendly in the process as well.

Leibniz-Institut fĂźr Polymerforschung Dresden e.V. (IPF) (Germany)

52 JUNE / JULY 2017

Recurve bow riser This innovation is a new generation of ERZ ULVHUV PDGH RI FDUERQ Âż EUH FRPSRV ite materials.

Whereas the use of composites in bow risers is now quite common, this riser was made utilising an unconventional but stress-adapted design, making it up to 40% lighter than current solutions (carbon or aluminium) while also improving the PDVV VSHFLÂż F VWLIIQHVV E\ DERXW compared to a reference riser made of aluminium.

To be able to manufacture an actual part, IPF used the Tailored Fibre Placement (TFP) technology, a process

invented at IPF Dresden, to produce four preforms with a truss-like structure. With this highly versatile technology, IPF managed to demonstrate the capability of a variable-axis composite design. Because state-of-the-art composite manufacturing is mainly based on multi-axial design, the realisation of a stress-adapted design may be quite hard, if not feasible at all.

The application of composite materials according to precalculated variable-axis directions can therefore lead to superior part performance, using the anisotropic QDWXUH RI Âż EUHV LQ WKH EHVW SRVVLEOH ZD\ and can help to use far less resources,

thus allowing for cost savings.

Another important phase of the project was the development of the manufacturing process. Due to the partâ&#x20AC;&#x2122;s complex shape, with various holes and inserts, the development of a closed pressurised RTM mould was not possible. Instead, a quasi-closed tool was manufactured with special inserts for resin inlet and areas for DLU SUHVVXUH HYDFXDWLRQ 7KH Âż QDO FRQVROL dation process is basically a closed-mould infusion process, which helps to reduce the manufacturing costs as no RTM pressurisation device is required, without affecting the part quality.

DESIGN

Software

e-Xstream (Luxembourg)

Digimat AM With the impressive growth rate of additive manufacturing $0 RYHU WKH SDVW \HDUV H ;VWUHDP VHW XS D VROXWLRQ WR help the AM industry transitioning from prototyping to actual manufacturing of composite parts.

This innovation combines different software programs to offer solutions for materials development, process simulation and printed part performance. )URP WKH PDWHULDOV SRLQW RI YLHZ H ;VWUHDP ZLOO SURYLGH WKH WRROV 'LJLPDW 0) DQG 'LJLPDW )( WR HQJLQHHU DGYDQFHG FRPSRVLWH PDWHULDOV VSHFL¿ FDOO\ IRU $0 5HJDUGLQJ SURFHVV VLPXODWLRQ 'LJLPDW $0 LV DQ innovative software program fully dedicated to modelling the Fused Deposition Modelling (FDM) and Selective Laser Sintering (SLS) printing processes for reinforced materials.

7KH JRDO RI 'LJLPDW $0 LV WR EH DEOH WR ³SULQW ULJKW WKH ¿ UVW WLPH´ E\ RSWLPLVLQJ WKH PDQXIDFWXULQJ SURFHVV TXDOLW\ (minimising part deformation, for example) and by predicting WKH DV SULQWHG SDUW SHUIRUPDQFH The Digimat platform will also be able to simulate the printed partâ&#x20AC;&#x2122;s performance as a function of the material and the printing process parameters such as tool or sintering ODVHU SDWK 7KLV XQLTXH WRRO LV D PDMRU VWHS IRUZDUG IRU WKH development and design of composite parts by AM, bringing WKH SHUIRUPDQFH DQG HI¿ FLHQF\ RI ' SULQWHG SDUWV WR WKH OHYHO UHTXLUHG IRU WKH LQGXVWU\ Digimat is the only software on the market that will HQDEOH HQG XVHUV DQG SULQWHU 2(0V WR EULQJ UHOLDELOLW\ WR printed parts, thanks to warpage prediction, evaluation of many process parameters by simulation, eliminating the cost of the trial & error previously needed to optimise these parameters. Moreover, as the impact of the printing direction can be assessed, the numerical simulation reduces the need for many mechanical tests down to a few validations.

Covestro Deutschland AG (Germany)

Raw Materials

Desmocomp® â&#x20AC;&#x201C; a novel solution for composites One of the main concerns of building and infrastructure manufacturers regarding composite materials is their ability to withstand environmental degradation, and in particular UV light. To face this issue, Covestro developed the Desmocomp® matrix material.

This polymer is based on aliphatic polyurethane (PU) and presents good weathering and UV resistance to SURWHFW WKH FRPSRVLWH IURP HQYLURQPHQWDO LQÃ&#x20AC; XHQFHV WKXV making the use of UV stabilisers, UV veils and protective coatings unnecessary.

To provide a complete solution for exterior applications, Desmocomp® can also rely on the good mechanical properties of PU, such as dimensional stability (low WKHUPDO H[SDQVLRQ FRHI¿ FLHQW WKHUPDO LQVXODWLRQ DQG JRRG FKHPLFDO DQG ¿ UH UHVLVWDQFH DV ZHOO DV DQWL JUDI¿ WL properties.

First developed for the pultrusion process, one of the main processes used for composites in infrastructure, Desmocomp® can be used in open and closed moulds, DQG WKDQNV WR DQ LQQRYDWLYH VLQJOH FRPSRQHQW V\VWHP LW LV easy to process and cost effective as no injection boxes, PHWHU PL[ SXPSV RU DGGLWLRQDO LQYHVWPHQWV DUH QHHGHG JUNE / JULY 2017 53

DESIGN

Design for safety, Completion of Asahi Kaseiâ&#x20AC;&#x2122;s drivable concept car AKXYâ&#x201E;˘ JAPANESE corporation Asahi Kasei and GLM Co, an electric vehicle manufacturer, have completed a jointly developed concept car called AKXYâ&#x201E;˘ showcasing a wide array of automotive-related materials and technologies from various Asahi Kasei businesses, focused on contribution to safety, comfort, and the environment.

Asahi Kasei and GLM began discussions and planning for development of the concept car in 2015. The car uses the electric vehicle platform of GLM to achieve a drivable design. The concept car further heightens appeal to customers by having a design based on the SUV, popular around the world.

The name AKXY comes from Asahi Kasei X (multiplied by) You (the customer). AKXY is equipped with a total of 27 different Asahi Kasei materials, components and systems, most of them available for adoption

in mass-produced vehicles. These include engineering plastics to replace metal and enable vehicle weight UHGXFWLRQ DUWLÂż FLDO VXHGH IRU VHDWV with superior comfort and an in-car communication system using speechprocessing technology. The car is also equipped with cutting-edge technology that has potential for commercialization in line with automotive industry trends for safe driving and accident prevention, including a contactless vital sign sensing system that is able to detect the pulse of drivers without their being aware of it, and CO2 sensors to monitor the in-car environment.

AKXY was displayed at the Automotive Engineering Exposition 2017 Yokohama, from 24-26 May. The concept car will also be displayed at the Automotive Engineering Exposition 2017 Nagoya, from 28-30 June. www.asahi-kasei.co.jp/amm

Factory of Ideas Cologne-based designer creates piece of furniture based on Covestro materials GERMAN DESIGNER Thomas Schnur has created a one of a kind piece, named â&#x20AC;&#x2DC;The Factory of Ideasâ&#x20AC;&#x2122;, for this yearâ&#x20AC;&#x2122;s interzum furniture supplier fair. The exhibit shows the transformation of a cloud structure into a seat, using a range of Covestroâ&#x20AC;&#x2122;s products, much of which is used throughout the furniture industry.

Based on a cloud structure, which transforms into a seat, Schnur, aged 33, said he designed â&#x20AC;&#x2DC;The Factory of Ideasâ&#x20AC;&#x2122; as he was intrigued by the potential of Covestroâ&#x20AC;&#x2122;s materials, having spent time researching and experimenting alongside the companyâ&#x20AC;&#x2122;s Leverkusen application teams. An integral element in the design process was Covestroâ&#x20AC;&#x2122;s cardyonâ&#x201E;˘ polyurethane foam, which is made using around 20% carbon dioxide.

By incorporating CO2 to synthesize plastics, the company is helping to preserve increasingly scarce fossil resources while closing the carbon loop.

Each element of Schnurâ&#x20AC;&#x2122;s design incorporates a Covestro material. The wooden surface uses a waterborne polyurethane coating made from BayhydrolÂŽ and BayhydurÂŽ raw 54 JUNE / JULY 2017

materials, which provides a high level of protection and appealing appearance with low solvent content.

The seatâ&#x20AC;&#x2122;s fabric covers are made from INSQINÂŽ, another waterborne polyurethane technology invented by Covestro, XVHG WR EULQJ IXQFWLRQDOLW\ WR D UDQJH RI FRDWHG Âż QLVKHG or printed textile materials. Colour, design, durability, breathability, waterproofness and pleasant hand feel are just some of these functionalities.

The blue transparent cube protecting the â&#x20AC;&#x2DC;cloudâ&#x20AC;&#x2122; is made out of MakrolonÂŽ polycarbonate, an extremely robust, lightweight material with glass-like transparency. It is impact resistant even at extremely low temperatures. www.covestro.com

comfort, environment

JUNE / JULY 2016

55

FEATURE

0W_ 5QLLTM -I[\ XM\ZWKPMUQKIT KWUXIVQM[ XWTaUMZ XZWL]KMZ[ IZM OWQVO OTWJIT

/MWOZIXPQKIT LQ^MZ[QĂ&#x2026; KI\QWV _QTT UISM \PMU M^MV UWZM QUXWZ\IV\ IVL QVĂ&#x2020; ]MV\QIT

BY NIALL MARSHALL

FOR most people the â&#x20AC;&#x2DC;Middle Eastâ&#x20AC;&#x2122; polymer industry is in, well, the Middle East. What is noteworthy is when a Kuwaiti companyâ&#x20AC;&#x2122;s progress report on the construction of its new â&#x20AC;&#x2DC;petrochemical plant in the Gulfâ&#x20AC;&#x2122; is actually referring to a US Gulf Coast project rather than one in the Arabian Gulf, especially when similar statements are made by Saudi Arabian and Emirati petrochemical companies! It is worth examining how the Middle East petrochemical companies, and polymer producers, are going global.

The best known of the â&#x20AC;&#x2DC;Middle Eastâ&#x20AC;&#x2122; polymer producers is SABIC, the third largest producer of polyethylene in the world as well as the fourth biggest polypropylene producer. SABIC, although listed on the Saudi Arabian Tadawal stock exchange and 70% owned by the Saudi Arabian government, is more than just a polymer producer. It is also one of the largest producers of ethylene glycol in the world; it produces a wide range of petrochemicals, agrichemicals and is one of the largest fully integrated steel producers in the world.

But SABIC is probably best known as a SRO\PHU SURGXFHU DQG ZDV WKH Âż UVW 0LGGOH East polymer producer to expand its manufacturing base outside of the region with its acquisition of the petrochemicals business of DSM in 2002. This gave it PE and PP capacity in Germany and the Netherlands. The European polymer production footprint was expanded into the UK in 2007 by the purchase of the 56

JUNE / JULY 2017

Huntsman Corporation plants in Teeside.

The next big expansion step by SABIC was the acquisition of GE Plasticsâ&#x20AC;&#x2122; polycarbonate and other engineering polymer production plants in the USA, South America, Europe and Asia.

SABIC has also established polymer joint ventures with Sinopec in China, SK Global Chemical in South Korea and, more recently, is studying a potential FRDO EDVHG JUHHQÂż HOG SHWURFKHPLFDO complex with Shenhua Ningxia Coal Industry Group in China as well as a potential joint venture with ExxonMobil in Texas, USA to include an ethane cracker and two polyethylene plants.

Even bigger than SABIC is the state-owned oil and petrochemicals behemoth Saudi Aramco with its 260 billion barrels of proven oil reserves (at $50/barrel that is worth $13 trillion!), 10 RLO UHÂż QHULHV LQ 6DXGL $UDELD DQG YDULRXV joint ventures in China, Japan, Korea, ,QGLD DQG WKH 86$ 7KH ODUJHVW UHÂż QHU\ in the USA, Motiva Enterprises in Port Arthur, Texas, was a joint venture with Shell but became a fully owned Saudi Aramco subsidiary at the beginning of May 2017. Aramco has announced it will be investing up to $30 billion in Motiva DV ZHOO DV LQ DFTXLULQJ DGGLWLRQDO UHÂż QHU\ and petrochemical plants in the USA. Saudi Aramco is more an oil company than a polymer producer, only in about 2008 it started producing polymers at its PetroRabigh joint venture with Sumitomo. /DWHU WKLV \HDU LWV SRO\ROHÂż Q FDSDFLW\ ZLOO more than double to 3.5 million tons per year when the PetroRabigh II expansion

plants come on-line, and its product range will be extended to include PMMA, PA6, EPR, TPOs and super absorbent polymers. Saudi Aramco has also signed a number of MOUs with Chinese companies including Norinco to study D SRWHQWLDO UHÂż QHU\ DQG SHWURFKHPLFDO complex joint venture and with Aerosun for a reinforced thermoplastic pipe project.

Another state-owned oil company with an interest in polymers is IPIC, the International Petroleum Investment Company established by the Abu Dhabi government. IPIC owns 64% of Borealis and also owns outright the Canadian polyethylene and EPS manufacturer Nova Chemicals, as well as the Spanish CEPSA oil and petrochemical company.

Borouge, the 4.5 million ton per year producer of PE and PP in Abu Dhabi is owned by Adnoc (the Abu Dhabi National Oil Company, the 12th largest oil producer in the world) and Borealis â&#x20AC;&#x201C; in other words by the Abu Dhabi government via IPIC and Adnoc. And Adnoc, via Borealis, is planning a to build an ethane cracker and a 650 000 tpa polyethylene plant in Port Arthur, Texas, in a joint venture with Total.

And so it is not just Equate, the Kuwaiti polymer producer and petrochemical company that is looking beyond the Arabian Gulf to the US Gulf Coast. All the major Middle East petrochemical companies are expanding DQG WKLV JHRJUDSKLFDO GLYHUVLÂż FDWLRQ ZLOO make them even more important and LQĂ&#x20AC; XHQWLDO DV JOREDO SRO\PHU SURGXFHUV and reinforce their presence in new markets in Asia and America.

MATERIALS

SABIC phthalate-free PP for rigid packaging Use less material, less energy to produce rigid packaging TODAYâ&#x20AC;&#x2122;S fast-paced lifestyles also are driving demand for pre-packed food; for KRW ¿ OOHG SDFNDJLQJ VXFK DV FXSV DQG ERWWOHV DV ZHOO DV PLFURZDYH XVH $W WKH VDPH WLPH FRQVXPHU H[SHFWDWLRQV are driving OEMs and brand owners to FUHDWH SDFNDJLQJ WKDW LV UREXVW HDV\ WR open and distinctively shaped with vibrant JUDSKLFV 7KHVH FKDOOHQJHV QHHG WR EH met while lowering weight and cost by UHGXFLQJ SDFNDJLQJ WKLFNQHVV ZLWK GRZQ JDXJLQJ IDVWHU SURGXFWLRQ F\FOH WLPHV DQG minimizing waste and the environmental LPSDFW 6$%,& LV KHOSLQJ FXVWRPHUV LQ SDFNDJLQJ LQGXVWU\ WR PHHW WKHVH FKDOOHQJHV E\ H[WHQGLQJ LWV )/2:3$&7 impact copolymers family with a new 6$%,& 33 )3& SRO\SURS\OHQH VROXWLRQ IRU ULJLG SDFNDJLQJ 7KLV KLJK Ã&#x20AC; RZ 0)5

LPSDFW FRSRO\PHU JUDGH EDVHG RQ a phthalate free catalyst is an injectionPRXOGLQJ JUDGH GHYHORSHG IRU DSSOLFDWLRQV VXFK DV FRQWDLQHUV FDSV DQG FORVXUHV LQ

ULJLG SDFNDJLQJ DQG IRU FRQVXPHU JRRGV ³2XU QHZ )/2:3$&7 JUDGH 6$%,& 33 )3& LV D SDUW RI WKH QHZ ZDYH RI SURGXFWV IURP 6$%,& IRU ULJLG SDFNDJLQJ DQG IRU RWKHU VHJPHQWV DV ZHOO ,W LV DQ LPSRUWDQW VWHS IRUZDUG WKDW VKRXOG HQDEOH RXU FXVWRPHUV WR XVH OHVV PDWHULDO DQG OHVV HQHUJ\ WR SURGXFH ULJLG SDFNDJLQJ with the same or even better properties WKDQ EHIRUH PRUH TXLFNO\ WKDQ EHIRUH´ VD\V /DGD .XUHOHF JOREDO EXVLQHVV GLUHFWRU 33 IRU SHWURFKHPLFDOV DW 6$%,& 7ULDOV DW VHYHUDO SDFNDJLQJ PDQXIDFWXUHUV KDYH DOUHDG\ GHPRQVWUDWHG WKH EHQH¿ WV RI WKH QHZ SURGXFW¶V PDUNHW OHDGLQJ combination of high stiffness and high LPSDFW VWUHQJWK 6$%,& 33 )3& DQVZHUV WKH FRQWLQXLQJ WUHQGV LQ WKLQ ZDOO SDFNDJLQJ E\ HQDEOLQJ XS WR WKLQQHU ZDOOV DQG IDVW LQMHFWLRQ WKXV UHGXFLQJ HQHUJ\ FRQVXPSWLRQ DQG LQFUHDVLQJ SURGXFWLYLW\ www.sabic.com

SABIC extends its impact copolymers with the new phthalatefree SABIC® PP FLOWPACT FPC70 grade for rigid packaging

58 JUNE / JULY 2017

Buzz Trading â&#x20AC;&#x201C; ready for contract work Capacity available: ready for contract moulding work Servicing the domestic appliance market in Southern Africa since 2003 â&#x20AC;¢ Injection moulding capability from 60 to 1300 tons clamp force â&#x20AC;¢ Own toolroom: we offer development from concept to finished product â&#x20AC;¢ We operate our own transport fleet: delivery to anywhere in SA within 48hrs

Buzz Trading 104 (Pty) Ltd t/a Master Products 16 Moller Street, Germiston Tel: 011 873 8050 | Email: orders@buzztrading104.co.za www.buzztrading104.co.za

HOW MUCH DO YOU 9$/8( 5(/,$%,/,7<" )RU \HDUV 6$%,& FXVWRPHUV KDYH EHQHÆ&#x201A;WWHG IURP UHOLDELOLW\ LQ RXU VXSSO\ FKDLQ DQG VHUYLFH DSSURDFK :LWK ZRUOG FODVV SODQWV D JOREDO VDOHV DQG GLVWULEXWLRQ QHWZRUN DQG VWDWH RI WKH DUW 7HFKQRORJ\ DQG ,QQRYDWLRQ FHQWHUV ZH DUH FRQÆ&#x201A;GHQW WKDW 6$%,& V QHZ 6\QWKHWLF 5XEEHU FXVWRPHUV ZLOO KDYH D VLPLODU H[SHULHQFH ZLWK WKH ODWHVW SURGXFW RIIHULQJV 3RO\EXWDGLHQH 5XEEHU %5 DQG (WK\OHQH 3URS\OHQH 'LHQH 5XEEHU (3'0 7KLV LV MXVW RQH PHDQLQJ RI Å&#x201D;&KHPLVWU\ WKDW 0DWWHUVâ&#x201E;¢ Å&#x2022; )RU PRUH GHWDLOV SOHDVH YLVLW ZZZ VDELF FRP 5XEEHU

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MATERIALS

An exhaust trim made from the high-temperature stable and electroplatable copolycarbonate ABS copolymer Apec 150 PG

Concept study for exhaust trim made of plastic

60 JUNE / JULY 2017

High-temperature stable & electroplatable COVESTRO has developed a blend for fabricating chrome-plated plastic components that is extremely heatresistant and suitable for electroplating.

Apec® 150 PG (plating grade) is based on a copolycarbonate and acrylonitrile-butadiene-styrene copolymer (PC-HT+ABS). Its Vicat B softening temperature (ISO 306) is 146 Grad Celsius, or about 35 degrees higher than that of electroplatable standard polycarbonate/ABS blends.

“The combination of high heat resistance and good electroplating properties is rare on the mainitiarket. It considerably expands the performance and application range of such materials in the production of chrome-plated design components,” explained Walter Köppchen, electroplating materials expert at Covestro.

The high-tech material was developed in response to an idea by Gerhardi Kunststofftechnik GmbH for making the exhaust trim part from plastic. Based in Lüdenscheid,

Germany, the electroplating specialist had engineered a substitute for the part, usually fabricated from stainless steel, and needed a thermoplastic material that could be decoratively electroplated and also withstand the temperatures prevailing in the vicinity of the exhaust.

7KH ¿ UVW SURWRW\SH YHKLFOHV ZLWK the plastic exhaust trim have already been out on the road to test the longterm performance. The objective is to soon establish widespread use of this innovative part in motor vehicles.

Covestro showcased a prototype at the recent K2016 plastics trade fair in Düsseldorf.

Smaller radii, integration of lighting effects The attraction of fabricating exhaust trim from a thermoplastic is that it weighs up to 50% less than its sheet steel counterpart. In addition, the plastic can be shaped much more easily than sheet steel to achieve tight radii and www.covestro.com

3D geometries. Furthermore, plastic provides greater design freedom in terms of colour and function integration.

For example, LEDs could be integrated into the exhaust trim to enhance its appearance with lighting effects in combination with either selective twocomponent electroplating or Gerhardi Strukturchrom.

The new blend displays high toughness, strength and rigidity across a wide range of temperatures. The thin metal coating deposited during the electroplating process adheres strongly to the plastic surface. “The plastic part easily passes the heat aging and cross cut adhesion tests that are so critical for automotive components.”

Other potential “hot” applications in automotive engineering include visible, electroplated parts under the hood, such as logos, emblems, lettering and covers. There also good opportunities in the electrical/electronics segments, i.e. in the production of chrome-plated bezels, trim strips and ventilation grilles.

MATERIALS

New tyre tread label meets global standards

62 JUNE / JULY 2017

Allows entire pallets of tyres to be read in a single pass AVERY Dennison and Ferm RFID Solutions KDYH FUHDWHG WKH ¿ UVW WUXO\ XQLYHUVDO W\UH WUHDG ODEHO ZLWK ZRUOGZLGH 5),' IXQFWLRQDOLW\ ZKLFK DOORZV HQWLUH SDOOHWV RI W\UHV WR EH UHDG LQ D single pass. +DQV (LFKHQZDOG VHQLRU SURGXFW PDQDJHU DW $YHU\ 'HQQLVRQ 0DWHULDOV *URXS (XURSH VDLG WKDW WKH QHZ SURGXFW FUHDWHV EHQH¿ WV DFURVV WKH ZKROH VXSSO\ FKDLQ IURP PDQXIDFWXULQJ TXDOLW\ FRQWURO WKURXJK WR GLVWULEXWLRQ VWRUDJH DQG SRLQW RI VDOH ³7KLV WHFKQRORJ\ KHOSV WR DGG YDOXH IRU PDQXIDFWXUHUV ZKR FDQ WUDFH JRRGV PRUH HI¿ FLHQWO\ GXULQJ SURGXFWLRQ ,W EHQH¿ WV logistics suppliers who can read entire pallets DW RQFH DQG ZDUHKRXVHV WKDW QHHG WR WUDFN W\UH H[SLUDWLRQ GDWHV ´ 7KH 5),' W\UH ODEHO WHFKQRORJ\ ZDV GHYHORSHG WKURXJK D FROODERUDWLYH HIIRUW E\ )HUP 5),' DQG $YHU\ 'HQQLVRQ 0DWHULDOV *URXS (XURSH )HUP 5),' DQG $YHU\ Dennison have contributed RFID and pressureVHQVLWLYH VROXWLRQV UHVSHFWLYHO\ 7KH ¿ QDO SURGXFW LV DEOH WR KDQGOH D YHU\ wide range of applications. The label uses FRSSHU ZLUH DQWHQQD WHFKQRORJ\ DQG LV FRPSDWLEOH ZLWK DOO 8+) (3& &ODVV *HQ

JOREDO 5),' VWDQGDUGV DOORZLQJ HDVLHU DFFHVV WR GLIIHUHQW PDUNHWV 7KH ODEHO FRSHV ZLWK DOO W\UH W\SHV ± IRU H[DPSOH W\UHV ZLWK KLJK FDUERQ EODFN RU VWHHO FRQWHQW 7KH 5),' UHDGLQJ GLVWDQFH LV WKH VDPH IRU FDU WUXFN RU DLUFUDIW W\UHV DQG IXQFWLRQV VXFK DV EXON UHDGLQJ RI entire pallets are straightforward.

3RO\SURS\OHQH DQG SRO\HVWHU W\UH ODEHOV LQ WKH $YHU\ 'HQQLVRQ SRUWIROLR SHUIRUP YHU\ ZHOO XQGHU FKDOOHQJLQJ FRQGLWLRQV The new RFID tread label WHFKQRORJ\ DOORZV XS WR W\UHV WR EH UHDG VLPXOWDQHRXVO\ DW D GLVWDQFH RI XS WR PHWUHV ZLWK PRUH GHSHQGDEOH SHUIRUPDQFH ORZHU HUURU UDWHV DQG UHGXFHG W\UH ZDVWDJH 5HDO ZRUOG GXUDELOLW\ LV HQVXUHG E\ DQ 5),' DQWHQQD WKDW has been designed so it cannot be disconnected from the RFID FKLS $ SURSULHWDU\ $YHU\ 'HQQLVRQ W\UH ODEHO DGKHVLYH ZLWK KLJK FRDW ZHLJKW DQG ORZ EOHHG JXP SDWWHUQ VXSSRUWV SURGXFWLRQ IULHQGO\ label conversion and reliable www.averydennison.com labelling results.

DuPont introduces one-step moulding technique DUPONT Performance Materials has introduced an innovative use of DuPont Surlyn® ionomer resins to achieve a one-step frosted effect for cosmetics caps, bottles and jars. This effect is achieved VWUDLJKW IURP WKH PRXOG WR HQDEOH ¿ QH GHWDLOV SOHDVDQW WDFWLOH quality and consistency without a need for a secondary process. The unique properties of Surlyn® enable it to FRS\ ¿ QH LQWULFDWH GHWDLOV RI D PRXOG WR DFKLHYH D KLJK gloss design with an entirely, or partially, frosted appearance. By applying this frosted effect in the mould, 6XUO\Q RIIHUV LQFUHDVHG SURGXFWLRQ HI¿ FLHQF\ DQG lower cost for manufacturers looking to achieve this effect for their packages. Surlyn offers the transparency of glass, without the fragility, and also can be IURVWHG IDFHWHG RU ¿ QLVKHG WR REWDLQ VSHFLDO HIIHFWV or coloured to create elegant translucency. It allows the use of many different decorative techniques for cosmetics, including metallization, hot stamping and lacquering. Some unique effects that can be created with Surlyn are marbling, bubbling, glittering and suspended animations. Its warm and silky touch is coupled with functional

www.plastics.dupont.com

candice@relloy.co.za

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Large-area structural part in thin-wall design

64 JUNE / JULY 2017

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New â&#x20AC;&#x2DC;SteadyEdgeâ&#x20AC;&#x2122; PET container base Combines creative opportunities with optimum performance SIDELâ&#x20AC;&#x2122;S new SteadyEDGE base technology is designed to meet the FKDOOHQJH RI SURGXFLQJ Ã&#x20AC; DW RYDO DQG UHFWDQJXODU FRQWDLQHUV LQ 3(7 ZKLFK DOO UHTXLUH D VSHFL¿ F SURGXFWLRQ SURFHVV WKDW GHOLYHUV WKH RSWLPXP PDWHULDO GLVWULEXWLRQ RI 3(7 WR DFKLHYH D WRS TXDOLW\ SDFNDJH ³,W PDNHV LW SRVVLEOH WR DFKLHYH SUHPLXP TXDOLW\ FRQWDLQHUV LQ 3(7 ZLWK VKDUSHU HGJHV ZKLFK KDYH D UDGLXV DV OLWWOH DV RQO\ PP FRPSDUHG WR D SUHYLRXV PLQLPXP RI PP ´ H[SODLQHG 3LHUULFN 3URWDLV 3DFNDJLQJ ,QQRYDWLRQ /HDGHU DW 6LGHO 7KHVH VKDUSHU HGJHV actually increase design freedom and facilitate the production of more elegant containers with bases which are less FXUYHG $OVR WKH\ RSHQ XS SDUWLFXODU PDUNHWLQJ RSSRUWXQLWLHV IRU FRQWDLQHUV

ZLWK FRPSOH[ VKDSHV DQG ODUJH ODEHOOLQJ VXUIDFHV 7KH WHFKQRORJ\ DOVR HQVXUHV PD[LPXP FRQWDLQHU TXDOLW\ E\ ZD\ RI DFFXUDWH SURFHVVLQJ RSWLRQDOO\ UHLQIRUFHG E\ D PRQLWRULQJ V\VWHP RI YLVXDO FRQWURO RI EDVH PRYHPHQW RQ LQGLYLGXDO EORZLQJ VWDWLRQV The sharper edges possible on WKH SDFNDJH DUH XVHG WR HIIHFWLYHO\ Ã&#x20AC; DWWHQ DQG LQFUHDVH WKH µVWDQGLQJ ULQJ¶ DUHD RI WKH EDVH 7KH DSSOLFDWLRQ RI SteadyEDGE to any design can enhance WKH SDFNDJH¶V VWDELOLW\ E\ DV PXFK DV

%HQH¿ WV LQFOXGH OLJKWZHLJKWLQJ SRVVLELOLWLHV RI XS WR WKURXJK WKH LPSURYHG PDWHULDO VWUHWFK RQ WKH EDVH $ reduction in blowing pressure decreases HQHUJ\ FRQVXPSWLRQ E\ XS WR GXULQJ

SURGXFWLRQ ZKHQ OLPLWDWLRQ LV OLQNHG WR EDVH GHVLJQ 7KH VROXWLRQ KDV EHHQ DFKLHYLQJ KLJKHU RXWSXW UDWHV ZKLFK DUH DOVR XS WR IDVWHU IURP ERWWOHV SHU KRXU SHU PRXOG IRU Ã&#x20AC; DW FRQWDLQHUV ZLWK D VWDQGDUG EDVH WR ERWWOHV SHU KRXU SHU PRXOG ZLWK 6WHDG\('*( 7KH VSHFL¿ F VKDUS EDVH GHVLJQ LV DFKLHYHG XVLQJ WKH QHZ 6LGHO patented base mould system: the Base 2YHU6WURNH 6\VWHP %266 %266 LV D SLVWRQ DFWLYDWHG LQ WKH EORZLQJ SKDVH WR VWURNH WKH EDVH 7KLV PHFKDQLFDO HOHPHQW allows for the raising and lowering of the base during the bottle-forming process independent of the opening and closing RI WKH WZR KDOI VKHOOV RI WKH PRXOG www.sidel.com/steadyedge

Aqueous acrylic binder for nonwovens in construction & abrasive applications :,7+ $FURQDO %$6) SUHVHQWV D QHZ DTXHRXV DFU\OLF ELQGHU IRU QRQZRYHQV PHHWLQJ KLJK WKHUPR GLPHQVLRQDO VWDELOLW\ UHTXLUHPHQWV 7KH ELQGHU LV SDUWLFXODUO\ VXLWDEOH IRU QRQZRYHQV WKDW DUH XVHG IRU FRQVWUXFWLRQ DQG DEUDVLYH DSSOLFDWLRQV $FURQDO RIIHUV D VHOI FURVV OLQNLQJ DFU\OLF GLVSHUVLRQ WKDW OHQGV QRQZRYHQV WKDW DUH H[SRVHG WR WKHUPDO VWUDLQ KLJK OHYHOV RI PHFKDQLFDO VWDELOLW\ 7KH ELQGHU LV SDUWLFXODUO\ VXLWDEOH IRU QRQZRYHQV PDGH RI V\QWKHWLF ¿ EUHV VXFK DV SRO\HVWHU 7KH QHZO\ GHYHORSHG SURGXFW LV FRPSDWLEOH ZLWK RWKHU FURVV OLQNLQJ V\VWHPV VXFK DV PHODPLQH DQG XUHD UHVLQV ,Q DGGLWLRQ LW FDQ HDVLO\ EH DSSOLHG ZLWK UHJXODU IRXODUG V\VWHPV www.basf.com 66 JUNE / JULY 2017

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

EQUIPMENT Close cavity spacing can allow the use of a single, multi-tip nozzle, reducing the costs and variables introduced by a manifold system required in a tool with side actions

Run Clean, Run Efficient â&#x20AC;&#x201C;

Luer caps moulded with expandable cavities in the mould

parts for medical, industries

68

JUNE / JULY 2017

Reduce risk, liability over the course of a medical mouldâ&#x20AC;&#x2122;s lifetime MEDICAL parts have different requirements than other moulded articles and as a result tooling engineers over the years have pioneered new mould materials, coatings and mould maintenance practices. )RU H[DPSOH D W\SLFDO OXHU Âż WWLQJ FRPSRQHQW IRU PDNLQJ OHDN IUHH FRQQHFWLRQV LV XVHG IRU PDNLQJ D VHFXUH OHDN proof attachment with tubing connections in medical devices and other instruments. These small connectors frequently have undercuts and, when they do, can create considerable FRVW DQG ULVN LPSOLFDWLRQV IRU WKH PRXOGLQJ RI WKHVH SDUWV However, practices are evolving and tooling engineers have begun using a single, expanding cavity component as an alternative to slide mould traditions of the past.

Containing the partâ&#x20AC;&#x2122;s undercuts within an expandable cavity, results in a mould that is smaller and simpler, with less moving parts. Design time is reduced and mould construction hours are less. With a smaller mould, lower hourly moulding machine rates result, and when a mould is less complex, it is easier and less costly to properly maintain.

Now these advanced mould components are available local from Mould & Die Solutions, the South African tooling equipment supplier which represents Roehr Tool Solutions of the USA. Slide moulds require lubrication, introducing opportunities for part contamination, while an expandable cavity requires no such grease. And rather than nesting round parts within long slides, more conformal cooling and a more balanced runner system can be achieved Eliminating side actions enables a simplerto-maintain tool to be run in a greaseless environment

by using a component that forms the part concentrically.

Expandable cavities are constructed in an expanded position, PHDQLQJ WKDW GXULQJ PRXOGLQJ WKH\ DUH SXOOHG EDFN DJDLQVW D VWULNHU ULQJ DQG FROODSVHG LQZDUG )RU HMHFWLRQ WKH FRPSRQHQW LV staged forward, which allows the segments of the expandable cavity to expand outward. This releases the undercut and the part LV WKHQ UHDG\ IRU HMHFWLRQ 7KH\ DUH FRPPRQO\ VWDJHG IRUZDUG during mould open to enable the fastest possible cycle time.

Success with expandable cavity system ([SDQGDEOH FDYLWLHV FDQ VRPHWLPHV EH D SURMHFW VDYLQJ VROXWLRQ DV LW ZDV IRU 0LNH 5RFNZHOO RI &DSH )HDU 0RXOG Tool of North Carolina, USA. Cape Fearâ&#x20AC;&#x2122;s customer required two hot runner moulds with undercuts. â&#x20AC;&#x153;One of the moulds was fairly simple except for some undercuts, but the second mould turned into a bear,â&#x20AC;? said 0LNH Âł,W KDG D ORQJ WKLQ FRUH UXQQLQJ WKURXJK WKH FHQWUH undercuts on the inside that required the expandable cavities, undercuts around the outside that required slides, and, to top it all off, it had a 0,04mm vent hole in the face.â&#x20AC;?

The complexity of the second mould wasnâ&#x20AC;&#x2122;t the only criterion that had to be met, but there were also space FRQVLGHUDWLRQV DQG D WLJKW GHOLYHU\ WLPH WR WKLQN DERXW â&#x20AC;&#x153;The expandable cavity system was really the only option,â&#x20AC;?

0LNH QRWHV Âł:H KDG ZRUNHG ZLWK VHYHUDO FROODSVLEOH FRUHV LQ the past and have always been quite happy with those, so I ZDV FRQÂż GHQW WKH H[SDQGDEOH FDYLW\ V\VWHP ZRXOG ZRUN MXVW as well. The beauty of the expandable cavities is that there is really no way to crash the mould.â&#x20AC;?

7KH SURMHFW ZDV D VXFFHVV DQG 0LNH VD\V KLV FXVWRPHU ZDV YHU\ VDWLVÂż HG ,Q PHGLFDO PRXOGLQJ WKH VWDNHV DUH KLJK 7KH UDPLÂż FDWLRQV WKDW are on every tooling engineerâ&#x20AC;&#x2122;s mind can cause one to default into EXLOGLQJ WKH QH[W WRRO PXFK OLNH WKH ODVW WRRO +RZHYHU EH\RQG WKH cost savings of a smaller and more straightforward mould build, containing the partâ&#x20AC;&#x2122;s undercut details within a single component ensures part accuracy, optimal cooling, greaseless moulding and GUDPDWLFDOO\ VLPSOLÂż HG PRXOG PDLQWHQDQFH 7KHVH DGYDQWDJHV UHGXFH ULVN DQG OLDELOLW\ RYHU WKH FRXUVH RI D PRXOGÂśV OLIHWLPH Mould & Die Solutions represents Roehr Tool Solutionsâ&#x20AC;&#x2122; range of collapsible cores and expandable cavities in South Africa, tel: 010 410 5350 or 021 555 2701 www.m-d-s.co.za

Vacuum resin drying for wider range of moulding, extrusion /RZHU RSHUDWLQJ FRVW LQFUHDVHG HIÂż FLHQF\ JUHDWHU FRQWURO A NEW vacuum resin dryer from Maguire Products enables more moulding and extrusion processors to obtain the substantial advantages of vacuum dryers over conventional desiccant systems, LQFOXGLQJ ORZHU RSHUDWLQJ FRVW LQFUHDVHG HIÂż FLHQF\ and greater control over the drying process.

The VBDâ&#x201E;˘ 300 vacuum dryer achieves throughputs of up to 136kg per hour, which is double the capacity of the companyâ&#x20AC;&#x2122;s VBD 150 model. While the VBD 150 is sized for the throughputs of many injection moulding machines and of small extrusion lines like those for medical tubing, the new VBD 300 model opens the EHQHÂż WV RI YDFXXP UHVLQ GU\LQJ WR D EURDGHU range of applications. Maguire also offers the VBD 1000 dryer for high-volume operations.

In comparison with desiccant dryers, the VBD vacuum dryer consumes 60% less energy, dries resin in one-sixth the time, and substantially reduces the heat history to which polymer is exposed.

The speed with which the VBD system removes

moisture makes properly dried polymer available for production only 35 minutes after a cold start.

Like other VBD models, the VBD 300 dryer is a gravimetric system that employs load cells that precisely monitor the weight of material at two critical points, making possible precise control over material consumption and documentation RI SURFHVV FRQGLWLRQV IRU FHUWLÂż FDWLRQ WR customers.

VBD vacuum dryers use gravity to move material through three vertically arranged stages of the drying process, with the discharge of material from one stage to the next controlled by high-speed slide-gate valves with an accuracy per dispense of +/- 4 grams.

Represented in South Africa by Hestico (Pty) Ltd www.hestico.co.za www.maguire.com JUNE / JULY 2017 69

www.coperion.com

EQUIPMENT

Automation from Wittmann â&#x20AC;&#x201C; a winning solution %HQHÂż WV LQFOXGH UHSHDWDELOLW\ LQFUHDVHG VDIHW\ RENYMED, with a production plant in Baldwin Park, California, is an industry leader in the moulding of specialty products for the medical market.

Automation systems from the Wittmann *URXS Âż W WKHLU QHHGV DQG KHOSHG WKHP improve their process.

RenyMedâ&#x20AC;&#x2122;s facilities are impressive â&#x20AC;&#x201C; their state-of-the-art facility in Baldwin 3DUN &DOLIRUQLD LV FHUWLÂż HG ,62 7KH\ KDYH RYHU HPSOR\HHV ZRUNLQJ RQ LQMHFWLRQ PRXOGLQJ PDFKLQHV LQ D P2 IDFLOLW\ WKDW LQFOXGHV D P2 cleanroom.

RenyMed prides itself on its capabilities. They are a fully integrated moulding shop, building moulds and then moulding the parts. Many of the MREV WKDW WKH\ JHW DUH RQHV WKDW ZHUH attempted at other moulding shops and IDLOHG 7KH QHHG LV WR EH Ă&#x20AC; H[LEOH DQG adaptive, which means they also need production equipment that can move as quickly as they do. And thatâ&#x20AC;&#x2122;s the point

where the Wittmann Group comes in. Âł:H Âż UVW EHFDPH DZDUH RI WKH :LWWPDQQ *URXS DW WKH . 6KRZ LQ DĂźsseldorf, Germany, where we saw an integration of one of the Wittmann robots RQ D :LWWPDQQ %DWWHQIHOG WRQ LQMHFWLRQ PRXOGLQJ PDFKLQH´ VD\V 6WHYH 5DLNHQ 5HQ\0HG 3UHVLGHQW Âł2XU HQJLQHHUV were impressed, and had a vision of XVLQJ WKH URERWV WR LPSURYH QRW MXVW RXU process but our employee safety. We went for it and have been using their robots ever since.â&#x20AC;?

Flexible design with a vision for quality $QRWKHU PDMRU UHDVRQ IRU WKH SXUFKDVH of these robots was that it simply made the most sense with RenyMedâ&#x20AC;&#x2122;s space and the application they needed them for. Because of this, RenyMed has a necessary awareness of space use.

7KH\ Âż W DV PXFK PRXOGLQJ SRZHU DV they could into their cleanrooms, and they wanted a robot that would be equally space-conscious.

Wittmannâ&#x20AC;&#x2122;s robots were the only robots that RenyMed tested with a low HQRXJK FHLOLQJ KHLJKW WR H[HFXWH D IXOO stroke inside of their cleanroom. â&#x20AC;&#x153;Witmmann Battenfeld was very helpful with solutions when we presented problemsâ&#x20AC;?, said Raiken. Âł7KH\ PRGLÂż HG WKH URERW WR EHWWHU Âż W LQ the room. We told them what we needed and where it needed to reach and they WULPPHG WKH UDFN DQG SRVLWLRQHG LW WR Âż W SHUIHFWO\ 7RGD\ LWÂśV UXQQLQJ ´ RenyMed also worked with Wittmann Battenfeld to integrate vision into the robots. After connecting with a camera supplier to get the right operating system, they designed and built a custom end-of-arm tool for their robots to be able to pick the part out, take a photo when the robot has the part, allows the mould to close, and then takes two more photos on each end to inspect the part dimensionally and make sure it is a full compliant part. This quality

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Premium-quality cosmetics packaging EVER Rich Fountain (ERF) based in Taichung, Taiwan, is a leading Taiwanese manufacturer of premium-quality FRVPHWLFV SDFNDJLQJ ,Q DGGLWLRQ WR ORFDOO\ SURGXFHG LQMHFWLRQ moulding machines, the company uses state-of-the-art LQMHFWLRQ PRXOGLQJ WHFKQRORJ\ IURP :LWWPDQQ %DWWHQIHOG RQ LWV SURGXFWLRQ Ă&#x20AC; RRU ERF is an all-in-one supplier of packaging solutions and offers its customers worldwide a complete service portfolio including counselling and design, mould technology, production and printing of the products using latest technologies such as metallizing, vacuum anodizing, hot stamping, screen printing, UV varnishing or soft-touch coating.

The companyâ&#x20AC;&#x2122;s product range includes airless pump bottles made of PP and PET, double-walled airless bottles, ORWLRQ GLVSHQVHUV 3(7 * DQG 33 H[WUXVLRQ PRXOGLQJ ERWWOHV 33 DQG 3(7 FUHDP MDUV SLSHWWHV DQG PDQ\ RWKHU LWHPV LQ PMMA cream jar â&#x20AC;&#x201C; left: coloured inner SDUW ULJKW Âż QLVKHG MDU

D YDULHW\ RI FRORXUV DQG VKDSHV ,WV PDLQ SURGXFW OLQH LV WKH airless bottle, developed in-house by ERF. The technology of WKLV SURGXFW HQDEOHV UHPRYDO RI WKH OLTXLG IURP LQVLGH the bottle. Consequently, these bottles are used primarily as packaging for lotions in the top price segment.

Today, ERF makes high-precision parts for dosing pumps in cosmetics bottles on two machines from Wittmann %DWWHQIHOGÂśV 0LFUR3RZHU VHULHV ZLWK N1 FODPSLQJ IRUFH 7KH UHOLDELOLW\ DQG FRVW HIÂż FLHQF\ RI WKLV LQQRYDWLYH PDFKLQH PRGHO ZLWK ZKRVH WZR VWHS VFUHZ DQG SOXQJHU LQMHFWLRQ XQLW WKHUPDOO\ KRPRJHQHRXV PHOW LV LQMHFWHG ZLWK VKRW YROXPHV UDQJLQJ IURP OHVV WKDQ XS WR FPĂą DEVROXWH SURFHVV stability and short cycle times, has convinced ERF of the TXDOLW\ RI LQMHFWLRQ PRXOGLQJ WHFKQRORJ\ IURP :LWWPDQQ Battenfeld. ,Q 'HFHPEHU (5) DGGHG D K\GUDXOLF PXOWL FRPSRQHQW PDFKLQH IURP :LWWPDQQ %DWWHQIHOG WR LWV HTXLSPHQW ,W LV DQ +0 + 6 ZLWK D YHUWLFDO URWDU\ XQLW 7KH PXOWL colour machine is used in the production of PMMA cream MDUV 7KH RXWHU OD\HU RI SODVWLF LV FU\VWDO FOHDU WKH LQQHU OD\HU LV SUH G\HG WR FUHDWH D SLDQR Âż QLVK HIIHFW :LWWPDQQ %DWWHQIHOG LV UHSUHVHQWHG LQ 6$ E\ ,SH[ 0DFKLQHU\ www.wittmann-group.com

www.ipex.co.za

View of the RenyMed automation system: Wittmann robots working on the RenyMed injection moulding machines at their plant in Baldwin Park, California, USA

control feature was custom designed and built and has performed as designed, with RenyMed moulding over a half million shots without a single complaint.

The Wittmann Battenfeld robots have allowed RenyMed to inspect 100% of their parts and have also resulted in other EHQHÂż WV WKDW FRPH ZLWK DXWRPDWLRQ (repeatability, increased safety). This, plus the controls that allow for easy handling, has helped RenyMed move even more quickly with each changing project and continue to succeed at the â&#x20AC;&#x153;hard stuffâ&#x20AC;? that keeps coming their way when itâ&#x20AC;&#x2122;s too much for everyone else.

A view of the RenyMed inspection system

Ipex to host Open House in SA to launch Innovation Centre in August IPEX, the South African representative for Wittmann Battenfeld, will host an Open House from 21-23 August to mark the opening of its new Innovation Centre. The Open House will be held at Ipex premises at 55 Trump Street, West Selby, Ext 4, Johannesburg, from 10am to 6pm each day. Presentations will be held at 11am and 3pm.

The presentation will include robotics and automation, cost per part, energy HIÂż FLHQF\ DQG DSSOLFDWLRQ HQJLQHHULQJ LQFOXGLQJ &HOOPRXOG DQG &RPELPRXOG â&#x20AC;&#x153;We will have a 110 ton IMM with robot showcasing Wittmann 4.0, loading and dosing equipment, as well as the full integration of all the auxiliaries into the HMI of the machine, using Wittman 4.0 software,â&#x20AC;? says Ipexâ&#x20AC;&#x2122;s Sean Kleingeld, Wittmann Battenfeld Product Manager. â&#x20AC;&#x153;We will also have a separate robot which will be there for training purposes for clients who want to send their operators for training.â&#x20AC;?

www.wittmann-group.com

www.ipex.co.za JUNE / JULY 2017 71

WITTMANN 4.0 W818 pro

R8 Robot control UNILOG B8 Control Unit

TEMPRO plus D DRYMAX

FLOWCON Plus

GRAVIMAX

EcoPower 55 â&#x20AC;&#x201C; 300 t

Join us in introducing the future of manufacturing!

In association with Plastics SA

(Pty) Ltd. IPEX Machinery 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

EQUIPMENT

1

Gebo Cermex helps achieve major PET line upgrade Installation, full speed production achieved in less than three weeks CAROLA, one of the largest producers of mineral water in France, is producing a new, lighter PET bottle and, in doing so, has also increased output speed by 3 000 containers per hour. This follows a line upgrade

by Gebo Cermex, with installation and ramp-up to full speed production achieved in less than three weeks.

Following the buy-out of the company by Spadel, the international group focused on the bottling and marketing of natural mineral waters and a varied range of refreshing drinks, a new investment strategy called for a complete overhaul of the RibeauvillĂŠ PET line facility, in Alsace (France). The ageing line was causing problems because of its limited Ă&#x20AC; H[LELOLW\ UHVWULFWHG DFFXPXODWLRQ capacity, reduced speed due to the limitations of certain machines within the line and poor working conditions.

More importantly, the performance of the line was preventing Carola from keeping pace with the fast-changing EHYHUDJH PDUNHW DQG WKH Ă&#x20AC; XFWXDWLRQV in consumer demand. The company 72

JUNE / JULY 2017

formats in no more than was also eager to 21 days. On the other minimise the weight The new line has hand, the customer of the bottles it had to upgrade the was producing and increased output line, taking up no more to switch to more rates by 3 000 room in a facility where modern packaging bottles per hour for Ă&#x20AC; RRUVSDFH ZDV DOUHDG\ formats. at a premium.

Within this type of all packsâ&#x20AC;&#x2122; formats.

The new line has installation, which increased output rates covers everything by 3 000 bottles per hour for all packsâ&#x20AC;&#x2122; from bottle conveyors right through formats. This increased productivity to the palletiser, the connection means that Carola can now produce between the lineâ&#x20AC;&#x2122;s various pieces of greater volumes to tighter deadlines, equipment is vitally important. Output enabling the company to respond to performance is largely determined spikes in demand while reducing the E\ WKH HIÂż FLHQF\ ZLWK ZKLFK WKH OLQH stock managed for this purpose by an handles increases in speed as well external storage provider. as stoppages. The project at the The most crucial stage of the project, Carola-RibeauvillĂŠ factory presented the team in Gebo Cermex with several the dismantling of the existing line and the assembly of the new equipment, other challenges. On one hand, the took place well within schedule and company had to change everything the restart proved successful for all within a complete production line formats, which now includes packs of without creating a supply problem 6, 8 and 24 bottles. Production speed for the water producer. This meant was quickly ramped up and within a that Gebo Cermex had to replace all month the whole line was running at the equipment and get the entire line OLQH HIÂż FLHQF\ $OO WKH PDFKLQHV back in operation at full speed in all

3

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and conveyors were reinstalled as close as possible to the ground so that they were directly accessible with no need to climb up on walkways â&#x20AC;&#x201C; unlike the previous line. Line control is one of the major strengths of the new system, not least the advanced management of stoppages and restarts on the conveyors and the accumulation

tables between the machines. Format changeovers on the new line are also PXFK PRUH HIÂż FLHQW WKDQ WKH\ XVHG to be.

Sidel in South Africa, tel: 011 466 2230, email: henri.attias@sidel.com www.gebocermex.com

5

Carola pack conveyors 1 Gebo Cermex line automation 2 Palletizer with robotic layer preparation 3 Robotic layer preparation 4 Carola accumulation table 5

www.sidel.com JUNE / JULY 2017 73

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 $QG VHOOLQJ LW PLQG \RX 7KH ÂżUVW SLSHV SURGXFHG DW KLV QHZ FRPSDQ\ ZHQW GLUHFWO\ IURP PDFKLQH WR WKH EDFN RI WKH GHOLYHU\ WUXFN Âą ZLWKRXW HYHQ WRXFKLQJ WKH IDFWRU\ Ă&#x20AC;RRU Inkulu Plastic Pipes leased a 3440m2 factory in Hammarsdale. Inkulu Plastic Pipes has not looked back since, and the machines DUH QRZ UXQQLQJ 7KH FRPSDQ\ KDV DOVR DFTXLUHG 6$%6 FHUWLÂżFDWLRQ *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

EQUIPMENT

In-mould-graining vacuum thermoforming machines

ZZZ IHUURVWDDO FRP

ZZZ NLHIHO FRP

Successfully expanding offering for production of large, complex instrument panels AS a specialist in the production of high-quality car interiors, Keifel has launched the latest generation of vacuum thermoforming machines for the production of instrument panels.

The In-Mould Graining process (IMG) â&#x20AC;&#x201C; either in the form of IMG laminated onto a substrate part, or of a foam-backed IMG moulded skin â&#x20AC;&#x201C; has become increasingly popular and produces high-quality surfaces on instrument panels with a homogeneous structure as well as good haptics.

When it comes to their forming areas, the two machines are identical. The difference is that one is explicitly designed for WKH SURFHVVLQJ RI Âż OP PDWHULDO LQ UROOV ZKLOH WKH RWKHU FUHDWHV Âż OP EODQNV IURP WKH VXSSOLHG UROOV RI Âż OP PDWHULDO 7KH XVH RI prefabricated blanks is also possible.

The IMG guarantees uniformly moulded surfaces, even for distinctly three-dimensional forms. The desired grain is only applied to the surface in question in the thermoforming process.

The machine lower table is a servo motor-driven swivel table with a swivel angle adjustable in increments of 7.5° up to a maximum of 90°, and offers ideal ergonomics for the user, taking account

In-Mould-Graining (IMG) Vacuum 7KHUPRIRUPLQJ 0DFKLQH ./9 = IRU ODPLQDWLRQ RI LQVWUXPHQW SDQHOV

of the height of the individual. The large forming area allows two instrument panels to be produced at the same time. For a threeshift operation, the output can reach up to 2 000 panels per day.

Kiefel is represented in South Africa by Ferrostaal Equipment Solutions (Pty) Ltd. ZZZ IHUURVWDDO FRP

Starlinger: Unabated interest in odour reduction during recycling Homogenous regranulate quality and permanent odour reduction SINCE Starlinger recycling technology presented its technology for odour reduction in post-consumer recycling in 2016, it continues to be in high demand: a customer already ordered the second recycling system equipped with it.

Post-consumer plastic scrap often contains migrated substances from food, cosmetics or cleaners, which cause an unpleasant smell during the recycling process. But also residues of monomers, oxidation or hydrolysis, as well as decomposition products (VOCs â&#x20AC;&#x201C; volatile organic compounds) can be the reason for unwanted smells in recycled granulate.

Depending on the polymer type, source or type of the odour, its intensity, and the VSHFLÂż FDWLRQV RI WKH SURGXFHG UHJUDQXODWH Starlinger recycling technology individually adapts the recycling and odour reduction process according to the needs of the recycler. It basically consists of the stages material preparation, degassing, and post-treatment.

74

JUNE / JULY 2017

Material preparation: the SMART feeder heats and homogenises the input material until the ideal operating point is reached. Highly volatile odours are already extracted during this process.

Degassing: the C-VAC degassing module after the extruder increases the melt surface by 300 %, thus achieving an extremely high degassing HIÂż FLHQF\ 7KLV UHVXOWV LQ SHUPDQHQWO\ removing also deeply embedded odours.

Post-treatment: The odour extraction unit at the end of the process gives the UHJUDQXODWH WKH Âż QLVKLQJ WRXFKHV +HUH the most persistent odours are reliably extracted and removed permanently.

With Starlingerâ&#x20AC;&#x2122;s odour reduction technology, recyclers of post-consumer plastic scrap have the opportunity to turn their input material into a high-grade secondary resource: excellent and homogenous regranulate quality and permanent odour reduction ensure the

Washed post-consumer Âż OP EHIRUH WKH recycling and odour reduction process Recycled granulate without GLVWXUELQJ VPHOO WKDW FDQ EH used in many applications

reuse of the regranulate to up to 100% also in demanding applications.

Starlinger Recycling is represented by Zerma Africa in SA

www.zerma.com

www.recycling.starlinger.com

New Veloblow series proves versatile ,QGLDQ Âż OP VSHFLDOLVW UHÂż QHV FR H[ VROXWLRQ VISHVA Exim of India has introduced its latest â&#x20AC;&#x2DC;Veloblowâ&#x20AC;&#x2122; WKUHH OD\HU EORZQ Âż OP H[WUXGHU The ABB line, for LDPE processing, is said to cost virtually half that of 3-layer â&#x20AC;&#x2DC;normalâ&#x20AC;&#x2122; systems used to date, said Vishva &(2 8GD\ 6KDK LQ $KPHGDEDG Other advantages include the fact that it can use 100% UHSURFHVVHG PDWHULDO LQ WKH PLGGOH OD\HU Âł<RX FDQ GRZQ JDXJH \RXU PRQR OD\HU Âż OP EXW WKH VWUHWFK ZLOO UHPDLQ WKH VDPH <RX JHW Âż OP TXDOLW\ DV QHDU DV YLUJLQ PDWHULDO DIWHU XVLQJ 53 DQG Âż OOHU LQ WKH Âż OP ´ DGGHG 6KDK The Vishva team set out to develop an ABB system that FDQ PDNH DOO WKH Âż OPV ZKLFK D FRQYHQWLRQDO OD\HU OLQH FDQ UXQ DQG KDYH VXFFHHGHG LQ WKH SURFHVV 6KDK EHOLHYHV 7KH V\VWHP LV FDSDEOH RI PDQXIDFWXULQJ Âż OPV IRU VKRSSLQJ EDLOHU FRXULHU H FRPPHUFH DQG ERXWLTXH EDJV DV ZHOO DV IRRG packaging, stretch, masking laminate grade, shrink, mulch and PHGLFDO Âż OPV Veloblow was exhibited at the K2016 www.vishvaexim.com

7KH ODWHVW YHUVLRQ RI 9LVKYD ([LPÂśV 9HOREORZ Âż OP extrusion lines can run high levels of recycled PDWHULDO DQG Âż OOHUV JUNE / JULY 2017 75

Presents

RANGE OF BAG MAKERS In this competitive market processer cannot afford to run dedicated machines for speciďŹ c jobs. So the Veloss 800s is the perfect choice for customers. Their new Veloss 800s, multi-purpose, side seal machine â&#x20AC;&#x201C; 300 cycles/min â&#x20AC;&#x201C; is a huge hit in the market because of its varsitility with running many different jobs and materials with minimum change over time. One can run hdpe, ldpe, pp, cpp and bopp on the same machine just by changing the jaw of the machine.

Talk to us about our work horse machine. They also stock spares in the country to give faster after sales services.

VELOSS 800S â&#x20AC;&#x201C; MULTI PURPOSE â&#x20AC;&#x201C; SIDE SEAL MACHINE â&#x20AC;&#x201C; SPEED: 300 BAGS/MIN Side sealing: www.youtube.com/watch?v=uSO9JxfHFa8

THE TYPE OF BAGS THAT CAN BE MADE: 1. Patch Handle Bags 2. Die Cut / Handle Punch Bags 3. Courier / Dhl Bags 4. Postal Bags

5. Simple Side Seal Bags 6. Low Microns Bags 7. Grape / Nursary Bags 8. Chicken Bags 9. Pen Bags

WWW. VISHVAEXIM. COM Contact us: Vishva Exim Pvt Ltd T: +91 98 797 97910 M: +91 909 991 6958 1225 E: info@vishvaexim.com

MORE THAN 50 INSTALLATIONS IN 3 YRS

EQUIPMENT

Fig.1: Capsules made of a 7-layer composite foil are the modern way of storing coffee in portions.

7KH Âż OP FRPELQHV EDUULHU properties and recyclability

Precision in seven layers Motan conveying and dosing technology at Greiner Packaging GmbH

INFO: Multi-layer foil coffee portion capsules Which foil structure?

A 7 layer compound foil is used for the coffee capsules. Its central layer consists of EVOH (ethylene vinyl alcohol co polymer). It forms the oxygen barrier and is embedded on both sides via adhesion promoter layers of recycling material (punching waste). Coloured polypropylene layers (homo polymer and co polymer) are additionally applied as cover layers.

WORLDWIDE, up to 2.5 billion cups of coffee are drunk every day. Much of this is prepared from coffee powder capsule portions in coffee machines. Due to the necessary oxygen barrier to prevent ageing of the coffee due to oxidation, these capsule portions consist of either aluminium or a plastic composite foil with an integrated oxygen barrier.

Since 2015, the latter have been produced by Greiner Packaging in KremsmĂźnster, Austria (Fig.1). For this purpose, a sustainable production concept was developed together with the peripheral equipment manufacturer motan and the Austrian agent Luger.

With this concept, the punching waste left over after punching out the deep-drawn capsule bodies is completely fed back into the 7 layer extrusion line in accordance with all quality limits.

As coffee is a natural product it is subject to an oxidative ageing process, in particular when exposed to the open air and moisture. In particular,

WKH Ă&#x20AC; DYRXULQJ VXEVWDQFHV UHOHDVHG during roasting of the coffee and the unsaturated fatty acids in the coffee bean oil oxidise very quickly. The only way to prevent this is to stop the oxidation reaction as quickly and completely as possible, by packaging it in air tight and water-tight containers, such as coffee capsules.

Greiner Packaging produces coffee capsules from barrier plastic As mentioned at the beginning, the portion containers consist either of aluminium or plastic, both made of deep-drawn foils. However, without evaluating which is the better packaging solution, there is a VLJQLÂż FDQW GLIIHUHQFH EHWZHHQ WKH WZR alternatives. Whereas an aluminium foil is a good barrier against almost all H[WHUQDO LQĂ&#x20AC; XHQFHV WKHUH DUH RQO\ YHU\ few plastics which are gas tight and aroma tight.

EVOH, an ethylene vinyl alcohol copolymer, offers the best barrier properties against both oxygen and Fig. 2: The 7 layer barrier foil which comes out of the extrusion machine runs directly into a multi-cavity deep drawing and punching machine.

The remaining punched frame and any bad parts produced are then fed directly into a cutting mill (in the background at the end of the machine) and fed back into the production line from there

76

JUNE / JULY 2017

Fig. 3: A 5 aggregate extruder is used to produce the 7 layer barrier foil. The central extruder is responsible for 70% of the foil in the form of the UHF\FOLQJ SHUFHQWDJH ,W LV Ă&#x20AC; DQNHG E\ WKH H[WUXGHUV for the barrier layer and the adhesion promoter layers. On a production level arranged above this, the extruders for the PP cover layers are arranged, ZKLFK DUH FRQQHFWHG WR WKH IHHG EORFN YLD YHUWLFDO VPHOWLQJ OLQHV YLVLEOH LQ WKH EDFNJURXQG

steam. It is just as water tight as an LDPE layer which is 10,000 times as thick. As it is comparatively expensive, it is used centrally as a thin barrier layer within a compound foil together with other plastics.

At Greiner Packaging in KremsmĂźnster, Upper Austria, a 7-layer compound foil is used to produce coffee capsules.

As the cups of the coffee capsules are produced from the compound foil by deep drawing and punching, more than RI WKH Âż OP UHPDLQV DV D SXQFKHG frame. As this quantity of waste could

Fig. 4: The 7 layer foil machine is constructed in three functional levels on top of each other. On WKH ORZHVW OHYHO QRW YLVLEOH KHUH WKHUH DUH WKUHH H[WUXGHUV VHH )LJ RQ OHYHO WZR WKHUH DUH WZR extruders for the cover layers, on the top level the dosing units to supply the extruders situated below

not have been disposed of logistically or economically due to the projected mass production, Greiner Packaging developed a concept for complete recycling of the punching waste during ongoing production together with the long term system partners, the German motan group, a manufacturer of peripheral systems, and Luger GmbH from Austria, as motan project planners DQG SODQW Âż WWHUV DQG WKH H[WUXVLRQ technology supplier.

For this purpose, the multi-layer foil to

Fig. 5: Central mixing station to supply the â&#x20AC;&#x2DC;regrind extruderâ&#x20AC;&#x2122;. In this, four material components come together (regrind from the silo or from the BigBag, stabiliser for the adhesion SURPRWHU DQG QHZ 33 PDWHULDO ZKLFK are added from the gravimetric dosing units on the third level

be produced must be adapted in such a way that up to 60% of it can consist of the regrind of the original foil. The punched frame and waste parts are ejected directly from the deep-drawing machine and fed into a mill (Fig. 2). The regrind goes either into a storage silo or into BigBags and is fed from there to the extrusion plant, where it is made into a mixed polymer which provides the two main layers of the compound foil. Therefore, including the addition of new material, 70% of the total material

>>

JUNE / JULY 2017 77

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EQUIPMENT >> throughput of the projected conveying and dosing unit is provided by the recycling circuit.

The comparatively small material throughputs of the additional four extruders represent the remaining 30%. These four extruders are arranged on two levels around the central regrind extruder, which is on WKH EDVH OHYHO ,W LV Ã&#x20AC; DQNHG E\ WKH extruders for the central barrier layer and the adhesion promoter layers. The extruders for the two top layers are â&#x20AC;&#x153;on WKH ¿ UVW Ã&#x20AC; RRU´ 7KH PDWHULDO WUDSV IRU the extruders underneath are on the VHFRQG Ã&#x20AC; RRU )LJV WR

Compared to the complex dosing and mixing technology, the design of the pipeline system is simple DQG GLUHFW ZLWK ¿ [HG SLSLQJ WR HDFK material trap. There is no coupling station or intermediate material drying.

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Dosing precision lies in the detail As mentioned above, most of the material throughput is from the regrind layers, which are supplied via gravimetric dosing units and a downstream mixing system due to SRVVLEOH Ã&#x20AC; XFWXDWLRQV LQ WKH EXON GHQVLW\ â&#x20AC;&#x153;In this regard it is worth mentioning WKDW WKH UHJULQG IHG EDFN LQWR WKH PXOWL OD\HU IRLO DV ¿ OOHU PDWHULDO FRQVLVWV RI WKH 7 layer foil and is therefore composed RI WKH ¿ YH GLIIHUHQW YLVFRVLW\ PDWHULDOV which this contains. It was our joint objective to achieve stable mixing DQG Ã&#x20AC; RZ SURSHUWLHV IRU WKLV PDWHULDO PL[WXUH ´ VDLG +HOPXW 5HFN]LHJHO +HDG of Business Unit Capsules. â&#x20AC;&#x153;An unstable material composition, ZKHWKHU GXH WR Ã&#x20AC; XFWXDWLQJ EXON GHQVLW\ or a change in material proportions, leads to reductions in quality of the extrudate, in particular when seven layers have to harmonise with each other. As we wanted to install a control option for this, we provided for the addition of virgin PP material to the regrind. Therefore, the continual enrichment of the concentrations of WKH SHUFHQWDJH RI (92+ DQG RI WKH adhesion promoter in the total foil, triggered by the return of the stamping grid, can be stabilised at 14 and 12% respectively and consequently the melt Ã&#x20AC; RZ LQGH[ ´ )LJ

A further concept detail is worth mentioning: due to the shortest possible return of the regrind, it does not cool down completely. A large part of the heat energy contained therein can thus be used for faster melting in the extruder, which leads to an improvement in the energy balance in view of a material WKURXJKSXW RQ WKH UHJULQG H[WUXGH´ RI 78

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up to LINKnet, a comprehensive plant DSSUR[LPDWHO\ NJ KU PDQDJHPHQW V\VWHP )LJ ,W LV WKXV All other material percentages are SRVVLEOH ZLWK /LQNQHW WR FROOHFW added volumetrically as virgin material and log the process sequences and in constant quality. The throughput application data and to operate all quantities for the barrier material and connected controls up to device level. the adhesion promoter are a maximum RI NJ KU 7KH WKURXJKSXW RI 33 OD\HUV All motan controls with communication capability can be connected. Batch which are additionally mixed with a WUDFNLQJ LV WKHUHIRUH FRQWLQXRXVO\ white or brown colour master batch, possible. is somewhat more, at approximately NJ KU VHH )LJ

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WORLD NEWS

Total silence at the

Guggenheim

Museum

IN New York City â&#x20AC;&#x201C; ranked among the top 10 loudest cities in the world â&#x20AC;&#x201C; noise is a constant. The din in restaurants soars over 90 decibels, and subways rushing across the city register more than 80 decibels.

Since the end of March and running until 2 August, the Solomon R. Guggenheim Museum offers a serene and silent escape: the PSAD Synthetic Desert III. The art work, conceived by Doug Wheeler, realised by the Guggenheim Museum, and sponsored by BASF Corporation, manipulates sound, light and space in a â&#x20AC;&#x2DC;semi-anechoic chamberâ&#x20AC;&#x2122; designed to suppress all but the lowest levels of ambient sound. The installation

makes use, in part, of the technology of sound suppression that is normally applied to experiments and tests in the realm of sound engineering. The roomâ&#x20AC;&#x2122;s OLJKWLQJ DQG FRQÂż JXUDWLRQ DUH DOVR designed to induce an optical impression RI LQÂż QLWH VSDFH :KHHOHU FRPSDUHV the visual and acoustic impression of Synthetic Desert III to his own experience in the deserts of northern Arizona where near-silent conditions SURIRXQGO\ LQĂ&#x20AC; XHQFH WKH YLVXDO VHQVDWLRQ of distance. â&#x20AC;&#x153;Silence as we know it measures at 30 decibels, and Wheelerâ&#x20AC;&#x2122;s semi-anechoic chamber will measure in the range

of 10-15 decibels â&#x20AC;&#x201C; so quiet it could be possible to hear your own heartbeat,â&#x20AC;? said Doyle Robertson, an expert on melamine foam for BASF in North America.

The exhibitâ&#x20AC;&#x2122;s anechoic properties are partly enabled by a product known as %DVRWHFWÂ&#x160; D Ă&#x20AC; H[LEOH RSHQ FHOO PHODPLQH foam with high sound absorption properties. Basotect is used in an array of architecture, construction and industrial

Collaboration, innovation recognised for packaging design

80 JUNE / JULY 2017

Accolades for Amcor in DuPont Packaging Awards 2017 AMCORâ&#x20AC;&#x2122;S customer-focused approach and accomplishment in collaboration and innovation has been recognised three times over by the 2017 DuPont Awards for Packaging Innovation.

The global packaging company received a gold award in the Technological Advancement and Responsible Packaging categories for its Ventoâ&#x201E;˘ coffee packaging; silver for the 20-ounce VitaminwaterÂŽ bottle in the Responsible Packaging category; and â&#x20AC;&#x201C; in partnership with Crown

+ROGLQJV ,QF Âą D JROG DZDUG IRU 3HHOÂż WÂ&#x152; in the Technological Advancement and Responsible Packaging categories.

The PET Vitaminwater bottle uses two Amcor innovations to improve performance, while weighing less than convenWLRQDO KRW Âż OO FRQWDLQHUV 7KH EDVH RI WKH bottle features Amcorâ&#x20AC;&#x2122;s PowerStrapâ&#x201E;˘ technology to strengthen its structure and LQFUHDVH YDFXXP DEVRUSWLRQ GXULQJ Âż OOLQJ The sidewall incorporates the companyâ&#x20AC;&#x2122;s ActiveHingeâ&#x201E;˘ technology to further improve rigidity. Besides reducing the weight of the package, these technoloJLHV DOVR LPSURYH ODEHOOLQJ HIÂż FLHQF\ DQG stacking strength.

A second award was given for Vento, Amcorâ&#x20AC;&#x2122;s high-performance laminate for ground coffee and whole beans. The innovative packaging allows coffee proGXFHUV WR FDSWXUH WKH Ă&#x20AC; DYRXU DQG DURPD

of freshly roasted coffee without the need for hard valves, extra machinery, and extra processing steps.

Vento maintains barrier integrity and product freshness, weighs less, and has a reduced carbon footprint compared to coffee packaging with hard valves. It removes the need to purchase and apply traditional valves, and allows coffee to be packed immediately after roasting with no additional equipment or steps.

7KH WKLUG KRQRXUHG SURGXFW 3HHOÂż WÂ&#x152; ZDV developed by Crown Holdings Inc. using $PFRUÂśV &DQ6HDO 3UR 3HHOÂż W LV GHVLJQHG for dry-food markets to address demands for greater convenience, reduced packaging weight, and increased product protection.

Amcorâ&#x20AC;&#x2122;s CanSeal Pro is a revolutionary Ă&#x20AC; H[LEOH PHPEUDQH ZKLFK DOORZV 3HHOÂż W WR use less metal while maintaining performance DQG IXQFWLRQDOLW\ 6XVWDLQDELOLW\ EHQHÂż WV include the elimination of the rigid steel ring typically required in double seaming applications, making the container 16% lighter than conventional foil seam cans.

www.amcor.com

Addivantâ&#x20AC;&#x2122;s Weston 705 stabiliser has passed the FDA tests, even after it even further tightened its scrutiny on infant formulation using the most stringent screening procedures for this application

applications. Through a blend of chemistry, art and architecture, the Guggenheim presentation will feature 400 pyramids and 600 wedges of Basotect covering the FKDPEHUÂśV Ă&#x20AC; RRU ZDOOV DQG FHLOLQJ

The PSAD Synthetic Desert III exhibitâ&#x20AC;&#x2122;s anechoic properties are partly enabled by BASFâ&#x20AC;&#x2122;s %DVRWHFW D Ă&#x20AC; H[LEOH RSHQ FHOO melamine foam with high sound absorption properties. The exhibit features 400 pyramids and 600 wedges of Basotect FRYHULQJ WKH FKDPEHUÂśV Ă&#x20AC; RRU walls, and ceiling

www.basf.com

www.averydennison.com

â&#x20AC;˘ Addivant is represented in SA by Synetica.

Plastic scrap used for road repairs, construction

New Avery Dennison complete compliance AVERY Dennison Label and Packaging Materials has created a new set of tools designed to help customers choose products that are fully compliant with regulations.

Complete Compliance is about working with converters and brand owners â&#x20AC;&#x201C; supporting them in meeting all necessary regulatory demands. &HUWLÂż FDWHV DQG VWDWHPHQWV DUH FUXFLDO for Avery Dennisonâ&#x20AC;&#x2122;s customers and the company has created an online application. It can generate immediate customized compliance statements for

ADDIVANT, a world leading supplier of liquid phosphite antioxidants for plastics, has received formal approval from the US Food & Drug Administration for the use of its nonylphenol-free stabiliser WestonÂŽ 705 in infant formula and human milk plastic packaging. It covers the use of Weston 705 at levels up to 2000 ppm in multiple types of polymers for repeat use articles intended for infant formula and breast milk, as well as in polymers intended for use with powdered infant formula.

converters, which can be downloaded straight away.

Support extends beyond immediate application needs; Reliable, complete and up-to-date compliance information can be found on the new Complete Compliance portal. The portal covers a large amount of information on the various (EU) regulations, and also links to a number of compliant portfolios including food and direct fatty-food approved products; British Standard (BS) 5609 labelling; and the current listing on SVHC, such as BPA-free materials.

Avery Dennisonâ&#x20AC;&#x2122;s &RPSOHWH &RPSOL DQFH LV DERXW ZRUN ing with converters and brand owners â&#x20AC;&#x201C; supporting them LQ PHHWLQJ DOO QHF essary regulatory demands

A SCOTTISH engineer-entrepreneur is developing a method of using waste plastic as a binding agent in asphalt â&#x20AC;&#x201C; in order to replace the bitumen used conventionally. According to Futurism, a BBC website programme, Toby McCartney wants to use recycled plastic instead of bitumen, which is derived from oil, to repair some of the worldâ&#x20AC;&#x2122;s 40 million kilometres of road. The idea would solve more than one problem: poor road quality, the continued use of fossil fuels and the waste plastic epidemic. His Scottish start-up company, MacRebur, mixes waste plastic into asphalt to create roads that last longer and are less prone to getting potholes.

McCartneyâ&#x20AC;&#x2122;s mix replaces most of the bitumen with plastic pellets. Bitumen, a material extracted from oil, is widely used as a binding agent in road construction.

The pellets are made from plastic scrap WKDW LV PDLQO\ GHVWLQHG IRU ODQGÂż OOV 7KH plastic waste pellets are then mixed with the usual stone aggregate and a small amount of bitumen at the asphalt plant. The process is exactly the same, so new equipment is not required, says McCartney.

He has persuaded two English councils to start using their local waste plastics to build their roads this way. He says these roads are cheaper to make and last longer than conventional roads.

If heâ&#x20AC;&#x2122;s right, he may be putting us on the road to a cleaner planet.

JUNE / JULY 2017 81

AROUND THE WORLD

FDA approval for Addivant antioxidant

WORLD NEWS

The largest concentrated solar complex in the world in the Moroccan desert will produce enough energy to power over one million homes by 2018. By the end of its construction the complex will cover an area of about 30km² and produce energy of roughly 500 Megawatt

Specialised solutions in construction of

biggest solar plant in the world BASF contributes to sustainable construction

AROUND THE WORLD

STAGE one of the three-phase construction project of the Noor solar complex in Morocco was set in motion in February 2016. Innovative solutions based on the BASFâ&#x20AC;&#x2122;s global knowledge and experience is used in the construction of the concentrated solar power system â&#x20AC;&#x201C; a more complicated process to install than the widely used photovoltaic panels.

Several BASF products were used in the construction of this project such as concrete admixtures, grout, mortars, seal-

Lanxess expands PA production in Antwerp LANXESS is to further strengthen its integrated production complex for polyamide and precursors for plastics in Antwerp.

With an investment of roughly â&#x201A;Ź25-million this year, the specialty chemicals company will primarily implement measures to IXUWKHU HQKDQFH HIÂż FLHQF\ â&#x20AC;&#x153;Our integrated production complex in Lillo is the backbone of our global business for high-tech plastics. Given the trend toward lightweight construction in the automotive industry, for example, this is a major future market. Therefore we are continuously strengthening the competitiveness of this site. In total, our company 82 JUNE / JULY 2017

ants, and joint water-resistant sealants.

The requirements for the construction of the worldâ&#x20AC;&#x2122;s largest solar plant were YDULHG DQG YHU\ VSHFLÂż F 7KH PDWHULDO KDG WR FRQIRUP WR FRQVWUXFWLRQ VSHFLÂż FDWLRQV and provide high early strength development. It was also necessary to take into consideration the desert area where the complex is being built, namely sand, clay, and high temperatures.

BASF MasterGleniumÂŽ Sky 671 superplasticiser provides a new generation of

concrete with extended workability at high temperatures and ensures high strength and stability of the mirrorsâ&#x20AC;&#x2122; structure. Due to the productâ&#x20AC;&#x2122;s good stability and resistance to exterior conditions and reaction to sand, it maintains the high mechanical performance of the concentrated solar power system.

Lanxess has made substantial investments in polyamide and caprolactam production at the site in Lillo, Antwerp since 2004

Rapid Granulatorâ&#x20AC;&#x2122;s major investment for full control of US production

has invested more than â&#x201A;Ź300-million in Lillo since 2004 â&#x20AC;&#x201C; a sum that shows our Âż UP FRPPLWPHQW WR WKLV VLWH ´ VDLG 0DWWKLDV Zachert, chairman of Lanxess group.

The announcement was made on the occasion of the 50th anniversary of caprolactam production at the site. Caprolactam is a key precursor for the production of high-tech plastics. Besides the automotive industry, these plastics are also used in electrical and electronics applications.

In recent years Lanxess has focused on building a balanced value chain for its hightech plastics production operations, which absorbs the lionâ&#x20AC;&#x2122;s share of the intermediates produced for captive use. A milestone on that strategic path was the construction of a world-class polymerization plant with an annual capacity of 90,000 metric tons connected directly to the caprolactam production facility. Since its start in summer 2014, the polyamide is shipped from Antwerp to Lanxessâ&#x20AC;&#x2122;s global network of compounding facilities, where it is further processed into the high-tech plastics.

RAPID Granulator is making one of its biggest investments in decades to bring US production back under its full control. The company says this is a major move in its most important market.

Rapid will begin in-house production of its full product range of equipment for granulating and shredding plastics in Pittsburgh, early in the second quarter of this year. The subject of a multi-million dollar spend by the Swedish company, the 6000-m² facility will also include a 325-m² showroom, wareKRXVLQJ DQG RIÂż FHV Rapid was acquired by Swedish company, Lifco, just over two years ago. US production has continued uninterrupted at the previous ownerâ&#x20AC;&#x2122;s operations, but now Rapid is taking everything back in-house.

The new facility, situated close to Pittsburgh DLUSRUW ZLOO KDYH VXIÂż FLHQW VSDFH WR VKRZ case all of Rapidâ&#x20AC;&#x2122;s wide range of equipment for granulation and shredding of plastics production waste and for recycling of postconsumer material. www.rapidgranulator.se

www.basf.com

7KH LQFOXVLRQ RI KLJK VWUHQJWK FDUERQ ¿ EUHV HPEHGGHG LQ D OLJKW SODVWLF PDWUL[ FUHDWHV FRPSRVLWH VWUXFWXUHV ZLWK H[FHSWLRQDOO\ KLJK VSHFL¿ F ULJLGLW\ DQG VWUHQJWK

Ensinger of Germany buys Next Composites of Switzerland ENSINGER of Germany, a manufacturer of compounds for lowIULFWLRQ GH¿ QHG HOHFWULFDO PHGLFDO and related sectors, has taken over Next Composites of Switzerland.

The small company operating from near Zurich develops thermoplastic ¿ EUH FRPSRVLWH PDWHULDO VROXWLRQV Its customers use these composite materials to create prototypes and also to put complete production lines into operation. Ensinger alUHDG\ RIIHUV VHPL ¿ QLVKHG SURGXFWV PDGH RI KLJKO\ ¿ OOHG FDUERQ ¿ EUH composite material; however, the process technologies from Next Composites will enhance the range

of technologies for manufacturing components.

Carbon reinforced thermoplastics are particularly suitable for lightweight construction applications in the automotive industry, in medical technology and mechanical engineering. Sports goods such as bike components or winter VSRUWV HTXLSPHQW DUH DQ DGGLWLRQDO growth market for these modern materials.

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Amcor on-site plant in Texas $0&25 5LJLG 3ODVWLFV KDV H[SDQGHG LWV UHODWLRQVKLS ZLWK ORQJ WLPH FXVWRPHU &DPSEHOO 6RXS &RPSDQ\ ZLWK WKH RSHQLQJ RI DQ RQ VLWH ERWWOH PDQXIDFWXULQJ RSHUDWLRQ LQ 3DULV 7H[DV $PFRU¶V QHZ LQ OLQH RSHUDWLRQ LV H[SHFWHG WR SURGXFH DSSUR[LPDWHO\ PLOOLRQ KRW ¿ OODEOH 3(7 ERWWOHV D \HDU $PFRU LQYHVWHG PLOOLRQ WR UH SXUSRVH Pð RI WKH 3DULV PDQXIDFWXULQJ IDFLOLW\ 7KH RQ VLWH RSHUDWLRQ ZLOO SURGXFH D QXPEHU RI 3(7 FRQWDLQHUV IRU D YDULHW\ of V8® 9HJHWDEOH -XLFH SURGXFWV

SONGWON Industrial has opened a new Technology Innovation Centre in Korea. Songwon says that the new centre will support innovation and will enable the company to take another key step forward in entering new business areas with high value and sophisticated technology.

Located on the companyâ&#x20AC;&#x2122;s Maeam site in South Korea, the centre encompasses 32,000m² and is currently three stories high. However, keeping an eye on the future, the facility has been especially designed with future expansion in mind and is constructed to allow the company to add WZR PRUH Ã&#x20AC; RRUV ODWHU DV UHTXLUHG 7KH QHZ IDFLOLW\ will host both R&D, Global Application Community and Technical Service. It will enable the organization to leverage the synergies between the groups, consolidate Songwonâ&#x20AC;&#x2122;s technologies and support the complete development of new SURGXFWV IURP WKH GHVLJQ SKDVH WR ¿ QDO FXVWRPHU applications. The centre will support the needs of the existing and new Songwon businesses and includes analysis labs, synthetic rooms, clean rooms, kilos lab scale rooms, polymer processing and application labs. www.songwon.com

From feathers into biodegradable plastics THE European poultry industry throws away more than three million tons of feathers from poultry slaughterhouses each year. It is an LPSRUWDQW NHUDWLQ VRXUFH WKDW HQGV LQ ODQG¿ OOV or is incinerated but which could be the source of different high added-value products, such as fertilizers, bioplastics, biocomposites, additives for biodegradable packages and coatings for the fabrics industry.

Aimplas, the Plastics Technology Centre, participates in the European project KARMA 2020, which aims at developing innovative processes to extract the keratin from the poultry litter. For that purpose, under the coordination of CIDETEC and with the participation of a total of 16 partners from 10 different countries, research work has begun to design this innovative valorization process.

Fish processing, municipal solid waste gets second life 5(67 UDZ PDWHULDOV IURP WKH ¿ VK SURFHVVLQJ industries and the organic fraction of municipal solid waste will have a second life as plastics, EDUULHU SDFNDJHV HGLEOH FRDWLQJV DQG ¿ UH retardant additives Aimplas is coordinating the European project DAFIA whose objective is recovering the organic fraction of municipal solid waste and marine rest UDZ PDWHULDOV IURP WKH ¿ VK LQGXVWU\ WR REWDLQ new products and additives of high added value.

7KLV SURMHFW LQYROYHV WKH GHYHORSPHQW RI Ã&#x20AC; DPH retardants, barrier packaging and edible coatings H[WHQGLQJ WKH VKHOI OLIH RI ¿ VK DV ZHOO DV FKHPLFDO substances to produce new plastics from renewable resources, among others. www.aimplas.com JUNE / JULY 2017 83

AROUND THE WORLD

Songwon opens new Technology Innovation Centre

BOOKS

BASF presents â&#x20AC;&#x2DC;Material Selection 17/18â&#x20AC;&#x2122; '\QDPLFDOO\ DGDSWLQJ FRDWHG SODVWLF ¿ OPV IRU JHRPHWULHV RI WKH IXWXUH â&#x20AC;&#x2DC;MATERIAL Selection 17/18â&#x20AC;&#x2122; is the second material trend book by BASF that offers a global perspective on trends and materials, and innovative plastics solutions that help customers face these trends.

The trend book was developed jointly by the designfabrik® experts in Tokyo, Shanghai and Ludwigshafen. â&#x20AC;&#x153;We do not see trends as singular phenomena but as a chain of developments.

Two main trends emerge as a result of this chain reaction: â&#x20AC;&#x2DC;Morphologyâ&#x20AC;&#x2122; and â&#x20AC;&#x2DC;Mindfulnessâ&#x20AC;&#x2122;. We believe that they will be PDMRUO\ LQÃ&#x20AC; XHQWLDO´ VD\V $OH[ +RULVEHUJHU designfabrik Ludwigshafen, BASF. â&#x20AC;&#x153;With this study, we offer customers a way to PDWHULDOLVH WKHVH WUHQGV ´ The trend study is exclusively available to designers and other creatives of customers and potential customers as part of a scheduled personal presentation. It cannot be bought or requested separately. â&#x20AC;&#x2DC;Morphologyâ&#x20AC;&#x2122;, materials for a changing world The end of certainty as we know it, is

GH¿ QLQJ IRU RXU WLPHV 7KH RQO\ FHUWDLQW\ lies in seeing opportunity in uncertainty, and not to perceive it as a threat. In times of accelerating changes, the speed of technological innovations increases VLJQL¿ FDQWO\ WRR )URP WUDGLWLRQDO FRPEXV tion engines to cars powered by electricity, from cars traditionally controlled by steering to autonomous driving: Materials are needed that can keep up with these dynamic changes in a three-dimensional space. For these applications in particular, %$6) SUHVHQWV D QHZ ¿ OP PDGH RI 738 WKHUPRSODVWLF SRO\XUHWKDQH ZLWK D Ã&#x20AC; H[LEOH coating, which could possibly be used in automotive interiors or furniture. â&#x20AC;&#x2DC;Mindfulnessâ&#x20AC;&#x2122; means more attention, for oneself and the environment The second trend in the BASF study is based on an increased awareness for traces of human behaviour and action.

7KH GHVLUH IRU PDWHULDOV IXO¿ OOLQJ FXVWRP ersâ&#x20AC;&#x2122; demands without leaving traces is JURZLQJ +HUH %$6) RIIHUV ELREDVHG particle foam which is robust and also fully

compostable. The material is attractive where sensitive or heavy goods should be protected by biobased and biodegradable transport packaging.

www.performance-materials.basf.com

84 JUNE / JULY 2017

DPIâ&#x20AC;&#x2122;s sewer range highlighted in updated design manual '3, 3ODVWLFV KDV XSGDWHG LWV VHZHU design manual to showcase its expanded sewer range of up to 630mm. The manual forms part of the companyâ&#x20AC;&#x2122;s value-added services for its customers.

The updated manual contains detailed WHFKQLFDO VSHFL¿ FDWLRQV RQ VSHFL¿ F VHZHU SURGXFWV PDQXIDFWXUHG E\ '3, 3ODVWLFV as well as comprehensive information to aid designers and installers, explained '3, 3ODVWLFV 7HFKQLFDO DQG 3URGXFW Manager, Renier Snyman. â&#x20AC;&#x153;The sewer manual is aimed at providing guidance with the design, installation, transportation, and storage of our products. It covers product VSHFL¿ FDWLRQV LQ DGGLWLRQ WR LQVWDOODWLRQ and related issues. It will include

our expanded sewer range of up to 630mm, which is now in production at RXU 5RRGHNRS -RKDQQHVEXUJ IDFLOLW\ ´ Snyman said. +H HPSKDVLVHG WKDW WKH VHZHU PDQXDO IRUPV SDUW RI '3, 3ODVWLFV¶ value-added service offering for its extensive client base. This service LQFOXGHV WUDLQLQJ LQ WKH XVH RI '3,¶V products. The manual is aimed at installers, engineers, and plumbers.

It is available in an on-line format.

First local plumbing app '3, 3ODVWLFV LV DOVR UHSUHVHQWHG RQ WKH QHZ $33 3/80%(5 IURP WKH ,QVWLWXWH RI 3OXPELQJ 6RXWK $IULFD ,236$ 7KLV LV WKH ¿ UVW ORFDO SOXPELQJ $SS OLQNHG WR

DPIâ&#x20AC;&#x2122;s Durodrain sewer pipe made up to 630mm

ERWK WKH 3OXPELQJ ,QGXVWU\ 5HJLVWUDWLRQ %RDUG DQG &HUWL¿ FDWH RI &RPSOLDQFH system, as well as providing access to all the tools and products required. The App includes installation guides from leading PDQXIDFWXUHUV VXFK DV '3, 3ODVWLFV www.dpiplastics.co.za

(PHUJLQJ WKUHDWV WR SRO\ROHÃ&#x20AC; Q LQGXVWU\ THE petrochemical industry is going through a period of extreme price volatility which impacts on margins and competitiveness. Albeit JURZLQJ SRO\ROH¿ Q GHPDQG UHPDLQV H[SRVHG to various unpredictable factors, while recent investments will bring new capacity online this year. ICIS senior consultant Fabrizio Galiè explores emerging threats to the global polyole-

¿ Q LQGXVWU\ LQFOXGLQJ WKH HFRQRPLF VORZGRZQ in China, new plant start-ups and implications on international markets. Fabrizio Galié is the global lead of Polymers Insight for Consultingâ&#x20AC;&#x2122;s petrochemical division within ICIS. He is also author of the price forecast reports for European polyethylene and polypropylene, which provide an â&#x20AC;&#x2DC;at a glanceâ&#x20AC;&#x2122; view of the

market to support your short- to medium-term decisions. Download the full market insight now at https://www.icis.com/contact/icismarket-insight-emerging-threats-to-the-polyROH¿ Q LQGXVWU\ "FPSLG (03_&+(0_&+35, 2017-1004-GLOBAL-fabrizio_ HPHUJLQJBWKUHDWVBSRO\ROH¿ QVB HPDLO V¿ G Z -6/

COMING UP AFRICAâ&#x20AC;&#x2122;S BIG 7 AFRICAâ&#x20AC;&#x2122;S Big 7 show, Africaâ&#x20AC;&#x2122;s premier food and drink tradeshow, takes place in Johannesburg from 25-27 June. Expected to showcase the wares of over 300 exhibitors and attract over 14,000 delegates, the event will also feature packaging prominently.

Record-level

MANUFACTURING INDABA THIS yearâ&#x20AC;&#x2122;s most important manufacturing event â&#x20AC;&#x201C; the Manufacturing Indaba Conference & Exhibition, takes place from the 27-28 June at Emperors Palace in Johannesburg and brings together leading manufacturing experts, small and large manufacturers, consultants, Âż QDQFLDO LQVWLWXWLRQV DQG UHODWHG VHFWRUV DOO ZLWK D common aim, to help grow the manufacturing sector.

The fourth annual event â&#x20AC;&#x201C; partnered with the Manufacturing Circle, the DTI, the City of Ekurhuleni, the Department of Science & Technology, the Department of Public Enterprises and the NCPC-SA â&#x20AC;&#x201C; is the forum for manufacturing in South Africa and aims to become a leading event for all manufacturers.

A major focus this year will be on exporting products DQG VHUYLFHV LQWR WKH UHJLRQ DQG VSHFLÂż F IRFXV DUHDV within the conference will discuss these opportunities IRU 6RXWK $IULFDQ PDQXIDFWXUHUV RI Âż QLVKHG JRRGV materials and components, machinery and much more.

SPECIFIC EVENT FOR HEAVY-DUTY SACKS AMI of the UK has launched a new event, Heavy Duty Sacks, which takes place from 27-28 June at the Maritim Hotel in Cologne, Germany. Heavyduty sacks, made both of plastic and paper, have recorded rapid growth in the past two decades.

Plastic sacks have been successfully taking market share from paper alternatives in recent years thanks to the development of sophisticated coextruded FRQVWUXFWLRQV HVSHFLDOO\ LQ WKH IRUP Âż OO VHDO ))6

VHFWRU 7KLV KDV DOORZHG VLJQLÂż FDQW GRZQ JDXJLQJ and material saving opportunities as well improved performance for plastic sacks. Also, further innovative developments in deaeration systems have enabled ))6 Âż OPV WR PDNH JUHDWHU LQURDGV LQWR WKH Âż QH SRZGHU sack markets, such as cement packaging, which have traditionally been dominated by the paper alternatives.

Thanks to its consulting activity, AMI has unrivalled insight into the key business and technical issues facing the industry today. The conference will build on that knowledge and offer a forum for key players in the industrial bag and sack industry. www.amiplastics.com

INTâ&#x20AC;&#x2122;L CONFERENCE ON DISPOSABLE & BIOPOLYMERS IN IRAN 7+( Âż UVW ,QWHUQDWLRQDO &RQIHUHQFH RQ 'LVSRVDEOH %LR 3RO\PHUV BioDisPlast ZLOO EH KHOG RQ 18-19 July in Tehran, Iran.

7KLV LV WKH Âż UVW SUHPLHU UHOHYDQW HYHQW LQ WKH Middle East, by the Association of Iranian Producers RI 'LVSRVDEOHV $,32' LQ FRRSHUDWLRQ ZLWK ,,&,& DQG WHFKQLFDO DQG VFLHQWLÂż F VXSSRUW RI 3RO\PHU ,QGXVWU\ 0HGLD ,QWHUQDWLRQDO 3,0, 7KH FRQIHUHQFH will explore investment potential for launching new production units; transferring advanced technologies for optimisation of present production lines; introducing partnership opportunities as joint ventures, bilateral or under-licensed production in Iran market; and assessing the role of new materials in market development for disposables. â&#x20AC;˘ Contact Ms Taghizadeh at secretariat@bdpiran.com www.bdpiran.com/index.php/en/ 86

JUNE / JULY 201

High-performance production with all-electric machines and Industry 4.0 applications KAUTEX Maschinenbau exhibited at this yearâ&#x20AC;&#x2122;s Interpack event, showcasing the all-electric packaging machines in its KBB series, and a number of potential solutions that manufacturers of bottles, containers and other plastic packaging can use to set new standards in productivity.

These solutions not only include material-saving and advanced quickchange production systems, but also services that help to reduce the â&#x20AC;&#x2DC;time to marketâ&#x20AC;&#x2122;. The companyâ&#x20AC;&#x2122;s new IntelliGate integration system was also developed with the aim of increasing WKH SURFHVV HIÂż FLHQF\ RI LWV PDFKLQHV These Industry 4.0 applications help

to transform Kautex machines into a closed system for high-performance production and enable Kautex to secure its typical high level of process quality.

The main component of the IntelliGate integration system is its modules, which are connected to the newly developed Connext interface.

This helps to make downstream processes, such as quality control processes, an integral part of the machine. The individual modules can be coordinated on KBB blow moulding machines by the Kautex experts and connected or exchanged using a â&#x20AC;&#x153;plug and playâ&#x20AC;? interface www.kautex-group.com

DIARY

international attendance at Interpack 2017 A top trend was the further digitalisation of production processes A RECORD 2,865 companies were represented at Interpack 2017 in May in Düsseldorf, Germany: 74% of the approximately 170,500 visitors travelled to Düsseldorf from abroad â&#x20AC;&#x201C; three quarters of them were decision-makers.

Proving a top trend at many stands was the further digitalisation of production processes on the way to Industry 4.0 applications. Production linked along these lines makes LW SRVVLEOH WR PDQXIDFWXUH SHUVRQDOLVHG SDFNDJLQJ HI¿ FLHQWO\ or to guarantee traceability, to name but two options.

The modular design of packaging machines, process lines and optimised digital operating concepts also play a pivotal role to reduce complexity in manufacturing and achieve the KLJKHVW GHJUHH RI Ã&#x20AC; H[LELOLW\ SRVVLEOH IRU FKDQJLQJ EDWFK VL]HV or product versions. Some companies even focused on virtual reality applications that allow machines or equipment to be experienced holistically in order to manage complexity better even in the manufacturing process of machinery and equipment as well as in training and operation.

The sustainability theme was ever-present at Interpack &RPSDQLHV SUHVHQWHG LPSURYHG UHVRXUFH HI¿ FLHQF\ in terms of both the material used with ever smaller wall thicknesses and of manufacturing processes.

Not only the exhibitors had innovations in store for Industry 4.0 â&#x20AC;&#x201C; the Interpack special show of the same name organised in cooperation with the German Engineering Federation VDMA showcased the latest ideas and approaches. Proving one of the major attractions was the Demonstrator â&#x20AC;&#x2DC;smart4iâ&#x20AC;&#x2122; that produced and packaged SHUVRQDOLVHG SRZHUEDQNV 1RW RQO\ WKH HQWLUH ZRUNÃ&#x20AC; RZ ZDV digital â&#x20AC;&#x201C; from online ordering to tracking and tracing â&#x20AC;&#x201C; but the machine itself was also installed in record time thanks to a virtual twin and the networked planning in cooperation with several universities.

The next Interpack will be held in May 2020 at Düsseldorf Exhibition Centre.

Ultrasonic machines for fast, reliable sealing 6:,66 FRPSDQ\ 5LQFR 8OWUDVRQLFV VKRZFDVHG XOWUDVRQLF ZHOGLQJ VROXWLRQV IRU YDULRXV DSSOLFDWLRQV LQ WKH SDFNDJLQJ LQGXVWU\ $PRQJ WKHP ZDV WKH EOLVWHU ZHOGLQJ GHYLFH $%: DFWXDWRU )3$ 7 DQG XOWUDVRQLF KDQG WDFNHU +7 DOO SLFWXUHG KHUH 7KH VPDOO KLJK SHUIRUPDQFH DXWRPDWLF EOLVWHU ZHOGHU $%: KDV EHHQ GHVLJQHG VSHFL¿ FDOO\ IRU WKH UHOLDEOH VHDOLQJ RI EOLVWHU DQG ¿ OP SDFNV DV ZHOO DV FRDWHG DQG ODPLQDWHG SDFNDJLQJ PDWHULDOV 5LQFR DOVR GHPRQVWUDWHG WKH HDV\ WR XVH XOWUDVRQLF KDQG KHOG GHYLFH WKH +7 IRU SRLQW SUHFLVH XOWUDVRQLF ZHOGLQJ 7KH UXJJHGO\ GHVLJQHG )3$ VHULHV ZKLFK LV IXOO\ HTXLSSHG ZLWK GLJLWDO HOHFWURQLF FRPSRQHQWV FRPSULVHV WKH )3$ DQG )3$ 7 ZKLFK GLIIHU PHUHO\ LQ WKHLU VL]H 7KH\ DUH FRQWUROOHG YLD WKH XOWUDVRQLF JHQHUDWRU $*0 7KH SDFNDJLQJ DFWXDWRUV FDQ EH LGHDOO\ LQWHJUDWHG LQWR ))6 PDFKLQHV IRUP ¿ OO VHDO

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Expertise in specialty PET containers EQUIPMENT and process technology specialist SIPA spotlighted its expertise LQ VSHFLDOW\ 3(7 FRQWDLQHUV DW ,QWHUSDFN )RU WKH ¿ UVW WLPH 6,3$ SUHVHQWHG D QHZ PRGHO RI LWV EHVW LQ FODVV OLQHDU EORZ PRXOGLQJ V\VWHPV WKH 6)/ (92 SLFWXUHG KHUH 7KH 6)/ (92 RXWSXW KDV LQFUHDVHG E\ LW QRZ UHDFKHV E K F ZKLOH FRQVXPSWLRQ RQ ERWK SUHIRUP KHDWLQJ DQG ERWWOH EORZLQJ KDV EHHQ UHGXFHG $QRWKHU LQQRYDWLYH IHDWXUH LV WKH QHZ FODPS RSHQLQJ DQG FORVLQJ V\VWHP GLUHFWO\ GULYHQ E\ D EUXVKOHVV PRWRU UHGXFHU WKH FODPS FDQ DGMXVW WKH ZLGWK RI WKH RSHQLQJ DFFRUGLQJO\ ZLWK WKH FRQWDLQHU WR EH EORZQ WR H[SDQG SURGXFWLRQ Ã&#x20AC; H[LELOLW\ 6,3$ DOVR KLJKOLJKWHG LWV (&6 UDQJH RI VLQJOH VWDJH ,6%0 HTXLSPHQW (&6 63 PDFKLQHV DUH LGHDO IRU SURGXFWLRQ RI FRQWDLQHUV DV VPDOO DV PO LQ VPDOO WR PHGLXP VL]HG ORWV JUNE / JULY 2017 87

COMING UP 10TH AGRICULTURAL FILM EVENT IN BARCELONA THE tenth edition of the annual conference Agricultural Film will discuss issues and UHVHDUFK ¿ QGLQJV DQG SRVVLEOH VROXWLRQV WR WKH SUREOHPV IDFHG E\ WRGD\¶V SURWHFWHG DJULFXOWXUH The conference at the Crowne Plaza in %DUFHORQD 6SDLQ IURP 6HSWHPEHU looks DW SODVWLF ¿ OP WHFKQRORJLHV XVHG LQ DJULFXOWXUH VLODJH PXOFK JUHHQKRXVH DQG WXQQHO ¿ OPV 7KH SURJUDPPH ZLOO NLFN RII ZLWK WKH JOREDO RYHUYLHZ RI WKH DJULFXOWXUDO ¿ OPV PDUNHW EDVHG RQ WKH VWXG\ FRQGXFWHG E\ AMI Consulting 7KLV ZLOO EH IROORZHG E\ ExxonMobil Chemical LQYHVWLJDWLQJ KRZ KLJK SHUIRUPDQFH UDZ PDWHULDOV DGG YDOXH WR WKH DJULFXOWXUDO ¿ OP XVHUV DQG E\ Erema and Starlinger FRQVLGHULQJ SRVW FRQVXPHU SODVWLF ZDVWH JHQHUDWHG E\ WKH DJULFXOWXUDO VHFWRU ZLWK D IRFXV RQ WKH DGYDQFHPHQWV WKDW WKH UHF\FOLQJ WHFKQRORJ\ KDV PDGH WR WDFNOH WKLV EXUQLQJ LVVXH 7KH OHYHO RI FRQWDPLQDWLRQ RI PXOFK ¿ OPV FUHDWHV D SDUWLFXODU FKDOOHQJH IRU UHF\FOLQJ DQG so the second session will host AITIIP Technological Centre, BASF, Novamont, Repsol and Tomas Bata University GLVFXVVLQJ GHYHORSPHQWV LQ ELRWHFKQRORJ\ HQDEOLQJ ELRGHJUDGDWLRQ RI PXOFK ¿ OP LQ VRLO DV D SRVVLEOH DOWHUQDWLYH VROXWLRQ ZKLOH 2:6 ZLOO VKDUH ¿ QGLQJV RQ LWV UHVHDUFK UHODWHG WR DFFXPXODWLRQ RI ELRGHJUDGDEOH SODVWLFV LQ VRLO RYHU WLPH DQG ZKDW LPSDFW RQ VRLO TXDOLW\ LW PD\ KDYH LQ WKH ORQJ WHUP 7KH XVH RI PXOFK ¿ OP KDV SURYHQ WR EH KLJKO\ EHQH¿ FLDO LQ JURZLQJ D ZLGH YDULHW\ RI FURSV DOO RYHU WKH ZRUOG Braskem ZLOO SURYLGH LQVLJKWV LQ KRZ WKLV WHFKQRORJ\ KDV KHOSHG LQFUHDVH FURS \LHOGV RI FRIIHH EHDQV E\ in Brazil, while Hydrox Technologies will LQWURGXFH D QRYHO VRODU UHDFWLYH VKULQNLQJ PXOFK ¿ OP ZKLFK LPSURYHV RQ IDUP HI¿ FLHQFLHV LQ $XVWUDOLD

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Innovative biobased packaging Included both high heat and standard PLA grades TOTAL Corbion PLA exhibited a number of partner applications in packaging and serviceware based on Luminy® PLA (Poly Lactic Acid) resins from Total Corbion PLA. The Luminy PLA portfolio, which includes both high heat and standard PLA grades, is an innovative material that is used in a wide range of markets from packaging to consumer JRRGV ¿ EUHV DQG DXWRPRWLYH Included in the applications on display was the newly launched thermoformed PLA cup from Pacovis, under the Naturesse product range.

The cups are fully biobased, made from renewable materials and have a reduced carbon footprint compared to PS or paper coated cups. To highlight this innovative product, Total Corbion PLA served fresh coffee and tea to booth visitors to demonstrate the excellent performance of the cups.

Other examples of innovative PLA packaging and single use applications on display included thermoformed domes from Alphaform, nonwoven wipes from HengTian-Yangtze, PLAlined paper cups from Totempak,

Total Corbion PLA served fresh coffee and tea to booth visitors at Interpack in the newly launched thermoformed PLA cup from Pacovis to demonstrate the excellent performance of the cups

WKHUPRIRUPHG WUD\V WKLQ ¿ OP EDJV DQG single-use aprons from Gaia, coffee cup lids from WinGram, tea bags from NonWoven Networks, coffee capsules from ATI, thermoformed packaging from Bio4Pack and ice cream foamed packaging from Synbra.

Alternative materials for extrusion blow moulding Challenges of PET blow moulding well mastered by high-quality EPET class IV materials BEKUM focussed on the latest trends and production processes for extrusion-blown packaging at Interpack 2017. On the material side, Bekum focussed on the newly developed EPET IV materials, the processing of calcium carbonate (chalk) and the resource-saving recycling of materials. The fully transparent, newly introduced EPET class IV material has VXI¿ FLHQW VWDELOLW\ IRU H[WUXVLRQ EORZ PRXOGLQJ 7KH SDUDPHWHUV RI WKH LPSURYHG FODVV ,9 DUH higher than the 1.0 PET recycling stream launched on the market. The typical challenges of PET blow moulding are well managed by the high-quality EPET class IV materials. EPET IV has a comparatively high resistance to wear. The material can be completely melted in the extrusion unit without causing excessive wear.

www.bekum.de/en/

COMING UP

DIARY

INTâ&#x20AC;&#x2122;L ELASTOMER EVENT IN USA IN OCTOBER THE International Elastomer Conference, to be held at the Huntington Convention Centre in Cleveland, Ohio, USA, from 9-12 October, is one of the premier events for elastomer convertors, manufacturers and suppliers of materials, equipment, tools and services in this sector.

Presented by the Rubber Division of the American Chemical Society, the event provides a forum for the exchange of ideas, observations, regulatory reforms DQG HPHUJLQJ VFLHQWLÂżF WHFKQRORJLHV 7KH conference/exhibition takes place every October, in Cleveland on odd numbered years and travels to different locations on even numbered years.

Gebo Cermexâ&#x20AC;&#x2122;s CareSelect bottle infeed system won the Modular Machines category in the Best Future Machines Awards

Gebo Cermex wins best modular machine award

www.gebocermex.com

Delegates at the IEC 2016 put elastomers to the test on a night run around the exhibition halls

ASIAN POLYMERS EVENT IN BANGKOK FOR those interested in the global polymer supply market, the ICIS Asian Polymers conference in Bangkok on could prove interesting. A large portion of international polymer capacity originates from SE Asia and with China and India being among the largest consumers, the region determines prices to a large extent. Hence the interest.

UTECH IN AMSTERDAM IN OCTOBER THE 2017 Polyurethanes Automotive Conference will form an essential part of the UTECH calendar and will take place at the Hotel Novotel, Amsterdam City, Netherlands on The automotive industry is challenging its suppliers to save weight, LQFUHDVH FRPIRUW LPSURYH IXHO HIÂżFLHQF\ DQG reduce emissions â&#x20AC;&#x201C; and the polyurethane industry is well placed to provide answers along the supply chain from raw material suppliers, to systems houses, component makers and Tier 1 suppliers.

The conference will address automotive LQGXVWU\ WUHQGV IXHO HIÂżFLHQF\ HPLVVLRQV and lightweighting opportunities with polyurethane; sustainable technology and ÂľJUHHQHU DXWRPRWLYH VROXWLRQV LQ Ă&#x20AC;H[LEOH applicationsâ&#x20AC;&#x2122;; and the very topical, how WR FRQYLQFH DXWRPRWLYH ÂżUPV WR FKDQJH from existing materials to polyurethane for traditional components.

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JUNE / JULY 201

FOLLOWING a global launch at Interpack 2017, Gebo Cermexâ&#x20AC;&#x2122;s CareSelectâ&#x201E;˘ bottle infeed system has won the â&#x20AC;&#x2DC;Modular 0DFKLQHVÂś FDWHJRU\ RQH RI ÂżYH FDWHJRULHV in the Best Future Machine Awardâ&#x20AC;&#x2122;s scheme sponsored by Rockwell Automation.

CareSelectâ&#x201E;˘ LV D SDWHQWHG XQLYHUVDO and modular shaped-bottle infeed and collating system for robotic or traditional case packers, powered by Rockwell Automationâ&#x20AC;&#x2122;s iTRAKÂŽ technology. &DUH6HOHFW LV FDSDEOH RI DFKLHYLQJ speeds of up to 400 products per minute depending on package size, shape and weight, easily surpassing traditional â&#x20AC;&#x2DC;endless screwâ&#x20AC;&#x2122; collation systems in terms of bottle integrity and protection. The

V\VWHP GHOLYHUV VKDSHG ERWWOHV WR WKH packing machine with precision and care in the correct orientation and pitch, turning HDFK ERWWOH Â&#x192; (YHQ XQVWDEOH VKDSHG SURGXFWV DUH VPRRWKO\ DQG LQGLYLGXDOO\ KDQGOHG YLD LQGHSHQGHQW PRYHUV To eliminate contact between SURGXFWV Ă&#x20AC;RZ LV PDQDJHG ZLWKRXW accumulation at the infeed and â&#x20AC;&#x2DC;friction timeâ&#x20AC;&#x2122; between the bottle and the system â&#x20AC;&#x201C; when the bottles come into contact with machine parts â&#x20AC;&#x201C; is dramatically reduced (by at least 20 times) compared to traditional infeed systems. It also RIIHUV IXOO\ DXWRPDWLF FKDQJHRYHUV LQ less than one minute, with no need for mechanical adjustments.

Sun Ace at PVC 2017 forum on vinyl in Brighton in the United Kingdom, in April. Representing the Sun Ace group were Ryo Sasaki (Japan), Ian Lilja (Australia), Alistair Calder (South Africa), Shigetaka Seki (TBC) and Terence Hobson (also SA). Alistair also gave a presentation at the conference.

The PVC conference is a venture by the Institute of Materials and is reputed to be the top international event for the vinyls sector.

Eilif Johansen of Easy-Laser (second from left) visited the Userve Plastic Machinery stand and chatted with the Taldonn Conn, Umberto Favini and Cesare Favini

The MJH Machine Tools squad, including Dale Lazenby, Ricky Lazenby, Mark Haslam and Martin Haslam, were at MTA â&#x20AC;&#x2DC;017

Machine Tools Africa 2017 sees huge turnout QUALITY TOOLS and machinery are the backbone of the South African manufacturing industry which is why Machine Tools Africa 2017 showcased the very latest technology developments, machinery, products, services and solutions in this innovative sector.

Held at the Expo Centre, Nasrec, in Johannesburg from 9-12 May, the exhibition brought machinery alive Chris Oberem of Demaplastech demonstrated the Stratasys printer on the AUTODESK stand with Helen van der Schyff and Daneel Ballaram of Baker Baynes

through the daily demonstrations and interactive displays. On view was equipment in machining such as turning and milling, grinding and drilling as well as all types of sheetmetal machinery, LQFOXGLQJ ÂżEUH ODVHU SODVPD FXWWLQJ bending and punching and presses.

Also exhibiting were various suppliers of tooling and CAD/CAM software, who are an integral part of any successful engineering shop.

Close to 100 local machine tool suppliers together with their international principals exhibited. By the end of day 2 of the four-day show, exhibitors had already booked their stand for the 2020 show.

Machine Tools Africa 2017 was a great success. A standDORQH VKRZ IRU WKH ÂżUVW WLPH in 20 years, the feedback received from exhibitors was extremely positive. The show attracted a high quality

audience with thousands of visitors attending. Hundreds of sales leads were generated, major sales were made from the stands and existing customers had the opportunity to see live demonstrations on machinery and equipment brought in exclusively for the show.

Yolande van Loggerenberg and Steven Andrews on the EDM Shop stand

JUNE / JULY 2017

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PHOTOS: LOWRIE SHARP

Nikita Ribeiro, Tracy Eliot, Kay-Lee van Noort and Kim Eliot on the UTP Mould & Die stand

COMING UP 2018

ADDITIVE SUPPLIERS SIGN UP FOR COMPOUNDING EXPO THE Compounding World Expo 2018 is attracting strong interest from additives suppliers with many leading players booking stands in the four months since the exhibition was launched. Omya, Imerys and Solvay/ Cytec are among the latest companies to sign up for the exhibition, which will take place on 27-28 June 2018 at Messe Essen in Germany.

Organised by AMI and Compounding World magazine, the trade fair will be free-to-attend and will feature a packed programme of seminars, industry debates and technical presentations. â&#x20AC;&#x153;We have seen large numbers of suppliers of PLQHUDOV DQG IXQFWLRQDO Âż OOHUV MRLQ RXU H[KLELWRU list in recent weeks,â&#x20AC;? said Matt Wherlock, AMIâ&#x20AC;&#x2122;s exhibition sales and marketing manager. â&#x20AC;&#x153;They include Imerys, IMI Fabi, LKAB, Magnesia Germany, Mondo, Omya, Reverte and Victor 0H\HU ´ 7KHVH FRPSDQLHV MRLQ D JURZLQJ number of exhibitors offering a very broad range of additives, including JavaChem, Krahn Chemie, MPI Chemie, OCSiAl, Polyscope, 6ROYD\ &\WHF 9HOR[ DQG =KHMLDQJ ;XVHQ On the machinery front, leading suppliers of extruders, kneaders, mixers and complete turnkey compounding lines who are to exhibit include Brabender, Buss, Coperion, Dr Collin, Extricom/CPM Century Extrusion, Farrel Pomini, Feddem, ICMA San Giorgio, JSW, KraussMaffei-Berstorff, Leistritz, Mixaco, Plasmec, Promixon, SM Platek, Steer, and ;LQGD â&#x20AC;&#x153;We continue to be very pleased with the extremely positive response to our ODXQFK RI WKH Âż UVW IRFXVHG H[KLELWLRQ IRU WKH thermoplastics compounding industry,â&#x20AC;? said Andy Beevers, events and magazines director at AMI. â&#x20AC;&#x153;The large exhibition hall is already Âż OOLQJ XS IDVW DQG ZH DUH UHFHLYLQJ ORWV RI interest from throughout the supply chainâ&#x20AC;?. www.compoundingworldexpo.com

PLASTIC PIPES 2018 IN VEGAS THE international conference and exhibition Plastic Pipes XIX is scheduled to take place in Las Vegas, Nevada, USA from 24-26 September 2018. The event is expected to host almost 500 participants from over 45 countries.

Sarah Patterson, chair of the PLASTIC 3,3(6 ;,; &RQIHUHQFH LV FRQÂż GHQW WKH HYHQW SURPLVHV WR EH WKH ODUJHVW HYHU VLQFH WKH Âż UVW was held in Southampton, UK in 1970. â&#x20AC;&#x153;Our conference is a truly global platform that brings together the movers, choosers and users in the business and technical world of plastic pipes systems.â&#x20AC;? â&#x20AC;&#x153;Las Vegas is Las Vegas. However, chance should not be relied upon to secure attendance. All the global indicators point WRZDUGV D VLJQLÂż FDQW XSWXUQ LQ GHPDQG IRU plastic pipes whether for replacement of aging non-plastic pipes or investment in modern and more enduring plastic pipelines.â&#x20AC;?

The Plastic Pipes Conference Association (PPCA) is the organiser of the show, working with conference group Evacon. Standard registration fee is $1500. Attendees are advised to opt for the early bird fee of $1300.

92

JUNE / JULY 201

Altair host successful technology event Latest technology trends, developments in simulation-driven design, manufacturing STELLENBOSCH-based Altairâ&#x20AC;&#x2122;s Âż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Âś LPSURYHG EXVLQHVV SHUIRUPDQFH :LWK RYHU SDUWLFLSDQWV DQG QLQH SUHVHQWDWLRQV IURP $OWDLU DQG LWV FXVWRPHUV WKH HYHQW DW WKH 5LYHU 0HDGRZ 0DQRU LQ ,UHQH ZDV YHU\ VXFFHVVIXO DQG OHDGV WKH ZD\ WR IXWXUH 6RXWK $IULFDQ HYHQWV KRVWHG E\ $OWDLU ,Q KLV NH\QRWH SUHVHQWDWLRQ Chris Maxwell of Bloodhound SSC FRQVLGHUHG WKH TXHVWLRQ Âľ:K\ 'HVLJQ D &DU WR 7UDYHO DW NP K"Âś 7KH %ORRGKRXQG 66& ZLOO DWWHPSW WR VXUSDVV WKH ZRUOG ODQG VSHHG UHFRUG DW +DNVNHHQSDQ LQ WKH 1RUWKHUQ &DSH LQ 0D[ZHOO VKDUHG KRZ WKH HQJLQHHULQJ FRPPXQLW\ ZLOO EHQHÂż W IURP WKH WHFKQRORJ\ DQG H[SHULHQFH JDLQHG IURP WKLV LFRQLF HQJLQHHULQJ DGYHQWXUH ,W ZLOO LQVSLUH VWXGHQWV WR SXUVXH FDUHHUV LQ VFLHQFH WHFKQRORJ\ HQJLQHHULQJ DQG PDWKHPDWLFV DQG IHOORZ HQJLQHHUV WR VWULYH IRU PRUH LQQRYDWLRQ LQ WKHLU SURMHFWV $OWDLUÂśV +\SHU:RUNV VXLWH RI FRPSXWHU DLGHG HQJLQHHULQJ WRROV KDV EHHQ XVHG LQ WKH GHYHORSPHQW RI WKH MHW DQG URFNHW SRZHUHG FDU Gideon Potgieter of Resolution Circle VKRZFDVHG KLV FRPSDQ\ÂśV SURFHVV IRU GHYHORSLQJ DQ LGHD WKURXJK WR WKH Âż QDO GHVLJQ +LV SUHVHQWDWLRQ ORRNHG DW WKH FKDOOHQJHV VWDUW XSV DQG ODUJH FRUSRUDWLRQV IDFH ZKHQ JHWWLQJ DQ HQWLUHO\ QHZ LGHD RII WKH JURXQG

Enjoying a break during Altairâ&#x20AC;&#x2122;s Technology Conference were Gordon Mayhew-Rodgers (principal engineer at Vodacom) and Gronum Smith (country manager Altair Engineering) â&#x20AC;&#x201C; PHOTO: BRUCE CRAWFORD (MetalCasting News)

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DIARY

Automotive industry gains insight to masterplan development at NAACAM show THE inaugural NAACAM Show in Durban during $SULO UHÃ&#x20AC;HFWHG D VLJQL¿FDQW LQWHQW DQG VWUDWHJ\ VKLIW ZLWKLQ 6RXWK $IULFD¶V DXWRPRWLYH VHFWRU 1DWLRQDO $VVRFLDWLRQ RI $XWRPRWLYH &RPSRQHQW DQG $OOLHG 0DQXIDFWXUHUV RI 6RXWK $IULFD 3UHVLGHQW 'DYH &RIIH\ VDLG WKH DFFHSWDQFH E\ LQGXVWU\ UROH SOD\HUV RI WKH QHHG WR LQFUHDVH ORFDO FRQWHQW LQ PDQXIDFWXUHG YHKLFOHV IURP LWV FXUUHQW OHYHO RI WR ZDV VLJQL¿FDQW $XWRPRWLYH 0DVWHUSODQ OHDG 'U -XVWLQ %DUQHV VDLG WKH DFKLHYHPHQW RI D OHYHO RI ORFDOLVDWLRQ ZRXOG PDNH D VLJQL¿FDQW LPSDFW RQ WKH 6RXWK $IULFDQ HFRQRP\ LQFOXGLQJ WKH FUHDWLRQ RI QHZ MREV DQG DQ DGGLWLRQDO 5 EQ LQ *'3 %DUQHV VDLG WKH $XWRPRWLYH 0DVWHUSODQ DQG DVVRFLDWHG SROLF\ OHYHUV ZKLFK ZRXOG UHSODFH WKH $XWRPRWLYH 3URGXFWLRQ 'HYHORSPHQW 3ODQ LQ National Association of Automotive Component and Allied Manufacturers of South ZDV DW DQ ³DGYDQFHG VWDJH RI GHYHORSPHQW´ Africa (NAACAM) Executive Director Renai Moothilal, NAACAM President Dave Coffey, DQG WKDW PRUH FRQFUHWH GHWDLOV ZRXOG EH VKDUHG Ethekwini Municipality Mayor Zandile Gumede and Minister Rob Davies show unity at RYHU WKH FRPLQJ ZHHNV the NAACAM Show in Durban

Connected Industries show at Africa Automation Fair

JUNE / JULY 2017

The goal of the Automation and Connected Industries events is to gain understanding and utilization of smart production methods to make SURFHVVHV PRUH HI¿FLHQW DQG FRVW HIIHFWLYH

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DIARY

Altairâ&#x20AC;&#x2122;s HMI presence at Hannover Messe New development methods for smart devices, modern manufacturing ALTAIR presented its solutions for simulation-driven design and a technology demonstrator of a virtual â&#x20AC;&#x2DC;cobotâ&#x20AC;&#x2122; (collaborative robot) as well as customer examples to demonstrate how its solutions can be applied to develop innovative products at the Hannover Messe in April.

The Hannover Messe is regarded as one of the worldâ&#x20AC;&#x2122;s leading trade fairs for industrial technology.

Founded in 1985, Altair is headquartered in Troy, Michigan, with regional operations throughout 22 countries, LQFOXGLQJ 6RXWK $IULFD ZLWK RIÂż FHV LQ 6WHOOHQERVFK 7KH global organisation is focused on the development and broad application of simulation technology to synthesize and optimize designs, processes and decisions for clientsâ&#x20AC;&#x2122; improved business performance.

Altair also hosted a â&#x20AC;&#x2DC;Design the Differenceâ&#x20AC;&#x2122; day in Hannover, offering a conference programme that addressed the challenges and needs of engineers working on the development of increasingly complex products, featuring customer examples of successful product developments.

Today product creators have to consider the entire mechatronic system, including its structure, sensors, actuators, controllers and much more. How these complex processes can be handled was presented with a virtual cobot demonstrator, showing the challenges in the development of smart devices and offering solutions for

2017 PPP Expo Kenya Millennium Hall, Addis Ababa Vinyl SA 2017 Hilton Hotel, Sandton

2-4 June www.expogr.com 7 June www.savinyls.co.za

Africa Automation Fair 2017 6-8 June Ticketpro Dome, North Riding, Jhb www.africaautomationfair.com Plastic Closure Innovations 6-8 June 6RÂż WHO .XUIÂ UVWHQGDPP %HUOLQ *HUPDQ\ www.amiplastics.com/events

EVENTS

Plastics Recycling Technology 20-21 June 0DULWLP +RWHO &RORJQH *HUPDQ\ ZZZ DPLSODVWLFV FRP Saitex *DOODJKHU (VWDWH 0LGUDQG Rotomould Australia Melbourne, Australia

25-27 June ZZZ VDLWH[DIULFD FRP 25-27 June

www.rotomouldconference.com.au Intâ&#x20AC;&#x2122;l Thermprocess Summit 27-28 June ,QWHU&RQWLQHQWDO +RWHO 'Â VVHOGRUI ZZZ LWSV RQOLQH FRP Manufacturing Indaba 27-28 June Emperors Palace, Johannesburg www.manufacturingindaba.co.za

Altairâ&#x20AC;&#x2122;s stand at Hannover Messe

innovative IoT products. From 1D to 3D â&#x20AC;&#x201C; from sensors to optimized structures, as well as data analytics â&#x20AC;&#x201C; all required development steps can be conducted and solved with Altairâ&#x20AC;&#x2122;s software platform and its simulation-driven innovation approach.

How to handle manufacturing methods and smart materials was showcased with exhibits of products by Altair customers. $PRQJ WKHVH ZDV WKH Âľ5RERW %LNHÂś D ELNH WKDW FRPELQHV FDUERQ Âż EUH DQG ' SULQWLQJ WHFKQRORJLHV UHVXOWLQJ LQ D fully customizable, lightweight and high strength mountain bike. Another exhibited item which attracted attention was PROTIQâ&#x20AC;&#x2122;s additively manufactured injection moulding tool WKDW RIIHUV XQSDUDOOHOHG SURÂż WDELOLW\ WKURXJK VWUXFWXUDO DQG thermal optimization. www.altair.com

KZN Industrial Technology Expo 26-28 July Durban Exhibition Centre, KZN www.kznindustrial.co.za

Interplas UK 26-28 September 1(& %LUPLQJKDP (QJODQG ZZZ LQWHUSODVXN FRP

Africa World Expo 30 July-1 Aug *DOODJKHU &RQYHQWLRQ &HQWUH 0LGUDQG

www.gallagher.co.za

Automechanika 27-30 September Johannesburg Expo Centre, Johannesburg www.automechanikasa.co.za

PPP Expo Tanzania Dar-es-Salaam

*UHHQ %XLOGLQJ &RQYHQWLRQ 2FWREHU CTICC, Cape Town www.greenbuildingconvention.co.za

22-24 August www.expogr.com

PIPES XI & PPCA conference Emperors Palace, Johannesburg

4-5 September www.sappma.co.za

3RO\ROHÂż Q $GGLWLYHV Vienna, Austria

Petnology Europe 0XQLFK *HUPDQ\

11-12 September ZZZ SHWQRORJ\ FRP

Intâ&#x20AC;&#x2122;l Elastomer Conference Cleveland, USA

Drinktec 0XQLFK *HUPDQ\

11-15 September ZZZ GULQNWHF FRP

OEEC Amsterdam, Netherlands

10-11 October www.offshore-energy.biz

,&,6 (XURSHDQ %XWDGLHQH &RQI 6HSWHPEHU 1RYRWHO 0XQLFK &LW\ *HUPDQ\

www.icisconference.com/butadiene

UTECH (PU Congress) Amsterdam, Netherlands

12-13 October www.utechcongress.com

PU Elastomers . 1 1Â UWLQJHQ *HUPDQ\

13-14 September LQIR#IDSX GH

EMO Hannover 18-23 September 0HVVH +DQQRYHU *HUPDQ\ ZZZ KDQQRYHU PHVVH GH Intâ&#x20AC;&#x2122;l Composites Congress 18-19 September ICS International Congresscenter Stuttgart www.composites-germany.org

Propak Cape CTICC, Cape Town PPCA conference Hangzhou, China

ICIS Asian Polymers %DQJNRN 7KDLODQG

27-29 June www.refocussummit.org

Intâ&#x20AC;&#x2122;l Composites Congress 19-21 September ICS International Congress Centre, Stuttgart www.composites-germany.org

2018

African Marine Waste Conference 9-13 July The Feather Market Centre, Port Elizabeth www.sstconference.org.za

RubberTech China 20-22 September Shanghai New Intâ&#x20AC;&#x2122;l Expo Centre www.rubbertech-expo.com

%LR'LV3ODVW ,UDQ Tehran, Iran

Agricultural Film 2017 %DUFHORQD 6SDLQ

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26-28 September ZZZ DPLSODVWLFV FRP HYHQWV

24-26 October www.propakcape.co.za 26-27 October www.ppia-china.com

Eurasian Composites Show 2017 9-11 November Istanbul, Turkey www.eurasiancomposites.com

Propak West Africa 19-21 September Landmark Centre, Lagos, Nigeria www.propakwestafrica.com

Refocus Orlando, Florida, USA

9-12 October www.rubberiec.org

Euromold 24-26 October ([KLELWLRQ &HQWHU 0XQLFK *HUPDQ\ ZZZ HXURPROG FRP

27-29 June ZZZ SVH HXURSH FRP

PSE Europe 02& 0XQLFK *HUPDQ\ (Polyurethane Solutions Expo)

2FWREHU www.aimplastics.com/events

PLAST 2018 Milan, Italy

14-15 November ZZZ LFLVFRQIHUHQFH FRP

29 May-1 June www.plastonline.org

Compounding World Expo 27-28 June (VVHQ *HUPDQ\ ZZZ FRPSRXQGLQJZRUOGH[SR FRP Plastic Pipes XIX Las Vegas, USA

24-26 September www.pvc4pipes.com

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1. Set of 13 Moulds for range of 3 prestigious, renown sewing boxes valued R400K selling R140K (Machine Req. 250T & 100T) 2.a Set of 9 moulds for modular shelving/tables. 820x420mm shelve die & table top die. 520x420mm shelve die & table top die. 500mm round table die. Foot & wheel adapt dies. Value R550K selling R200K. 2.b 9 Fitting moulds for modular shelves i.e. T/P, connectors, elbows.

Valued R250K Selling R80K 3. Set of 6 moulds (to combine with outsourced square tubing) for mnfg of point of sale display stands, racking & shelving.

Valued R200K selling R80K. (Mach Req. 200T &100T) 4. Beer mug mould + optional rubber handle overmould.

Valued R100K â&#x20AC;&#x201C; Selling R50K for both. (Mach Req. 150T) 5. Set of 7 moulds for plastic plates, bowls & halve spheres. Selling at R12K each mould or R60K job lot (Mach Req. 50T to 200T) 6. CD rack, wine rack, bucket & divIded snack tray mould. TOYS = penguin, clown & tree. (selling at R20K each or R80K for job lot.)

7. Set of 10 cutlery moulds 24cav spoon, 32cav small spoon, 16 cav 4 prong fork, 16 cav 4 prong heavier fork, 16 cav knife. 4cav 100ml Atcha cup, 4cav Lid, 2cav airline cup, 4 cav cocktail fork.

Valued R900K. Selling at R50K each or R150K for job lot.

8. 20 Litre Oval Bucket Die and Handle Die R80K for both.

9. Other Tooling available from R8K per tool.

10. INJECT MOULD MAC â&#x20AC;&#x201C; POTENZA 250T â&#x20AC;&#x201C; 2008 PT25C â&#x20AC;&#x201C; R300K Core pulling, 22KW, 17.5 MPA, 100Kg Hopper Dryer â&#x20AC;&#x201C; Shot Wght 600g PS. New Water Flow Meter, new oil & service.

Prod Ready.

11. INJECT MOULD MAC â&#x20AC;&#x201C; GOTTY 258T â&#x20AC;&#x201C; 2010 HDJS â&#x20AC;&#x201C; R550K SERVO â&#x20AC;&#x201C; 22KW, Core Pulling â&#x20AC;&#x201C; Shot weight 630g PS. 100Kg Hopper Dryer. PS New Flow Meter, new oil & service. Prod ready. Less than 3 years in service.

12. FORKLIFT â&#x20AC;&#x201C; Hyster 3 TON â&#x20AC;&#x201C; R120K. GAS/PETROL (NEWLY RECON) 5.4 M Mast & Side Shift. All lights fitted 13. CHILLER â&#x20AC;&#x201C; V50-98-T-28 â&#x20AC;&#x201C; Ginger Brown â&#x20AC;&#x201C; R50K 14. GRANULATOR Wensui â&#x20AC;&#x201C; 5.5KW â&#x20AC;&#x201C; R15K 15. Material Mixer Strong Multi Drum 210 Litre R14K 16. HOT FOIL PRINTER â&#x20AC;&#x201C; R3K 17. GANTRY â&#x20AC;&#x201C; 2 Ton Cert. + 1 Ton Electric Hoist & Side Shift â&#x20AC;&#x201C; R26K

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Recycle your plastic with us We buy most forms of clean factory waste

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PRICES NEG. COD. EX GERMISTON. CONTACT: JASON 082 956 4760 / GEORGE 083 684 7121

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

Contact: Desiré Preston for more info Tel: 011 894 3520 | Cell: 083 774 6038 | Email: desire@jcl.co.za www.jcl.co.za For more info Tel: 011 894 3520 / 083 774 6038 Email: desire@jcl.co.za / / www.jcl.co.za

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

0$/7$ 5(&<&/,1*

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

High-quality recycled HDPE, LDPE, PP

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96 JUNE / JULY 2017

)XQFWLRQDO FRROLQJ WH[WLOHV XVH VXSHU DEVRUEHU Ă&#x20AC; HHFH IURP %$6) Humans are born runners. Evolution once gave us the ability to overcome the distance of many kilometers through the hot savannas of Africa. In addition to the upright posture of the body and head and the optimized mechanics of legs and feet, cooling by millions of sweat glands plays a key role. Under extreme stress, they can release about one liter of sweat per hour and cool down the body by evaporation.

But as often seen in nature, this specialisation comes at a price. To keep its core temperature stable, the body has to expend much energy to protect itself from overheating. About 75% of the energetic processes in physical exertion are used for thermoregulation and therefore only 25% of the energy can be used for muscular processes such as sports or work performance.

This limits our performance even at moderate outdoor temperatures. Athletes as well as workers and many other people worldwide who are exposed to high temperatures are therefore now using active functional cooling clothing. Thanks to innovative materials, this provides evaporative cooling which is individually dosable and lasts for hours. The functional cooling textiles of the E.COOLINE and IDENIXX brands, incorporating the specially developed

superabsorbent nonwoven fabric from BASF, offer a mobile air conditioning system to wear which effectively supports the cooling system of the human body.

Cooling vests, for example, are easy to use and can be worn like any other item of clothing once being activated by â&#x20AC;&#x2DC;chargingâ&#x20AC;&#x2122; with water. The water enters the active OD\HU Âą WKH /XTXDĂ&#x20AC; HHFHÂŽ from BASF â&#x20AC;&#x201C; after being rapidly absorbed and distributed through a bacteriostatic textile fabric. Like D Âż VKLQJ QHW WKH SRO\PHU QHWZRUN RI WKH superabsorber traps increasing numbers of water particles until its elastic restoring forces compensate the osmotic forces of the prevailing concentration gradient. ,Q WKLV ZD\ /XTXDĂ&#x20AC; HHFH FDQ DEVRUE WHQ times its weight in water and retain it so Âż UPO\ WKDW WKH IXQFWLRQDO WH[WLOHV DUH GU\ RQ the surface.

With higher outdoor temperatures or increasing skin temperature during sports RU ZRUN DFWLYLW\ WKH ZDWHU PROHFXOHV Âż UPO\ bound inside the functional cooling clothing absorb the thermal energy, evaporate from the large surface of the three-dimensional nonwoven structure and thereby cool down the wearer. The body sweats less and thereby saves energy that would usually be needed for thermoregulation. www.basf.com

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

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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:

ty t o G

Injection Moulding Machine

Servo Klockner

Rebuild

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