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BY THE WAY ...

Import duty

renewed?

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: Bronwen Moys (Blinc Design)

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GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew t: (031) 764 2494 f: (031) 764 0676 e: lynne@leafpublishing.co.za Europe & UK Eddie Kania RGH International, High Peak, England t: +0944 1663 750 242 e: ekania@btopenworld.com 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

Association of Rotational Plastics Institute

Moulders of South Africa

of Southern Africa

Plastics Converters Association

PET Plastic Recycling

Plastics Federation

South Africa

of SA

Institute of Materials

ONE unreported development of late is the fact that Safripol and Sasol Polymers applied late last year for the reimposition of import duties on polyolefins and some PVC grades. This may come as a shock to the people who fought to have the duties dropped, whose wishes were granted by the Department of Customs & Excise and the phasing out of the duties over the last two years. Import duties on polyethylene, polypropylene and PVC fell away at the beginning of 2012. Nothing appears to have come from the appeal.

Even we were caught off guard by the news, but then we hear that import duty The proportion protection is virtually standard in many of material of countries (if not most). Governments overall cost around the planet invariably have a vested has been interest in the successful performance of too high major entities such as polymer production plants, so it’s not surprising that they may seek to protect such assets.

But at the end of the day, price of material is a very important aspect for manufacturers: many have felt – and still feel – that the proportion of material of overall cost has been too high. On the other hand, a number of suppliers of imported material informed us that they could hardly ever compete with the prices of Safripol and Sasol Polymers, even after the duty was dropped.

Competition fines go into state coffers This issue we continue the series of articles about Competition Law legislation, and one aspect that’s become clear is that administrative fines for contraventions are paid to the fiscus via the Competition Commission.

That’s a scenario similar to the plastic bag levy, where the industry hasn’t smelt a cent of the levy which was set up ostensibly to help manage the problem of plastic litter. There has been discussion as to whether some of the penalties should go to compensate complainants, but this has not been implemented, according to Jac Marais of Adams & Adams of Pretoria.

The Act does make provision that parties affected by contraventions of the Competition Act may institute a civil claim against the responsible parties, he added, but such claims are apparently notoriously difficult to prove.

Postal blues PROBLEMS with the postal system, specifically regarding strikes at the Post Office, have resulted in readers in certain areas not receiving the publication. One reader commented that we were not performing satisfactorily, but seriously, this is one problem that is beyond us. If you haven’t received the publication, please phone us on 021 712 1408 or write to saplastics@iafrica.com and we’ll resend.

Our mag goes digital!

SA PLASTICS, Composites & Rubber magazine celebrates its 10th anniversary this year – and just one way we’re marking this auspicious occasion is to produce a digital version of our magazine in addition to the bi-monthly print version.

If you haven’t already seen it, visit www.saplastics.co.za and click on the ‘View Digital Mag’ button at the top of the page.

Once the digi-mag has loaded, you can quickly ‘flip’ through the magazine and decide what you want to read. Don’t be put off by the size of the page, just click anywhere on the article you want to read and it automatically enlarges to a size which is easily legible. You can also shift the page around on your screen by simply clicking HAVE … IF YOU and dragging it! Enjoy!

Y

NG TO SA : if you SOMETHI de e bright si Look at th wisdom to e gem of have som to us at e rit ease w impart, pl .com s@iafrica saplastic

REGLOPLAS High-performance temperature control units Find out more at www.saplastics.co.za

Volume 10 Issue 3

JUNE – JULY 2012

Contents

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

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

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INDUSTRY NEWS Evonik in joint venture with Ampaglas in SA

6

Rovetti brothers return, acquire Flamingo

10

Pluses of PVC outlined at SAVA conference

16

Type 150 Smart

16

ASSOCIATION NEWS PISA: Plastics, health & development

34

SAPPMA: Understanding pipe design

40

PCA: Let’s talk labour relations

44

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PEOPLE Vic Beaumont moves into training

50

Steve Mountain on USS Carl Vinson aircraft carrier

52

37

DESIGN Inventive product design

58 102

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

s 3OLID STATE RELAY 332 INSTEAD OF heating contactor

104

SPORTS Plastics are contender in 2012 Olympics

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s #LEAR ARRANGEMENT OF OPERATING AND indicating elements

DIARY Events coming up in 2012

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54

WORLD BMW unveils i8 Spyder

Temperature control units for oil up to 150°C

112

86

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

ON THE COVER CLARIANT’S additives business unit, a major supplier of products for functional effects in plastics, coatings and printing ink, showcased several innovative additive products at the recent NPE show in Florida, USA, in April.

(COVER PHOTO BY CLARIANT)

See page 72 for more information

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THIS ISSUE Evonik Acrylics Africa will be marketing its high-end extruded acrylic products into the building and architecture market segments, as well as the designoriented lighting technologies, furniture, shop-fitting and exhibition booth construction segments.

Tessa O’Hara

, Editor

POLYCO SETS OUT ITS PLAN UR main story this issue is an interview with the POLYCO team.

They’re keeping it quite simple at the outset and focussing on the recycling aspect of the polyolefins business and improving the industry’s Extended Producer Responsibility commitment.

COMMENT

O

One of the goals of the process is to improve cooperation with government. In the words of Dr Brigitte Dero of Europe’s VinylsPlus organisation, “selfregulation by an industry is the best way to achieve favour from governments’ (see page 16), so this is a clear objective for the industry in South Africa. She was speaking at the SA Vinyls Association’s first conference in Midrand in April.

We believe POLYCO could in fact produce much more for the industry, specifically for the thousands of people it employs, as it builds towards a sustainable and growing model. POLYCO can focus on the local industry’s strengths and build on those.

For example, production of electronic goods is not a strength locally, whereas production and development of agricultural and packaging products is. The development of pool cleaning systems, such as the Kreepy Krauly and Zodiac brands, was, as an example, at one time an area of world leading technology development here, and we hope other areas of strength will be developed under POLYCO’s flag.

Evonik in JV with Ampaglas in SA Exciting news in the industry is that Evonik Industries of Germany has established a joint venture with Ampaglas Plastics Group to boost production of its Plexiglas® PMMA extruded sheet products for the African market (see page 6). The new entity, Evonik Acrylics Africa (EAA), is based at the Ampaglas group head office in Elandsfontein, Johannesburg. The joint

4 JUNE / JULY 2012

venture came into being on 1 May. The goal of the joint venture, in which Evonik holds a 51% stake, is the production of high-quality Plexiglas PMMA sheeting and its marketing, particularly in the growth markets of the African continent.

“Self-regulation by an Evonik Acrylics Africa will industry is the best way be marketing its high-end to achieve favour from extruded acrylic products governments.” into the building and architecture market segments, as well as the design-oriented lighting technologies, furniture, shop-fitting and exhibition booth construction segments.

Bliss Chemicals commissions moulding plant New player in the FMCG market, Bliss Chemicals, has commissioned its moulding plant in Wadeville, Johannesburg (see page 7). Bliss has gathered momentum since it first became active in SA in 2003 and from that base has expanded its product range to include various household detergents and cosmetic products.

It also decided to manufacture packaging for its range of products ‘in-house,’ and built its own moulding plant alongside the Wadeville factory.

Besides We also have several other interesting and relevant articles in this issue, including those about Unilever’s new research and development facility which has opened at its Indonsa factory in Durban (p20); UCT alumnus turned internationally renowned yacht designer John Shuttleworth’s latest super yacht design (p28); and the award winners in the 2nd International Plastics Design Competition (p100-101) and much more …

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2012/05/09 11:04 AM

INDUSTRY NEWS

Evonik in joint venture with

Ampaglas in SA … to manufacture Plexiglas® PMMA sheeting for African market

EVONIK Industries of Germany has established a joint venture with Ampaglas Plastics Group to boost production of its Plexiglas® PMMA extruded sheet products for the African market.

Plexiglas® is used extensively in the photovoltaic market

The new entity, Evonik Acrylics Africa (EAA), is based at the Ampaglas group head office in Elandsfontein, Johannesburg. The joint venture came into being on 1 May. Ampaglas is southern Africa’s largest producer of extruded plastic sheet, including ABS, HIPS (high-impact polystyrene), polyethylene, polypropylene and sheet in various ranges, including solid and corrugated forms.

Evonik is an international group which – besides its range of acrylic products – is a global leader in a number of markets, includ-

Affect of oil on polymer prices reduced With reduced demand, polymer manufacturers have more options WE asked Mike Rex of Global Commodity Analysts of Johannesburg whether the sustained high prices of crude oil were having less of an impact on polymer prices than the previous ‘spike’ in crude prices, in 2008.

Mike commented: “You can clearly see – from the graph below – the point you are trying to make.

“The biggest factor describing this difference is the fact that, back in 2008, all world economies were running flat out at record

Graph shows indexed price history for Brent Crude Oil and Far East FOB (freight on board) LDPE and PP prices from 2006 to 2012

6

JUNE / JULY 2012

highs for many commodity materials, both in terms of volumes and prices. Unprecedented demand against limited supply pushed prices to new levels.

“Since 2008 many new plants have come on stream bringing excess capacity to many polymer markets (this is particularly the case with HDPE). Now in 2012, polymer and general commodity demand is not as high as it was in 2008. Political tensions in the Middle East have driven oil prices

higher due to emotions and futures market driven fears. However, with adequate supply of downstream petrochemical products like polymers, there is no support for much higher prices coming from a shortage of supply point of view.”

• GLOBAL COMMODITY ANALYSTS, PHONE 011 807 2127

ing polyamide 12, coatings, silica, multi-functional additives, agricultural chemicals, butadiene, catalyst technologies and other specialties. Its HQ is in Essen, Germany. Formerly known as Degussa, Evonik has been involved in SA for several decades. It was well-known through its carbon-black manufacturing business in Port Elizabeth; it sold that entire division internationally in 2010.

‘Attractive growth regions’ “Our aim with the new venture is to further consolidate our good market position through local production in attractive growth regions,” said Gregor Hetzke, head of Evonik’s Performance Polymers Business Unit. The goal of the joint venture, in which Evonik holds a 51% stake, is the production of high-quality Plexiglas PMMA* sheeting and its marketing, particularly in the growth markets of the African continent.

Evonik Acrylics Africa will be marketing its high-end extruded acrylic products into the building and architecture market segments, as well as the design-oriented lighting technologies, furniture, shop-fitting and exhibition booth construction segments.

“The new company combines the advantages of both its parents: production of innovative products by high international quality standards, coupled with high flexibility and short response times as a result of local production,” said Michael Träxler, head of Evonik’s Acrylic Polymers

The goal is the production of high quality Plexiglas PMMA sheeting and its marketing

Business Line.

Evonik ensures a continuous supply of raw materials from its moulding compounds production sites in Germany, China and the USA. Barry du Toit, CEO of Ampaglas Plastics Group, welcomed the joint venture: “Evonik Acrylics Africa will significantly raise the bar for extruded acrylic products in South Africa. The result will be high quality end products in our target markets. With EAA, we want to be able to speedily and comprehensively meet increasing demand in market segments that are important to us.”

Ampaglas Plastics Group is recognised as South Africa’s foremost extruder of rigid plastic sheeting and has gained a solid reputation for quality and reliability since 1973.

*Note: PMMA, polymethyl methacrylate, widely known as acrylic, was developed by Rohm & Haas in Darmstadt, Germany, in 1933. It is a hard, clear polymer which can be produced in blocks; its surfaces offer high scratch resistance and can be polished. Acrylic is used widely in optical, electronics and protective glazing applications.

Evonik Industries is a worldwide manufacturer of PMMA products sold under the Plexiglas® trademark on the European, Asian, African and Australian continents and under the trademark Acrylite® in the Americas.

www.evonik.com www.ampaglas.co.za

Bliss Chemicals starts moulding plant Veteran industry expert helps new FMCG supplier set up plant THE NEW player in the FMCG (fast moving consumer goods) market, Bliss Chemicals, has commissioned its moulding plant in Wadeville, Johannesburg.

Bliss has been active in SA since 2003, when it started supplying its range of ‘MAQ’ washing powders. It has gathered momentum from that base and expanded its product range to include various household detergents and cosmetic products. With this growth, Bliss has constructed a manufacturing plant in Wadeville.

It also decided to manufacture packaging for its range of products ‘in-house,’ and built its own

moulding plant alongside the Wadeville factory.

Bliss took the decision to hire experienced personnel to manage the set-up of the packaging plant and John Sutherland, who had just retired from Dutton Plastics, was the man selected. After over 40 years in the industry, John had at first contemplated taking it easy … and had just decided to offer his services as a consultant when Bliss Chemicals MD Shoaib Iqbal asked him to run the new plant.

Sutherland’s task was to get the plant

New moulding plant – Shoaib Iqbal of Bliss Chemicals (second from right) with, on his right, consultant John Sutherland and, flanking them, machine suppliers Patrick Bracke and Jo Spohr of Maritime Marketing at Bliss’s new moulding plant in Wadeville

running optimally. He doesn’t like “sick machines” and says machine operators are often inclined to work around machine problems, rather than address them directly. With a ‘hands-on’ approach, John has helped create a culture of sorting out problems.

This has also led to a preference to work with reliable and predictable equipment: Bliss has partnered with two of the local industry’s top machine experts, Maritime Marketing’s Patrick Bracke and Joe Spohr, injection and blow moulding specialists experts respectively. A range of TMC injection machines, SMC blow moulding machines and Nissei ASB injection-stretch blow moulding systems are now installed.

Originally from Dubai, Bliss MD Iqbal had been involved in trading in Africa for some years prior to the company’s entry to the SA market. Bliss has achieved exceptional growth over the nine years since start-up, and its choice of an experienced team to manage its packaging production is likely to give it an additional boost.

JUNE / JULY 2012

7

outlines future plans for industry Objective is to enable polyolefin industry to continue its impressive record of growth and job creation SA Plastics: What is POLYCO’s fundamental objective?

INDUSTRY NEWS

Jeremy Mackintosh, chairman of the POLYCO Board: There are actually four fundamental objectives, but essentially by investing in POLYCO we are doing the right thing, for our children, for our businesses, for our country and not least for our fragile planet.

POLYCO has spelt out its four objectives quite clearly: 1. To take responsibility for the environment by promoting and improving the waste management and recycling of post-consumer polyolefin products.

As members of the polyolefin industry, we have taken a bold step towards an inclusive and environmentally sustainable future. We need to do everything we can to minimise our impact on the environment, reduce the volume of polyolefin plastics that are sent to landfill and increase recycling.

POLYCO, led by the major plastic packaging converters in South Africa, has been established specifically to promote and grow the collection and recycling of postconsumer PP, HDPE, LDPE and LLDPE packaging materials as required of this industry sector in terms of its obligations to Government under Extended Producer Responsibility (EPR) as covered in the Industry Waste Management Plan. We recognise that self-regulation is better than having outside stakeholders manage the polyolefin industry. POLYCO’s formation demonstrates to Government that the polyolefin industry is capable of managing its own affairs competently, including expanded collection and recycling initiatives.

To capture the value of post-consumer polyolefins so that we can help create thousands of jobs through recycling and industry growth.

Polyolefin plastics are too valuable to throw away. POLYCO’s recycling targets are ambitious, but essential, if we are to achieve the vision of minimising the amount of plastic sent to landfill. Recycling polyolefins can create thousands of income opportuni2.

8 JUNE / JULY 2012

ties for South Africans and can add to our country’s GDP. 3. To recycle polyolefins so that they can be made into thousands of new and useful products.

We must develop the market for recyclate.

Creating a higher demand for products made from recycled polyolefins is essential. The greater the demand the more this will ‘pull through’ the supply chain and stimulate activity. This will take considerable investment in infrastructure, innovation and encouragement from both the private and public sector.

4. To create consistent demand for post-consumer polyolefins.

Recycling is a commodity business, and as such it is prone to significant cycles; a sustainable recycling economy with a constant supply and demand scenario needs to be generated. Recyclers need support for research and development, transport to outer lying areas and support for collectors and recyclers.

My guess is that in a few years time we will look back and say ‘Thank goodness for POLYCO’.

SA Plastics: Please briefly describe POLYCO’s working structure?

Mackintosh: POLYCO is the trading name of the Polyolefin Recycling Company (Pty) Ltd. The company was registered as a private company on 12 August 2011 by the Polyolefin Recycling Forum and comprises of representatives from: • Polyolefin polymer producers; • Polyolefin converters; • PlasticslSA The broader stakeholder group to which POLYCO is accountable is all of the above, plus: • Collectors • Recyclers • DEA – Department of Environmental Affairs; Waste Directorate • And any other organisation that may have a vested interest in Polyolefin recycling, such as the consumer good council, retailers, NGO’s and the media.

The interim board has been structured, so that it comprises two levels, a board level and an operational level: a) Board members, being representative of the polyolefin industry; and an b) Operations arm led by a GM, and having the support of admin staff, and/or other contracted services.

Currently there are two converters on the board of POLYCO, namely Charles Muller (Astrapak) and me, Jeremy Mackintosh (Polyoak). We are part of the interim Board that is helping to establish POLYCO. Bernhard Mahl of Safripol represents the polymer producers and Anton Hanekom, the executive director of Plastics|SA is also on the Board. New board members will be elected at the annual POLYCO AGM. The basis for such a structure was recorded in the minutes of the POLYCO board meeting held on 15 July 2011, and was informed by the need to safeguard confidentiality. A chief executive officer will be appointed to manage conflicting interests at Board level. Currently an acting CEO, Sheryl Ozinsky, a consultant, fulfils this role.

It bears emphasis that the confidential information received from producers will only be made available to the POLYCO chief executive officer and the financial director, who will be independent of any of the producers or converters represented on the Board. The CEO and the financial director will aggregate the confidential information before providing it to the Board.

SA Plastics: The company will initially be funded by a voluntary levy of R100 a ton – how will this be implemented, and how successful do you think the process will be?

Charles Muller, Astrapak and POLYCO board member: I think the process will be very successful as demonstrated by PETCO. Converters who agree to participate will pay a voluntary recycling levy, initially set at R100/ton plus VAT. The levy was implemented on 1 April 2012. The amount of the levy may be revised from time to time, by agreement, depending on the level of subsidy required to achieve the targeted

Jeremy Mackintosh … bright future lies ahead for the industry

Sheryl Ozinsky … promote the polyolefin industry’s image

recycling rates, and will be agreed to at the annual POLYCO AGM. The polymer producers, Safripol and SASOL, will add the levy to their invoices and pay it over to POLYCO on a monthly basis.

Polyolefin imports are also subject to the recycling levy by way of a voluntary import declaration. Import Declaration Forms are sent out

by POLYCO each month to those converters who have agreed to pay the levy.

SA Plastics: Will POLYCO be able to get the bulk of the industry to support the initiative?

Mahl: The major converting groups have already agreed to participate, so the accrued fund should grow within the first few months.

Should everyone pay, a substantial fund will be established. POLYCO, together with other role players such as PlasticslSA, will realize improvements for the polyolefin industry in terms of building market share, improving its environmental image, standards, training, relationship with government – in short, everything that a healthy industry involves. It stands to reason that the industry will support an organisation established by them and that accrues benefits to them.

SA Plastics: It has been recorded that ‘self-policing’ of industries is an example that governments internationally favour, and assuming that POLYCO structures do function effectively, do you think this will enable the industry association to develop a meaningful and positive rapport with the SA government?

Mackintosh: One of POLYCO’s core objectives is to work with Government to ensure a clear understanding of each other’s goals.

The objective of this approach is to enable the polyolefin industry to continue its impressive record of growth and job creation without fear of further unilateral government action, such as the plastic bag levy, which could jeopardize the entire industry.

At the same time, government needs to be assured of the fact that the polyolefin industry has embraced the concept of Extended

Bernhard Mahl … POLYCO is based on other successful Extended Producer Responsibility Organisations

Charles Muller … projects will be supported

Producer Responsibility (EPR) through the strategic promotion of polyolefin recycling activities.

Each year, POLYCO will set recycling targets, report annually on collection volumes and invite DEA to participate in setting the strategic goals of the company.

Two important elements of the National Waste Act July 2009 are the introduction of the concept of EPR and the power vested in the Minister to order an Industry Waste Management Plan (IWMP). The Department of Environmental Affairs (DEA) has already asked PACSA (Packaging Council of SA) and RAG (Recovery Action Group) to draw up an IWMP for packaging and paper.

POLYCO will be able to develop a meaningful and positive relationship with the SA government, if the initiative is credible and if everyone in the industry plays their part by contributing to the solution and that there are no ‘free riders’.

SA Plastics: Is the POLYCO strategy based on similar examples in the polymer industry internationally?

Bernard Mahl, Safripol and POLYCO board member: In actual fact the POLYCO strategy is based on a local model, namely PETCO. The PETCO model is similar to other successful Extended Producer Responsibility Organisations, such as Napcore (USA) and Petcore (Europe).

SA Plastics: Some people believe that POLYCO and the present industry governing body Plastics|SA will be duplicated: is this a problem, and how will the company’s role differ from that of Plastics|SA? Anton Hanekom, executive director of Plastics|SA and Board of POLYCO: Plastics|SA has a synergistic but very different role to POLYCO. Whilst both organisations are concerned with the development of a vibrant and sustainable plastics industry in South Africa, they differ in their primary objectives.

PlasticslSA is concerned with promoting the use of plastics as the material of choice

Anton Hanekom … development of a vibrant and sustainable plastics industry in South Africa

and developing the skills needed through accredited training programmes, whilst POLYCO’S primary objective is the growth of post-consumer polyolefin recycling.

SA Plastics: Assuming that POLYCO is able to develop a significant accrued fund, what will the funds be spent on?

Muller: POLYCO has three kinds of projects that it will support: Category ‘A’ projects will assist recyclers who will substantially increase the collection and recycling of post-consumer polyolefins. POLYCO’s preference is for a balanced portfolio of projects that can best assure sustained growth in tons collected and recycled every year. 70-80% of POLYCO’s budget will be spent on support for these projects.

Category ‘B’ activities are aimed at projects that contribute to the visible promotion of polyolefin plastics collection and recycling such as consumer education and awareness activities and new collection locations.

Category ‘C’ projects will enable research on the development of new enduse markets, so critical to the success of the recycling industry.

SA Plastics: Will POLYCO be able to effectively improve the industry’s environmental image?

Ozinsky: POLYCO will be able to promote the polyolefin industry’s image with respect to the environment if the actions of the industry are credible and if everyone in the industry plays their part by contributing to the solution. A marketing budget has been set aside to achieve this objective.

Continued on page 10

JUNE / JULY 2012 9

INDUSTRY NEWS

Rovetti brothers return, acquire Flamingo

Rovetti’s return – Richard and Leonard Rovetti are continuing with the momentum they built up at T3 Plastics Packaging on their return to Flamingo Plastics in Spartan, Johannesburg

T3 brothers complete 4-year hiatus in style THE Rovetti brothers are back at Flamingo Plastics in Johannesburg after a 4-year hiatus during which they, remarkably, started a business from scratch, built up a bank of over 20 machines and won two Gold Pack Awards.

The brothers, Leonard and Richard, had departed in 2007 and started T3 Plastic Packaging the following year. T3 (‘Teamwork, Talent and Technology’) rapidly built up momentum. Here are two guys who really “eat and breathe” plastic packaging: T3’s success has been driven by their initiative and innovative abilities.

Skills learned on the floor at Flamingo stood them in good stead, but that process had come to an abrupt halt following a

disagreement with their father, Eli Rovetti, over their roles at the business.

Family-run operations are the norm in this industry, but it’s often a delicate relationship. Parties in such relationships sometimes overlook the value of each other’s contributions, but the input of the brothers became clear when they made rapid strides on their own. T3 offered creative flair coupled with the ability to take a design from scratch, develop it and get it into production and commercial reality quickfire.

In the interim, Flamingo was put up for sale – the brothers tendered and bought the business from their father. Agreement was reached between the parties in Janu-

ary and the brothers returned to the plant in Spartan in February. All the T3 machines have since been moved over, resulting in a ‘new’ business which now has additional skills and capacity … plus the brothers are entering at least one new market this year.

Their intention is to continue with and grow the T3 brand and let Flamingo fade out.

Flamingo Plastics was bought by Eli Rovetti and partners in 1999.

Products from T3 are also being exported into Africa. This result is possibly one of the more unusual family business outcomes in the industry of late. Congratulations are due to all the Rovetti’s for acting decisively. www.t3pack.co.za

From page 9

SA Plastics: Looking down the line, where do you see POLYCO in five years time? And most importantly, will the company be able to assist in making the SA plastics industry more competitive?

ü POLYCO has supported polyolefinü

Mackintosh: POLYCO’s Board understands that the world is not likely to look the same in five years time. The strategies and business models that have been delivering success and wealth for companies over the past decades won’t stack up. We’re facing changes in how markets are regulated and governed. At the same time, we’re also facing social and environmental challenges and we’re pretty certain that new business issues like job creation and climate change will have to be high on the list of issues, which determine business success.

ü

Here is where I see POLYCO in five years time: ü All polyolefin converters, including those supplying recycled polyolefins are members of POLYCO and party to its objectives;

ü

10 JUNE / JULY 2012

ü ü

ü

recycling projects to the tune of some R75-million; POLYCO has grown post-consumer polyolefin recycling from 144 000 tons in 2011 (25%) to 222 000 tons (35%) in 2015; By adding 78 000 tons per annum to the material recycled annually, in 5 years’ time we will (at R10 000 per ton) add R 780 million per annum to SA’s economic activity with favourable spinoffs on job creation, waste reduction, the balance of payments, government coffers and real cash savings for the converting industry (circa R 234 million per annum).

POLYCO has an excellent relationship with government, one of mutual respect; POLYCO has developed an understanding of recycled polyolefin end-use economics; Increased consumer awareness, marketing and PR have enabled consumers to appreciate the benefits of plastics and has motivated them to separate at source; and POLYCO is working closely with munici-

palities across SA, to enable collection of better quality post consumer polyolefins.

SA Plastics: What else is in store?

Mackintosh: It’s very exciting to be part of history in the making. POLYCO has an incredible opportunity to shift consumer behaviour from that of a waste collection and disposal culture to a waste-management, minimisation and recycling culture. The organisation will seek alternatives to ‘dump-site collection’ (e.g. curbside-recycling initiatives) and help to facilitate the establishment of sorting centres that separate polyolefin waste prelandfill. These tend to be better organised, are much safer than landfill sites and have contracted employees.

I am privileged to be on the POLYCO Board and working with committed individuals who want to make a difference.

Consistent and quality masterbatches from

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INDUSTRY NEWS

Tinus van der Merwe monitoring output

Fine material is separated from the pellets, meaning that the quality of black masterbatch pellets supplied is highly consistent. The separated material is reprocessed

One of the extruders used for the production of black masterbatch at the same site in the 1950s and 60s, dwarfed by the new system, is now a museum piece The Berstorff extrusion system at Ferro Industrial Products in Brakpan on the East Rand

Ferro installs twin-screw line for high-grade black masterbatch Fine quality black aimed at high-dispersion, specialty applications

FERRO Industrial Products of Brakpan is continuing its ongoing production expansion process with the commissioning recently of a new line for highgrade black masterbatch.

Black masterbatch has long been seen as a commodity material, but the new line – a 75mm co-rotating extruder from Berstorff of Germany – is targeted at the production of high quality black masterbatches for speciality applications such as the extrusion of fibre, high-pressure pipe and dam lining sheet where high levels of dispersion are necessary.

The new high grade black masterbatches will utilise the highest quality carbon black with particles sizes between 20-40 micron, which is about half that of the standard commodity blacks. The ability to produce such material is made possible by the Berstorff twin-screw extrusion technology (it employs a 4.5m twin-screw system). The line uses Brabender hoppers and a BKG tungsten steel pelletiser 12

JUNE / JULY 2012

system and screenchangers, producing a high quality die face cut pellet.

The new material is significantly better dispersed than black masterbatch available in South Africa to date. For most highspec applications up till now, manufacturers have had to import material. According to Ferro director Tinus van der Merwe, that will no longer be necessary. The line has been in full production for some months and initial reaction from converters has been overwhelmingly positive, said van der Merwe, who has been involved in several divisions at Ferro, including plastics, for close to 20 years.

Ever since Ian Forbes and the late Bert Davids bought Ferro in 2004, the company has been improving its abilities and investing in capacity at its East Rand site. Besides the manufacture of black and white masterbatch, fillers and additives, the factory is now a major regional production centre for powder coatings, glass colours, porcelain enamels and tile coatings. A new 10,000m² factory and R&D centre for tile coating material which has just been

built is the most recent expansion at the Brakpan site.

Black and white materials Ferro is already one of SA’s top manufacturers of commodity black masterbatch, for which it uses internal mixing systems.

Although the commodity grade black masterbatch is difficult to produce, as the main ingredient, carbon black, is notoriously difficult to disperse, commodity blacks have been subjected to downward price pressure over time. In other words, converters have been reluctant to pay for better quality material.

Ferro has continued with the production of black and white masterbatches and its on-going investments have made it the SA leader in these areas.

Ferro has also expanded output of white masterbatch, including the purchase of two dedicated Farrel twin-screw lines for white production.

www.ferro-sa.co.za

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Cages for ball bearings manufactured in polyaryletherketone (PEEK from Victrex achieve a good balance between strength, elasticity and weight

Victrex PEEK polymers bear the strain, easily

INDUSTRY NEWS

PEEK achieves balanced combination of strength and elasticity

THE performance and reliability of roller bearings depends mainly on the bearing component materials. To fulfill the rising demands of discerning applications in the automotive industry, development engineers are increasingly turning to Victrex highperformance polymers for the design of deep-groove ball bearings.

Victrex’s range of polyaryletherketone (PEEK)* are especially suited to such applications.

Cages are mechanically stressed by friction, tension and inertia forces, and are exposed to external influences due to lubricants, lubricant additives and their aging products as well as organic solvents and coolants. The extent of these factors depends on parameters like temperature, impact resistance, vibrations or a combination of these and other unknown factors.

Consequently, both the design as well as the basic material is imperative for the loadbearing capacity and operating reliability throughout the cage’s service life. This is why almost all bearing manufacturers have developed cage types on the basis of Victrex PEEK to fulfill the most discerning requirements of their clients.

Materials for polymer cages Victrex PEEK cages are characterized by a balanced combination of strength and elasticity. The good sliding properties of the

polymer on a forged steel surface produce minimal friction between the cage surface and the balls so there is very little heat and wear inside the bearing. The low density of the material reduces the weight which has a positive effect on the inertia force of the bearing.

Due to the use of tribological optimized compounds, the bearings can run dry for a brief period without the danger of friction wear or damage.

Most applications are of a non-static nature, where the dynamic strength values of the materials have to be considered. Victrex has launched new materials containing special carbon fibres which, at a reinforcement fibre ratio of only 20%, withstand higher dynamic stresses than systems filled with 30 or 50%. A secondary effect is higher ductility and greater extension to favour ball or cylinder snap-in during assembly.

The PEEK material features no significant signs of aging as a result of bearing temperatures of 150°C for more than 5000 hours. The continuous use temperature is around 260°C. Applications close to the material’s melting temperature of 343°C for Victrex PEEK and 374°C for PEEK-HT are also possible after due consideration of the loss of strength and more rapid aging.

Victrex is based in Lancashire, England, with offices in about 30 countries around the world. It operates manufacturing plants

in the UK, USA, China and Japan.

Victrex PEEK (polyaryletherketone) polymer is regarded as one of the highest performing materials available.

Several different types of PEEK are manufactured, as well as dozens of blends and compounds. In addition to granules and powder, Victrex PEEK is readily available in finished forms such as stock shapes, fibres, films (Aptiv® film) and coatings (Vicote® coatings).

• THE DISTRIBUTOR FOR VICTREX PEEK IN SOUTH AFRICA IS PLASTICHEM. WWW.PLASTICHEM.CO.ZA

www.victrex.com

=<8KLI<J F= G<<B ADVANTAGES offered by Victrex PEEK in terms of metal replacement include: • Weight reduction (reduces moment of inertia) • Higher flexibility • Lower friction • More space for grease reservoir • High temperature wear resistance • Resistance against chemicals • No swelling in humidity • Continuous use at 150°C without performance loss • Vibration damping • Radiation resistance • UL V0 (Underwriters Laboratory is an international testing and standards organisation in the USA, similar to the SABS in SA, but accepted and recognised worldwide; ‘V0’ is a flammability rating given to materials (in this case, plastic) where a V0 rating will be better than a V2 rating, the ratings relate directly to results obtained in flammability test)

• FDA compliance • Long lifetime • Higher RBM

Dynamic tensile strength at 120°C with carbon-filled Victrex PEEK compounds 14

JUNE / JULY 2012

* NOTE: Polyaryletherketones are characterised by phenylene rings that are linked via oxygen bridges (ether and carbonyl groups (ketone).

The ratio and sequence of ether to ketones mainly affects the glass transition temperature and melting point of the polymer. It also affects its heat resistance and processing temperature. The higher the ratio of ketones, the more rigid the polymer chain, which results in a higher glass transition temperature and melting point. The processing temperatures can range from 350 to 430°C.

(this is a mechanical engineering term standing for Resisting Bending Mode and is used to describe the mechanical ‘rigidity/stability’ of beams and, in this case, bearings; this is coupled with very complex formulas and calculations which then determines the RBM)

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1. Keynote – Delanie Bezuidenhout of SAVA flanked by the two keynote speakers at the PSP event: Maggie Saykali of the European Council for Plasticisers and Intermediates (CEFIC) and Dr Brigitte Dero of VinylPlus (the European equivalent of SAVA), both of who are based in Belgium.

Delanie and Gary van Eyk of SAVA also took the European visitors to visit one of the game parks in the Lowveld, which proved very successful

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2. Maria Stephanou, marketing manager of Sasol Polymers’ Vinyls Business, gave an ‘Overview of the South African PVC Industry’ presentation

3. Annabé Pretorius of SAPRO gave a presentation about ‘PVC Recycling in South Africa’. More PVC is being recycled in South Africa than is widely believed, said Annabé, but she added that there are also products that are not practical or feasible to recycle

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4. Kumar Naidu (right) of Scinergy Chemicals of KZN gave a presentation about SAVA’s key commitments. Kumar’s an entertaining and capable speaker, and hence a good ambassador for the sector.

Here we see him with Scinergy colleague Nico Scheepers and Mark Holtes of Isegen, also of KZN. Isegen and Scinergy were both sponsors of the conference too

Pluses of PVC outlined at SAVA’s first conference Material has unique advantages, prompt sector to market more effectively

INDUSTRY NEWS

THE fact that PVC tubing doesn’t easily kink has made the material popular – essential in fact – in the medical sector. This aspect of PVC has in many cases proved life saving. And such applicationspecific characteristics have seen PVC – or vinyl as it is referred to internationally – being the material of choice in numerous other applications (albeit for other reasons), including water piping, cabling, floor tiles and footwear – all of which are high-volume markets globally.

The ability to avoid kinking has helped make PVC popular in the medical sector for over 50 years. Yet criticism of PVC has persisted and grown, the reality of which only dawned on the industry recently in South Africa. For long buoyed by consistent annual consumption growth, PVC material manufacturers and converters could have been forgiven for ignoring much of the criticism and thinking the momentum would last.

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8. Lufuno Siphuma and Karabo Mutloatse of Sasol Polymers and Leredi Mokoala of Keys-Makin Plastics were at the conference 16

Not unsurprisingly, it didn’t: consumption the European Council for Plasticisers and of PVC dropped dramatically at about the Intermediates (ECPI), both of who are based same time as the global economic crunch in Belgium. in 2009. That stung the sector into action, and one of the most tangible outcomes Overview locally was the creation SAVA, the Southern Maria Stephanou of Sasol Polymers’ Chlor African Vinyls Association. In a fastVinyls Business got the ball rolling with an track operation, a steering committee for overview of the South African PVC industry.

SAVA was formed in late-2010 and SAVA Global consumption of PVC took a big knock came into being in 2011. The association in the financial crunch of 2009, falling from now represents the bulk of the local about 37 million tons p/a to just over 30 PVC manufacturing, compounding and million p/a. That figure has since recovered to converting industry. an estimated 38 million In a further fasttons in 2011, but Sasol Current domestic track move, SAVA Polymers foresees a consumption of PVC in SA succeeded in gradual recovery. is estimated at 142 000 presenting its first Domestic conference, the ‘Best consumption of PVC in tons a year, well below the Practice PVC’ event SA is currently estimated historic high of 173 000 held at the PlasticsSA at 142 000 tons a year, tpa of 2008 offices in Midrand on well below the historic 18 April. The event high of 173 000 tpa of formed part of SAVA’s Product Stewardship 2008. Sasol Polymers’ nameplate capacity Programme (PSP). SAVA succeeded for PVC stands at 190 000 p/a, so it sees the in putting together a comprehensive need to stimulate demand and growth. speaker panel, and hosted visits by two There are encouraging signs of recovery, top European experts, Dr Brigitte Dero according to Maria, particularly for expanded of VinylPlus (the European equivalent of use of PVC in the housing market using SAVA) and Maggie Saykali, manager of alternate PVC based building technologies.

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9. André Botha of Sasol Polymers, Martin Wells of SA Plastics magazine and Gary van Eyk of Sun Ace SA were in good spirits; Gary is also chairman of the SAVA management committee.

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5. In the pipeline – Renier Snyman of DPI gave a presentation on the SA Plastic Pipe Manufacturers Association (SAPPMA) programme to phase out lead stabilizers and the substitute calcium/zinc and organic-based stabilizers. Here we see Renier with Pieter Snyman and Dr Kathy Garde of Carst & Walker

Other new areas of potential growth for PVC ; WPCs (wood plastic composites); large bore pipe and PVC windows, ceilings and wall panels as PVC remains a product of choice in building applications.

New biaxially oriented technology may provide opportunities for growth in the production of large bore pipe (over 550mm diameter).

Energy costs continue to be a big concern for the whole industry including end users, said Maria. However, the new building regulations and in particular the launch of SANS 204 will go a long way to achieve energy and cost efficiencies in the building environment where PVC products are ideally suited to meet these challenges.

Overall, Sasol Polymers remains committed to grow the PVC footprint in the local market.

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6. SAVA committee members Tandy ColemanSpolander of Polyflor and George Dimond of Continental Compounders

India is estimated to be increasing at an incredible rate: they require about 1 million tons more a year at present. Besides that, the material’s performance in some of the developing markets – such as Brazil, Turkey, Indonesia, Poland and Russia – is well above-average too. This has had the result that some of the countries which were formerly leaders in the PVC market in the West have since become nett exporters of the material, most notably the USA. www.cmaiglobal.com

VinylPlus in Europe The presentation Dr Brigitte Dero of VinylPlus of Europe was eagerly awaited.

VinylPlus is the European equivalent of SAVA, and has been one of the forerunners in the PVC’s fightback internationally

7. Richard Phillips of Sun Ace SA and Lowrie Sharp of SA Plastics magazine appeared in fine shape on the day

following persistent criticism from the environmental green lobby.

VinylPlus’s first programme, unveiled in 2000, was called ‘Vinyl 2010’ – a decade-long programme with the goal of “minimizing the impact of PVC products throughout their entire life cycle and improve their contribution towards sustainable development”. Following the completion of that programme, the new 10-year VinylPlus programme commenced in 2011, and the objectives became more specific, including five main challenges: • controlled-loop management; • controlled organo-chlorine emissions; • sustainable use of additives; • sustainable energy and climate stability; and • sustainability awareness.

www.sasolpolymers.co.za

Global market trend That was followed by a ‘conference call’ linkedup presentation from Germany-based Michael Smith of IHS Chemical World Vinyls Analysis (formerly CMAI World Vinyls Analysis). IHS presents a series of studies covering historical trends and forecasts for major global vinyl market fundamentals for PVC, vinyl chloride monomer (VCM), ethylene dichloride (EDC) and other vinyl products in 10 geographic regions.

According to Smith, the use of PVC in the West has reached a ‘maturity’ stage and is currently in an ever-declining phase, due at least partly to its dependence on the construction market. However, the material is still in a growth phase internationally: demand for PVC in China and India and the Asian market in general is continuing to grow and showing resilience. Demand for PVC in

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10 & 11. All the speakers were involved in a panel discussion with delegates following the presentations

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INDUSTRY NEWS

Dr Dero has had her hands full: the PVC/vinyls market in Europe is big – an estimated about 21,000 companies are involved, with about 500,000 jobs involved in 6 million tpa of PVC production and about €80-billion turnover.

VinylPlus’ success has had the important effect that it has managed to forestall possible legislation from the European Union. In fact, that is probably its main achievement to date.

Other achievements include the increase of recycling rate of post-consumer PVC to close to 1 million tonnes p/a; phasing out of cadmium stabilisers from PVC productions in the EU; the substitution of lead stablisers programme is ahead of schedule (set to disappear in EU-27 by 2015); and on-going research, testing and expert evaluations on plasticisers have led the industry towards non-classified high phthalates (>80% market).

It has also managed to increase recycled volumes, with an estimated 100,000 tons recycled in 2011. The challenge remains the fact that PVC is difficult to recycle, so VinylPlus is focusing particularly on this area.

VinylPlus has also succeeded in growing its funding structures, and this year for example has €6,6-million (about R66million) set aside for industry programmes.

It focusses on measurable targets and transparency, said Dero, and the initiative seems to be having a positive impact on the material’s image.

Dr Dero was born in the Congo, left as a toddler and had not returned to Africa since, so her visit to SA and particularly that to the Sabi Sands reserve in the Lowveld was

18 JUNE / JULY 2012

especially meaningful for her.

put into developing plasticisers for specific applications, and one of the problematic areas that have resulted is that a specific Plasticisers update plasticiser may impart one or more special Maggi Saykali of the European Council for properties such as low temperature flexibility, Plasticisers and Intermediates (ECPI) gave but not be suited to all PVC processing a presentation titled ‘Plasticisers Update and techniques and applications. Most – 96% Reputation Management within the Vinyls – of plasticisers are used in flexible PVC Value Chain’. ECPI represents the major applications. producers of plasticisers and intermediates To compound matters (literally!) in Europe, in two groups: secondary plasticisers are used to reduce • a Low Molecular Weight (LMW) group, cost or improve processing. including Arkema, Oxochimie, Deza and In Europe, according to Maggie, the trend ZAK; and is shifting towards High Molecular Weight • a High Molecular Weight (HMW) plasticisers, the most obvious reasoning group, including BASF, Evonik Oxeno, being that these plasticisers do not ‘migrate’ ExxonMobil and Perstorp. out of the polymer structure in application.

The HMW group members have www.cefic.org signed up for the new VinylPlus industry commitment.

Sponsors ECPI supports the safe, sustainable The sponsors for the 2012 SAVA conference and environmentally responsible use included: of plasticisers, and carries out research • Alpha Plast relevant to safety and sustainability.

• Continental Compounders Now we all know that plasticisers are • Elco Plastics essential in the polymer industry. Plasticisers • Isegen have been used to soften materials since • SASOL ChlorVinyls ancient times: for example, oil mixed with • Scinergy Chemicals pitch to seal boats has been used for many • SunAce South Africa centuries.

The travel expenses of the international Today, nearly 6 million tons of plasticisers speakers were also made possible by the are used worldwide annually, including one combined generous sponsorship of these million tons in Europe. Phthalates represent companies. more than 80% of this volume.

• THE CONFERENCE PRESENTATIONS ARE As outlined in the table, phthalate esters AVAILABLE FOR DOWNLOAD FROM THE account for about 75% of plasticisers used.

SAVA WEBSITE: Criticism directed towards PVC has originated largely due to the plasticisers www.savinyls.co.za used. A great deal of research has been www.vinylplus.eu

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AfriMold and TASA elaborate on new industry contract One of main features of new contract is a revolutionary form of dispute resolution

Pieter van R. Coetzee, attorney to the High Court, will be presenting at the AfriMold Conference in October this year.

His topic, ‘The tools of the law – creating a new culture,” provides an acceptable contract for commercial unity

THE Toolmakers Association of SA (TASA), which presents the conference at the forthcoming AfriMold Trade Fair, has commissioned the development of a new generic contract specifically for the toolmaking industry.

Pieter van R Coetzee, the attorney developing the contract, is a keynote speaker who will be addressing the issue at the AfriMold Conference.

form of dispute resolution.

“The contract will enable the entire tool making industry to unite in terms of a set of properly formulated and drafted terms and conditions which will set the course for the toolmaker to find itself in an industrial environment of protection,” he added.

Other topics to be presented at the conference will focus on intellectual property and registered designs; effective business and legal contracts; skills development; training and employment creation.

The theme this year will be ‘Tooling as a Key Enabler for the South African Manufacturing Sector – Climate Change Mitigation’, with various speakers, including international and local specialists in tooling technology and related fields.

The AfriMold conference will have valuable information to assist in revitalising the industry for sustainable growth and future development. It will showcase new technologies, innovation and effective methods to improve production and international competitiveness.

AfriMold, the international trade fair for application development via tooling, engineering, mould-making and design will take place from 10 to 12 October at the Gallagher Convention Centre in Midrand.

Van R Coetzee says a recent survey shows that despite rapid progress in the market place, the toolmaking industry both nationally and internationally have over the last few decades, failed to professionally update its legal administrative programmes, including contracts.

“A disturbing number of toolmaking enterprises have either not used a proper contract or have resorted to copying contracts they came across in the industry, exposing themselves to loss as a result of the absence of necessary terms, vagueness or ambiguity in the contract,” he said.

According to Van R Coetzee, the aim of the new contract is to level the playing field for all participants in the industry making the relationship between toolmaking and manufacturing more stable, fair and negotiator-friendly, while protecting the interests of all parties. One of the main features of the contract is a revolutionary

www.afrimold.co.za

Unilever looks to leading edge with R&D plant

INDUSTRY NEWS

R35bn the worth of the consumer market that Unilever has captured on the continent UNILEVER plans to create and improve more products from its new research and development (R&D) facility that opened at the Indonsa factory in Durban.

The R44 million R&D facilities will operate as a pilot plant for the Unilever research and development team, who through the facility would be able to improve on products such as Omo, Lux, Dove, Knorr and Robertsons among others.

Unilever had its global chief of research and development, Geneviéve Berger, visit South Africa in May to open the plant.

Globally, Unilever has employed about 6 000 scientists, engineers, chefs and technicians in 20 countries. “Brands and innovation are at the heart of everything we

do. At Unilever research and development is the home of breakthrough technology for bigger; better; faster innovations,” Berger said.

Ross Plumbley, vice-president of research and development in South Africa, said the pilot plant would serve as a unit performing research to improve products for the Durban region and also for the African market at large.

The pilot plant will also help Unilever to deliver new products quicker into the market and also maximize its growth.

Plumbley said tests would be done on a smaller scale and once it had been approved they would be done on a larger scale. “The plants’ testing equipment is

Consumer goods giant Unilever’s new, environmentally friendly savoury foods factory outside Durban. The R670 million plant, located at Riverhorse Valley and named Indonsa, is a global first for the group in advancing its focus on advanced sustainable ‘green’ technology. It is Unilever’s second-largest plant out of 250 worldwide, and is the company’s fifth plant in South Africa. The plant has been designed to produce 65 000 tons of product per year and has an expansion capability of up to 100 000 tons – which would make it Unilever’s largest dry foods plant worldwide 20

JUNE / JULY 2012

aligned to our global facilities including our African operation so that when we carry out tests and decide on a particular product, we do so together.”

Unilever owns more than 1 700 different brands and has carried out about 240 improvements on different products in the past year.

The plant’s priorities will involve developing great quality brands, and to obtain scientific proof that all products deliver on their claims.

The pilot plant is equipped with testing apparatus, boilers, laboratories and even washing machines to test improved washing powders. It is expected that researchers would run trials at least twice a week.

Science of colour revealed INDUSTRY NEWS

Coral Chem, Geotech technical seminars unveil fascinating facts about effect pigments CORAL Chem’s technical training seminars held during May in Johannesburg, Cape Town and Durban were a consummate success with existing and potential customers who attended.

The seminars were held in conjunction with Coral Chem’s Dutch principal, Geotech International BV. Tom Taekema, technical sales manager at Geotech, conducted the seminars with flair and expertise, obviously the result of well-honed experience in the world of colour effect pigments.

The training seminars covered all aspects of effect pigments, including glitters, aluminium and pearlescents in both cosmetic and industrial applications, in applications ranging from plastics, coatings and inks, to decorations and cosmetics.

Tom Taekema, technical sales manager at Geotech, with Coral Chem marketing manager Courtney Holley and Hans Leisegang, Coral Chem MD at the Cape Town seminar

Founded in 1984, Geotech International is based in Haarlem, The Netherlands. It is a fully independent, privately owned, family company with a young management team.

Its core business includes pearlescent pigments and glitter. Its main markets are cosmetics, plastics and coatings which are distributed worldwide via a network of agents and distributors.

Geotech effect pigments have been used in the plastics industry for many years by a variety of customers such as SABIC and Clariant. Geopearl®, Geodiamond® and Geometal® are now joined by the new Metalloy® metallic pigment range.

The new Metalloy effect pigments are aluminium based pigments offering metallic effects. Geotech offers a complete range of 35 new products for plastics, coatings and inks. Potential areas of application cover several methods of thermoplastic processing such as extrusion, co-extrusion, injection moulding and casting resins (buttons for textile).

And the science behind the product is fascinating stuff!

Tom Taekema explained that the metallic effect is based on the reflection of light on the surface of the pigment. This reflection is overlayed by the light scattered at the edges of the flake and by the micro-roughness of the pigment surface. The metallic effect is the sum of the reflection and the scattering of light: The higher the ratio of reflected light, the more intense the metallic effect. www.coralchem.co.za

Leafing and non-leafing, particle shapes and size The range of products can be divided into non-leafing and leafing products.

Leafing aluminium flakes float and align at, or near the surface of the film, creating an opaque coating with a silver or chrome effect. Leafing pigments form an excellent barrier which prevents penetration of corrosive substances.

Non-leafing aluminium flakes are evenly distributed throughout the coating film. This structure allows the light to be reflected by the flakes and emitted out through the coating film, enhancing whiteness, lightness and the vividness of films.

Applications include masterbatches or direct injection moulding, extrusion or blow moulding processes. The material is compatible with PE, PP, PVC and ABS. • GEOTECH OFFERS CUSTOMERS GUIDELINE FORMULATIONS FOR INJECTION MOULDING. ITS LABORATORY IN HAARLEM IN THE NETHERLANDS HELPS CUSTOMERS FORMULATE THE RIGHT PRODUCT AND MATCHES COLOURS ON REQUEST. www.geotech.nl

Ian Clark (Keniplas), TomTaekema, technical sales manager at Geotech, Hans Leisegang, Coral Chem MD, with Lurika Joubert and Mingaye Workman (Performance Colour Systems), David Rule (Plasticolors) and Shannon van der Merwe (Performance Colour Systems) at the Johannesburg seminar

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JUNE / JULY 2012

Xandra Anderson, national sales and marketing manager for Goldsun Industries with Coral Chem MD, Hans Leisegang and Ann Carse from A & T Trading, also at the Cape Town seminar

a brand of maag group

a brand of maag group

a brand of maag group

Joesten International P.O. Box 3208 1540 Brakpan South Africa

international@joesten.co.za T. +27 (11) 915 3269 F. +27 (11) 915 3267

Kevin Freese of Big Boy Plastics at the Alpha Creations factory in Industria, Johannesburg Operator Emanuel Mufamadi with one of the moulded seats (right)

Big Boy Plastics moulds own range of chairs ALPHA CREATIONS of Johannesburg, a supplier and importer of furniture for restaurants and public amenities, decided to put its money where its mouth is … and get into production.

The quest was possibly easier in concept than action, as Alpha MD Kevin Freese had practically no experience of plastics. That was three years ago, but the bug bit and Freese has become fully involved and now actually runs the formidable injection moulding machine – a 1 250-ton clamp force ‘Gotty’ system from SES. Alpha Creations supplies a range of plastic and metal bar stools, canteen tables, cocktail

and bar tables and café chairs. Freese established the subsidiary Big Boy Plastics to manufacture the plastic chairs as well as individual components (a number of the styles feature plastic parts with metal struts).

Currently all moulds are run in PP and Big Boy Plastics will be gearing up to do polycarbonate chairs and gas-assisted injection moulding later in the year.

Apart from the challenge of financing the venture, Freese has also had to deal with the problems that come with entering new territory, such as the need to raise the roof in order to install the machine at Alpha’s factory in Industria and reinforce the floor to accom-

Flying colours for Purple Line after

modate the weight of the machine. Three hydraulic jacks broke in the process, railway lines buckled and the factory floor caved in twice while the 70-ton machine journeyed to its destined location.

Despite the challenges, SES managed to commission the machine without any problems.

“There was never any concern and I could trust SES with all,” added Freese, who has set his sights on expanding output of superior style chairs and tables for the hospitality sector, such as cafeterias, restaurants and clubs. www.alphacreations.co.za

yrs

Specialises in production of small to medium size blown, ISBM containers BLOW moulding business Purple Line Plastics’ strategy of focusing on medium size production runs as its market niche has seen it complete its first 10 years in operation with flying colours.

It doesn’t compete in the high-volume business and is under no illusion about that: inquiries for big production runs are simply referred to the ‘big’ players.

Cape Town-based Purple Line specialises in the production of small to medium size blown and ISBM containers, ranging from 20ml cosmetic bottles up to 1-litre sports bottles. It also injection moulds the closures as well as cosmetic containers and a range of custom products, and builds some of its moulds. It processes all the polyolefins, PVC and PET. The company has had the advantage of MD Charl du Plessis’ acumen. Charl underwent an unofficial apprenticeship in the late 1970’s at Xactics and later at the Kohler-Xactics group, where several of the industry’s veterans cut their teeth. Knowhow 24

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learned during that time has proved important: Charl also handles the marketing side, the main advantage being that he is able to clearly assess customers’ needs and advise what is possible and what is not, and give accurate cost estimates – in most cases immediately. This has also allowed Purple Line to get new containers into production in close-to-record times.

Du Plessis started Purple Line in 2002 after his involvement with the erstwhile Harwill group was curtailed suddenly by its demise and liquidation, and the difficult lessons learned during that time are now being put to good effect. For example, multi-tasking is the order of the day for all staff at Purple Line Plastics.

One of Purple Line’s strengths is keeping customers informed of the progress of their orders. Late delivery is a widespread problem in most industries, but in some cases too-soon delivery can be a problem as well, since manufacturers do not always have sufficient storage space to

Purple patch – Charl du Plessis on the floor at Purple Line Plastics in Triangle Farm, Cape Town

accommodate early deliveries, and prefer ‘JIT’ delivery of packaging.

Purple Line is still in the building phase: it recently became involved in foiling “by accident” – when a supplier was not able to foil a series of closures. Charl and production manager Kevin Marle put their heads together and got the first order out, during which time they also redesigned the cap, with a lighter, more practical style to allow for more efficient production runs.

• PURPLE LINE PLASTICS: PHONE 021 948 5042

www.purpleline.co.za

PHOTOS: LOWRIE SHARP

EQUIPMENT

Johannesburg furniture manufacturer uses locally made ‘Gotty’ machine

cool houses love energy bills BASF’s construction solutions and energyefficient materials are more cost-effective than conventional insulating systems and materials, and have a much higher insulation capacity.

So, thanks to products like Neopor® and Elastopor®, houses stay cooler in the summer and waste less energy.

Saving on emissions means saving on bills? At BASF, we create chemistry.

www.basf.com/chemistry www.basf.co.za

Hot & Cold all the way!

EQUIPMENT

DME choose Mould and Die Solutions to expand their Hot Runner representation in SA DME, the leading mould component manufacturer operating out of Belgium, have been providing successful hot runner solutions since the beginning of this powerful technology – from introducing the ‘Cool One’ in 1972, all the way to today’s advanced new Electric Valve Gate technology.

To better showcase their extensive range of Hot and Cold runner programmes in South Africa, DME have elected Mould and Die Solutions to represent their entire Hot Runner range – that is, everything connected to hot runners, from single nozzles to fully assembled hot halves, and everything in between.

Mould and Die Solutions have been in operation since 2001, concentrating exclusively on servicing the toolmaking industry in South Africa. They are ideally suited to facilitate DME’s planned expansion into the local market.

As one of the more experienced and successful manufacturers of hot runners, DME are ideally poised to offer: • A complete range of products: from single nozzles, multi-nozzle assemblies, to fully assembled hot halves for virtually any need.

• Applications engineering: Determining the right hot runner for the application and maximising results.

• Moldflow modelling: To make sure the process and system are optimized for the application.

DME’s experienced team of mould

designers and applications engineers can help determine which of the two main varieties of hot runner systems a customer needs. Their applications engineers will look at the materials you’ll be running, temperatures, drop locations, gate diameters, viscosity, and then determine your ideal hot runner option to achieve the most material savings, shortest cycle times and greatest part quality enhancements.

DME has a wide selection of high-quality hot runner components and systems available: Valve Gates Valve Gates provide superior gate cosmetics, as well as sequential part filling.

They eliminate the need for trimming and secondary operations and are available in hydraulic, pneumatic and electric actuation.

Valve Gates are suitable for most material types, from small to large parts. DME’s fully integrated multi-use valve gate system is ideal for products that require different production volumes Thermal Gates Thermal Gates are the more common option, available at relatively lower costs, and in a greater variety of standardised products. They are ideal for high cavitation moulds with close cavity pitch dimensions and are available in a range of externally heated systems for outstanding processing results.

Nozzles Whether you’re building your own hot runner or replacing parts in an existing system, DME have the nozzles that will help make the project a success. They understand the need for heater replacements and other maintenance issues, thus most of their own nozzles are front-loading for fast, simple service access to the hot runner system.

Manifolds and nozzles

Manifolds and nozzles DME manifold and nozzle combinations or multi nozzle assemblies provide moulders with a foundation to build a world-class Hot Runner system. Their industry-leading nozzles and full hot half systems offer complete flexibility for unique moulding applications.

Hot sprue bushings When you have a single-cavity mould

26

JUNE / JULY 2012

www.dmeeu.com

www.m-d-s.co.za

Polifast

but still need the benefits of a hot runner system, a hot sprue bushing is the solution.

DME offers several models to customise to any application. Hot One - Hot sprue bushings can handle engineered and commodity resins. Straight-Shot will help reduce cycle times and save on material. Gate-Mate minimises gate vestige and eliminates the witness lines commonly found on direct gated parts.

Full hot half systems If you need a custom hot runner system reflecting your unique gate locations, materials and other parameters and are looking for a proven standardized system for greater cost effectiveness, DME has total hot runner system solutions for every need.

• High cavitation (up to 96 cavities) • Economical choices for direct gating at high cavitation and low cost • Easy operation, user-friendly, reliability and affordability • Green’ moulding, offering the first system engineered to overcome the unique challenges of processing biodegradable, starch-based resins including polylactic acid (PLa).

• Quick delivery on up to 8-drop configurations DME provides an installation kit with all rails, plate work you need for a complete turnkey hot runner package, along with advanced temperature controls optimised for your hot runner system.

• FOR MORE INFORMATION ON DME’S RANGE OF HOT RUNNER SOLUTIONS, CONTACT RICHARD CARTER AT MOULD AND DIE SOLUTIONS ON TEL:021 555 2701, OR EMAIL INFO@M-D-S.CO.ZA

Single nozzles

Everything Hot Runners From single nozzles to fully assembled hot halves ... and everything in between Standard Series A series of products available in standard ranges, enabling the customer to configure and build a solution • Single Nozzles: off-the-shelf nozzles and tips for integration with moulds & components • Cool-One DIY: budget line of Do-It-Yourself projects for simple solutions with limited colour changes • Essentials: the essential range of manifolds and nozzles for up to 4-drop systems producing products for simple materials (PE, PP, PS) • Standard Systems: the solution for projects to be build using standard products from DME standard series

Custom Solutions Tailored, customer specific projects delivering high quality output • Advanced Hot Runner Custom Solutions: Turnkey solutions, starting from customer drawings, delivering full service • Cold Runner Custom Solutions: Turnkey solutions for silicone products

moulds & components runnerless solutions die sets Contact: Mould & Die Solutions surface finishing P.O. Box 669, Edgemead 7407, Cape Town, South Africa customized solutions Tel: 021 555 2701 | Fax: 021 555 2707 | info@m-d-s.co.za www.dmeeu.com

www.m-d-s.co.za

Super-tech yacht makes waves!

DESCRIBED by Boat International as ‘one of the world’s most amazing super yachts that could spell the future for efficient longrange cruising’, the striking 42.5m trimaran, Adastra, was launched during early April in China for Hong Kong clients.

University of Cape Town Electrical Engineering alumnus turned internationally renowned yacht designer John Shuttleworth, is the visionary behind the Adastra.

Shuttleworth explained that the challenge was to develop new thinking on stability and comfort at sea, while creating a yacht that would boast low fuel consumption while still providing excellent sea-keeping qualities and luxury.

Adastra’s 16 m beam creates a spacious saloon area on the main deck which offers superb views through a panoramic window and accommodates a lounge area, dining table and navigation station. A forward facing door through the saloon window gives easy access to a large sunbed on the foredeck.

The aft deck has a sofa and bar area to port and a dining area to starboard, further Naval Architecture, John Shuttleworth Yacht Designs Ltd, www.john-shuttleworth.com. Exterior Styling, John Shuttleworth Yacht Designs Ltd and Orion 28

JUNE / JULY 2012

aft of this there is space for a 4.9 m tender and directly below is a garage which can store a 3.1 m tender. Adastra offers comfortable accommodation for nine guests and up to six crew members. The main helm station, which has seating for two, is positioned in a raised pilot house situated between the aft deck and the saloon area and forms part of the cross beam structure.

Extensive structural analysis of all parts

Shuttleworth Design Ltd, www.orionshuttleworth.com.

Structural Design, John Shuttleworth Yacht Designs and Applied Structural Technologies Ltd,

of the yacht was carried out. Simulations of loadings from side slamming, wave impact, and torsional effects of the outrigger riding through waves, were all applied to the computer model.

The superstructure is manufactured from carbon fibre with Nomex honeycomb core, while the hull is glass/kevlar foam sandwich and the interior light weight oak cabinetry using honeycomb panels. To help reduce weight, virtually every aspect of the boat is custom built. This includes carbon fibre hatches, portlights, ladders and even hinges, which are all built specifically for the vessel.

www.asta-web.com. Interior Design, Jepsen Design, info@jepsendesigns.imsbiz.com.hk. Builders, McConaghy Boats, www.mcconaghyboats.com

PHOTOS COURTESY OF JOHN SHUTTLEWORTH YACHT DESIGNS LTD

INDUSTRY NEWS

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for future generations

The 7 million-strong population of Riyadh, 400km from the Persian Gulf in the middle of the Arabian Desert, relies on 30 giant desalination plants on the Persian Gulf and 3 700km of water pipelines to supply most of their drinking water. By 2016 there will be a further 10 desalination plants built and this will require further investments in water pipelines

E PIPE MANUFACTUR G ONE OF TOP CONVERTIN

SECTORS IN MIDDLE EAST

Four polymer plants capable of producing special PE 100+ grades have come on line in the last few years

BY DR NIALL MARSHALL

FEATURE

THE lifeblood of the Middle East is pumped through an extensive network of pipes: oil, gas and water are all vital to the survival of the people living in the region and all are transported thousands of kilometres through pipes.

The oldest pipes, going back a couple of thousand years, are clay. More recently, steel or cement was widely used, but most of the latest pipelines rely on state-of-theart polymers produced in the Middle East.

And, as pipes are not easy or cost effective to transport across vast distances, they are mostly manufactured locally, making this one of the most important converting industries in the region.

Steel pipes were widely used because of their well accepted properties – they are strong, tough and durable … except when they corrode and leak. They are easy to handle and install – except when you don’t want to dig a trench or have limited access to heavy equipment. The advantages of steel pipes are still important, but increasingly rely on epoxy or polymer coating for surface protection. In the case of the new 910km, 1.8m diameter pipeline from Ras al Khair to Riyadh, the steel pipe was coated with a three-layer polyethylene coating for surface protection.

Riyadh, the capital of Saudi Arabia, is 400km from the Persian Gulf in the middle of the Arabian Desert. Its population of over 7 million relies on 30 giant desalination plants on the Persian Gulf and 3700km of water pipelines to supply most of their drinking water. By 2016 there will be a further 10 desalination plants built and this will require 30 JUNE / JULY 2012

further investments in water pipelines. But it is not only getting the water to the cities that requires investment in pipe infrastructure: it’s also about the distribution of water in the cities.

The Middle East is a gigantic construction site: new cities being built to meet the needs of fast growing populations, the extravagant property developments and the refurbishment of old sections of many cities. Most Middle Eastern cities have old sections with no water pipelines, no sewerage system and no drainage. The newly installed infrastructure mostly uses plastic pipes, their advantages including resistance to corrosion, ease of installation and, most importantly, properly installed polyethylene water pipes don’t leak.

Leakage rates in the water-poor Gulf region are reported to be between 15-50%.

Riyadh alone reported more than 1500 pipe leakages in 2006 causing losses estimated at $37-million. Many existing steel or clay pipelines need to be replaced – and another advantage of polyethylene pipes is that they can be inserted inside existing pipes, avoiding the cost and inconvenience of digging up streets to lay new pipes.

All the benefits of polymer pipes rely on the polymer having the required strength and stability, on the pipe manufacturer producing a quality pipe and the pipes not being damaged and being properly welded during installation. There is an international classification system for polyethylene pipes based on a minimum required strength after 50 years.

For gas and water pressure pipes, there is in practice an additional safety factor used, so the strength needs to be even higher and design lifetimes of 100 years are generally required. Hence the latest

generation of polyethylene pipes, denoted as PE100+, use special grades of bimodal polyethylene which can only be produced using certain polymerization technologies and require special stabilization packages to last for more than 100 years.

Production volumes In the Middle East no less than four polymer plants capable of producing these special PE 100+ grades have come on line in the last few years. There are a number of sophisticated high quality pipe manufacturers producing single and multilayer polyethylene pipes of various diameters, meeting these demanding requirements. It is expected that there will be more than 500 000 tons of HDPE pipe produced per year in the Middle East by 2015.

Polyethylene is the most important polymer used to make pipes in the region, but PVC, polypropylene and fibre reinforced polyester (FRP) pipes are also produced in significant volumes.

The use of PVC pipes is limited by the volumes of PVC available (PVC is in fact imported into the region), but pipes remain the largest single use of PVC. Polypropylene pipes are used for sewerage applications and FRP pipes are also important, particularly for large diameter corrosion resistant and fire resistant pipes.

Plastic pipes are important to the Middle East and will remain so as long as the region relies on oil, gas and water for its existence.

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

SALES AND TECHNICAL STAFF VACANCIES CONTACT US NOW!

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GETTING IT RIGHT

The Competition Act and relationships with competitors

By Abena Danso, attorney in the Adams and Adams Competition Law Practice Group (abena@adamsadams.co.za)

LEGAL

Competition Tribunal does not tolerate cartel conduct OVER the past few years many South African companies who have colluded with competitors by agreeing how they will compete in the marketplace or by agreeing not to compete in some way to maximize profits, have felt the heavy hand of the competition authorities and had to pay administrative penalties of many millions of Rands.

The Competition Act provides for the imposition of an administrative penalty valued at a maximum of 10% of a company’s annual turnover in South Africa and its exports from South Africa during the company’s preceding financial year.

Section 4 of the Competition Act controls the interaction between competitors. Section 4 prohibits agreements or concerted practices by firms, or a decision by an association of firms that are in a horizontal relationship.

The prohibition is qualified and relates to agreements which substantially prevent or lessen competition in a market, unless the parties to the agreement can prove that there is a technological efficiency or other pro-competitive gain that will flow from (and which outweighs) the anticompetitive effect of the agreement or behaviour.

Section 4 strictly prohibits agreements which have directly or indirectly fix prices (prices include discounts, rebates, margins and any other trading conditions); dividing markets by allocating customers, suppliers, territories or specific types of goods and services; and collusive tendering.

It must be noted that there is no prescribed form for the prohibited agreement in terms of section 4 - all that is required is for there to be a meeting of the minds or understanding between competitors.

Examples of agreements (discussions) which individuals from competing firms should never engage in include: ü agree with any competitor about the price a customer will be charged; ü agree with a competitor about the territories where the respective firms will sell products; ü reach an agreement with a competitor about the clients which each firm will target; ü discuss with competitors the terms on

32

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which a firm is dealing with a particular customer, or plans to do so in the future; and ü discuss with a competitor whether or not a firm intends to participate in a tender or bidding process, or the terms on which it intends doing so.

Premier Foods applied for leniency indicating its willingness to co-operate with the Commission and furnish it with information A case in point about its role in the bread cartel and disclose The Competition Commission v Pioneer the nature of the cartel as well as the key Foods (Pty) Ltd: The bread cartel a case players. in point (see The Competition Commission Premier Foods disclosed to the Comand Pioneer Foods (Pty) Ltd Case No15/ mission that it, Tiger Brands and Pioneer CR/Feb2007 and 50/CR/May08) Foods had been operating a bread cartel in In 2006 the Competition Commission the Western Cape (and other parts of the received information of an alleged bread country) by fixing selling prices and other cartel operating in the Western Cape. The trade conditions and by dividing markets Commission initiated a complaint against and allocating territories. The Commission Premier Foods (the initiated a second producers of Blue complaint about the “Cartels, by their very Ribbon bread), Tiger cartel operating in the nature, eliminate or restrict Brands (the producers national sphere which competition. Companies of Albany bread) and involved additional Pioneer Foods (proparticipating in a cartel players who were not ducers of Sasko and party to the Western produce less and earn Duens breads). It was Cape cartel. high profits. Society and held by the Competition Tiger Brands consumers pay the bill.”

Tribunal that Pioneer approached the ComFoods, Premier Foods mission to negotiate a and Tiger Brands had contravened section consent order agreement and undertook an 4(1)(b)(i) of the Competition Act in that durinternal investigation which confirmed the ing December 2006 they agreed that: truthful of the allegation against them. The ü they would increase the discounted price Commission imposed a fine of R98 874 869 of toaster bread on 5 February 2007 to on Tiger Brand for its role in the cartel. realise R4.25 per loaf including tax; Pioneer Foods was ordered to pay an ü they would increase the price of the administrative penalty of 9.5% of Sasko’s standard loaf of bread by 35c per loaf 2006 bread turnover for the Western Cape from 18 December 2006; which amounted to R46 019 954. ü the dates by which the bread price inThe Competition Tribunal held in relation creases were to be implemented would to the national complaint which had been be staggered so as not to be implementinitiated by the Commission that Premier ed on the same date; Foods, Tiger Brands, Pioneer Foods and ü discounts by all three firms to agents Foodcorp had contravened section 4(1)(b)(i) in the Paarl area would be capped at and (ii) of the Competition Act in that: 90c and 75c for agents in the Cape ü during 1999 they concluded an agreePeninsula; ment, or engaged in a concerted practice ü none of the firms would supply new in terms of which they divided markets distributors; and amongst themselves in the South ü none of the firms would supply each Gauteng, Free State, North West and other’s former employees and none of Mpumalanga regions; between 2003 the firms would make bread deliveries and 2004 they – on 25 and 26 December 2006. ü fixed the selling price of bread and the dates by which the prices were to be During the course of the investigation implemented;

www.adamsadams.co.za

LEGAL About Adams & Adams Adams and Adams, a full service law firm and the largest Intellectual Property (IP) law firm in Africa, provides services for all aspects of Competition Law, including advisory opinions, mergers and acquisitions and litigation in South African and Africa. Adams & Adams also provides highly specialised dispute resolution services in a broad spectrum of

ü entered into a ‘gentleman’s agreement’ in terms of which they resolved that during the period of bread prices increases, they would not allow customers to switch suppliers to benefit from any differences in the prices provided by each supplier; ü agreed not to poach one another’s customers; ü during July 2006, Pioneer Foods, Premier Foods and Tiger Brands agreed to fix trading conditions in that they agreed not to compete on price in the Vanderbijlpark area; and ü during the last week of November 2006, Pioneer Foods, Premier Foods and Tiger Brands fixed the selling price of bread by agreeing to increase the price by 30c per loaf in Gauteng with effect from 18 December 2006.

Foodcorp, which was cited in the national complaint, also approached the Commission to negotiate a consent order agree-

practice areas with a focus on contractual and commercial litigation, personal injury and medical negligence claims, employment, administrative law, consumer protection, banking and insolvency.

Adams & Adams also contributes to a number of multi-jurisdictional publications concerning IP, pharmaceuticals and

ment and the Commission imposed a fine of R45 406 359.82 on Foodcorp for its involvement in the national bread cartel.

Pioneer was ordered to pay an administrative penalty of 10% of Sasko’s 2006 national bread turnover less that of the Western Cape which amounted to R149 689 660.

The total penalty imposed on Pioneer Foods for both complaints amounted to R195 718 614 which amount had to be paid within 20 days of the judgement.

Conclusion It is evident from the Competition Tribunal’s findings and the administrative penalties it imposed on Pioneer Foods, that cartel conduct will not be tolerated.

Mario Monti, a former member of the European Commission in charge of competition, said: “Cartels, by their very nature,

Competition Law and its members are regularly asked to speak at conferences and seminars on these topics. The firm currently services an extensive client database, which include innumerable national and international corporates, boasting many of South Africa’s leading entities and multiple Fortune 500 companies.

eliminate or restrict competition. Companies participating in a cartel produce less and earn high profits. Society and consumers pay the bill.”

Needless to say, firms should make sure that they implement competition compliance programmes to ensure that their employees do not engage in prohibited conduct. “I did not know it was illegal,” is not an acceptable excuse in the eyes of the Competition Authorities.

CONTACT US: JAC MARAIS / PARTNER: COMPETITION LAW PRACTICE GROUP JAC.MARAIS@ADAMSADAMS.COM ALEXIS APOSTOLIDIS / PARTNER: COMPETITION LAW PRACTICE GROUP ALEXIS.APOSTOLIDIS@ADAMSADAMS.COM www.adamsadams.co.za

JUNE / JULY 2012 33

ASSOCIATION NEWS

Plastics, health & environment Consumers view of packaging, cancer research create interest at Cape seminar process; THE Western Cape branch of PISA used • Dr Carl Albrecht of the Cancer Assoits comparative independence to good ciation of South Africa (CANSA), who effect recently when it hosted a seminar suggested that the effect of some of the on the complicated topic of ‘Health and the additives used in plastic products is still not Environment’. properly understood; Presentations by two speakers from • Annabé Pretorius of SAPRO/Plastix 911, outside of the industry, in the important who gave a report about the ‘greenwashpackaging and cancer research areas, were ing’ of plastic packaging; and counter-balanced with presentations by two industry proponents at the event at the Gar- • Delanie Bezuidenhout of the Southern African Vinyls Association (SAVA) who den Court Boulevard hotel in Cape Town on addressed some of the myths or concerns Thursday, 29 March. voiced in the media about PVC and what The invited guests could ostensibly have SAVA is doing in the process. been critical of plastics, but their presentaAlthough it wasn’t the intention for the tions in fact provided an opportunity for speakers’ views to clash, the exchange was delegates to observe what consumers see positive and profesin plastics packaging sionally handled. It also as well as what cancer Packaging that isn’t presented an opporresearchers regard proving effective will tunity for the ‘outside’ as risks presented almost certainly result in speakers to be updated by plastic packaging, on developments in the particularly regardcontract termination industry. ing additive use.

The fact that PISA is not funded by an Both speakers outlined trends, enabling industry levy, with membership restricted to delegates to consider possible strategies to private individuals, has resulted in it being adopt. neutral, which is unexpectedly becoming an Retailers see packaging as a prime advantage. means of selling products with the aim of maintaining and growing market share. In order to partner effectively with retailers, the Complaints about packaging packaging solution needs to achieve exactly ‘What concerns our customers when it that. Retailers will do whatever is necessary comes to Food Packaging?’ was the topic of to maintain their market share and image. In Kiril Dimitrov of Woolworths.

In short, the retailer receives a lot of comother words, packaging that isn’t proving effective will almost certainly result in contract plaints about packaging and one of Kiril’s observations is that it appears that most of termination.

The industry’s strategies were covered in the complainants “do not know that much about plastics”. presentations by SAPRO (SA Plastics ReOriginally from Ukraine, Kiril completed cyclers Organisation) and SAVA (Southern an honours degree in polymer engineering African Vinyls Association). as well as a masters degree in chemical engineering at the University of Pretoria.

The speakers included: He spent most of the early part of his career • Kiril Dimitrov, packaging innovation manager at Woolworths, gave a summary in the paper sector at Sappi, but has since of the impressions the retailer’s customers transferred skills learned to the general have of plastic packaging and posed some packaging sector, specifically food packaging. interesting questions to the industry in the

1

‘Greenwashing’ One of the industry’s unofficial comedians, Annabé Pretorius took to the floor and immediately pointed out that we need to be aware of the issues raised by the Woolworths speaker.

Director of the SA Plastics Recyclers

2

1. Guest speakers at the PISA seminar were from divergent sectors: Annabé Pretorius is director of the recyclers’ organisation SAPRO (and also runs the aptly named company Plastix 911); Kiril Dimitrov is a packaging technologist at Woolworths; Dr Carl Albrecht is head of research at the Cancer Association of SA (CANSA); and Delanie Bezuidenhout is director of the Southern African Vinyls Association (SAVA) 34

Woolworths receives 4600 phone calls a week on average – thankfully, not all the calls are complaints about packaging!

Plastic bottles and anything to do with BPA (Bisphenol A)* are the most common complaints. Many of the complaints border on bewildering, but the retailer’s staff always seek to field these tactfully. Although few of the complaints have a ‘scientific’ basis, Kiril and his team are monitoring trends and working with packaging suppliers to achieve a better outcome.

According to Kiril, what is ‘accepted wisdom’ is in many cases not backed by properly researched data from testing.

For example, they have been informed that dishes moulded in polypropylene are suitable for microwave use, but none of the packaging suppliers have supplied actual results from testing. This has led to the creeping suspicion that items such as ‘microwavable PP dishes’ may possibly not be completely safe for use.

Kiril is also concerned about the “small stuff” in packaging, namely the additives – and it’s possible that suppliers may be requested to supply appropriate research results for packaging items provided. Such data would obviously make it easier to deal with complaints.

According to Kiril, the criteria of the Woolies’ ‘Packaging Challenge’ include: • Safe food packaging with desired functionality; • Sourced from packaging suppliers that are in compliance with Woolworths policies; • Designed considering key environmental priorities; • At the lowest overall cost.

2. Members of the PISA national executive committee at the Cape seminar included national chairman Alain Berichon, national seminars coordinator Bob Bond and national secretary David Rule

– a complex synthesis Organisation (SAPRO), Annabé focused on the ‘interface’ between the packaging market and plastic recyclers. There’s a lot of smoke and mirrors in this area, with the chief greenwashing practise being that of making unsubstantiated claims, said Annabé. Examples include: • ‘Recyclable’ when the pack is a multi-layer structure which cannot be recycled; • ‘BPA-free’ when the pack never contained BPA; • ‘Biodegradable’ when even elementary testing has proven that the item does not biodegrade; • ‘Carbon neutral,’ which is virtually impossible to achieve or prove.

Whereas retailers may on occasion be unaware that claims cannot be proven, it does show that their chief objective is that of protecting market share.

Greenwashing is obviously misleading, and is quite possibly the result of consumer and regulator complacency, said Annabé. It also produces cynicism on the part of consumers, which is not a positive outcome for the industry either.

Claims to be environmentally friendly on packaging are fundamentally aimed at attracting consumer attention, leading up to the purchase of the item. One wonders whether the claims are added to packs by the packaging designers, without the complete approval of the pack’s manufacturer, or the recycler downstream.

Annabé’s presentation was lighthearted, but the point was clear: packaging manufacturers should be fully informed of the performance of products they supply and need to cooperate in this area with the retailers they supply.

‘Unpacking the myths about PVC Packaging’ Delanie Bezuidenhout, CEO of the Southern African Vinyls Association (SAVA), may have been suffering a flight of nerves before her presentation: two of her co-speakers on the evening had made their reservations about PVC clear, at least that’s what the build-up to the seminar appeared to suggest. But Delanie has not become SAVA’s spokesman without reason: now she is putting the PVC/vinyls

sector’s case forward clearly and enthusiastically.

This is probably the most suitable antidote for the criticism the business has encountered over the last decade and longer. There clearly are products which PVC is not suited for, but there are others where the material is clearly the best choice.

Delanie’s quest on the night was to take “each myth or concern voiced in the media regarding PVC as a packaging material and address it with scientific fact”.

She first outlined SAVA’s programme, embodied in its Product Stewardship Programme. Goals of the PSP include: • by 1 January 2013, recycle 99% of all waste produced by PVC resin manufacturers and 95% of all waste produced by primary convertors in the PVC industry; • by 31 June 2013, removal of mercury from manufacturing processes in all local and imported PVC polymer and chlorinated paraffin; removal of cadmium from additives and pigments used in PVC applications; • by 1 January 2015, complete phase-out of all lead-based stabilizers used in PVC products.

The programme is in fact significantly more far-reaching (space restrictions prevent us from listing all the goals).

Delanie obviously listed the advantages of PVC, notably that it is mainly constituted from chlorine (sourced from salt reserves) and the fact that it is one of the most versatile polymers. World consumption of PVC is still substantial, estimated at 32 millions tons in 2009.

The main good news of late is that the use of PVC in the construction sector has been approved by the Green Building Council, which is a very important step.

However, the chief concern remains the plasticisers employed. Used to make PVC products flexible, the main plasticisers used to date include phthalates and adipates such as DEHA (di-2ethyl hexyl adipate), which is used in cling film. The advantages of PVC cling film have seen it shrug off the

3

3. The organising sub-committee for the event included Martin Wells, Claire Gibson, Billy MacMillan and Nina Dimitru

4. Heather Peplow of Summit Publishing, which was the sole exhibitor, showed the company’s title ‘SA Plastics’ magazine at the seminar. About half the delegates were not PISA members, or even in the converting industry, so most of the publications disappeared quickly

challenges from numerous alternatives over the years, but the doubts over the plasticisers used has continued to dog the sector.

She contested claims made by the US Cancer Research Institute, which reported that lab experiments had shown that exposure to phthalates had caused cancer in rodents, and hence could pose a similar threat to humans. The PVC sector has said that the problems only became apparent when the rodents were force-fed large quantities of phthalates.

It added that the mechanism known as peroxisome proliferation takes place in rodents but not in humans and other primates.

However, the allegations have spread and the PVC sector has only more recently begun to counter such claims with research of its own.

Other myths that Delanie exposed include claims that there is no recycling of PVC in South Africa, which is not the case.

‘Polymers and additives: Their effect on the human body’ The keenly awaited presentation by Dr Carl Albrecht, head of research at the Cancer Association of South Africa (CANSA), did not disappoint.

A local doyen of the cancer research area in South Africa, Dr Albrecht was from 1976 a researcher and lecturer in chemotherapy at the Department of Pharmacology at the Stellenbosch University Medical School. In 1997 he became a freelance medical research consultant, mainly for CANSA. He has been head of research, fulltime, at CANSA since 2007.

CANSA is a Section 21 not-for-profit company that has been in operation since 1933. It assists approximately 30 000 cancer patients annually.

The facts about cancer in South Africa alone are not be ignored: about 100 000 new cases are diagnosed annually and

4

5

5. Popular uses for PVC include hard wearing floor tiles as well as plastic pipe, in which areas the material is considered to be the best option available. It’s in the areas of food contact that reservations about PVC remain 35

ASSOCIATION NEWS about 60 000 people die of the disease in this country each year. One-in-four males and 1:6 females contract cancer at some stage during their lives, so the percentage is high. In the USA itâ&#x20AC;&#x2122;s now estimated that 1:2 males will suffer from cancer (yes, thatâ&#x20AC;&#x2122;s every second male), which stat has caused local researchers to further suspect that changes in the contemporary environment and lifestyles are closely related to the problem.

The â&#x20AC;&#x2DC;topâ&#x20AC;&#x2122; cancers are prostate, lung, colorectal and oesophageal, breast and cervix. Prostate cancer and breast cancer

are the main causes for males and females respectively.

About 90% of cancers are caused by â&#x20AC;&#x2DC;environmentalâ&#x20AC;&#x2122; factors (as opposed to hereditary problems), including smoking (30%), viruses (20%), chemicals (20%), obesity (15%), alcohol (10%) and exposure to sunlight (5%).

Dr Albrecht summarised the â&#x20AC;&#x153;excellent anti-cancer systemsâ&#x20AC;? in SA, including the widespread vaccination against hepatitis (leading to virtual eradication of liver cancer) and top class anti-smoking legislation.

However, the prognosis is not good, with

Approximately 242 000 tons of plastic material was recycled in South Africa in 2010 (about 18% of the total quantity of plastic material consumed in the year) and a large percentage of that ďŹ gure â&#x20AC;&#x201C; 182 000 tons â&#x20AC;&#x201C; was from packaging recycled. One of the biggest challenges faced by recyclers is sorting, which as such where â&#x20AC;&#x2DC;greenwashingâ&#x20AC;&#x2122; claims are exposed. Some packs which make lofty environmental claims are not even recycled!

the main factors being increased urbanization and increased exposure to manmade chemicals.

Both natural chemicals (such as contaminated peanut butter) and manmade chemicals are under the spotlight.

There is growing concern among cancer researchers that plastics are involved in the aetiology (cause) of certain types of cancer. Polymers as such are regarded as safe, but it is monomers that are seen as potentially carcinogenic and plasticisers as potentially carcinogenic and hormone disrupting, said Dr Albrecht. The main concern is that the small molecules can migrate out of the polymer structure, especially when heated.

Proving the extent of the problem is, however, complex. For example, tests were conducted on polystyrene drinking cups for coffee and tea which showed that â&#x20AC;&#x201C; at 80ÂşC â&#x20AC;&#x201C; styrene and benzene were given off. To prove

PHOTO: ANNABĂ&#x2030; PRETORIUS

â&#x20AC;&#x2DC;Greenwashingâ&#x20AC;&#x2122; â&#x20AC;&#x201C; Claims that the reďŹ ll pack for this custard container are a positive environmental solution are hard to justify: the reďŹ ll cost more than the original pack (at the time of purchase earlier this year) and, besides, the reďŹ ll pack is produced in a multi-layer structure which is very difďŹ cult, even impossible, to recycle 36

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the veracity of the claims, however, the tests had to look into a number of aspects, such as different temperatures, length of exposure, type of milk used and so on.

Dr Albrecht said DEHA used in PVC cling film was a “highly mobile plasticizer,” which caused concern.

The main problem appears to be that molecules from the plasticizer or other additive migrate and effect genes in the unexpectant host. The effect on a single microscopic gene could be that of ‘switching on’ other genes and causing them to behave in an unnatural way, which could interfere with the body’s control of fat metabolism and be a possible cause for cancers.

Some 80 000 chemicals are known to be in existence, of which only a few have been tested. One which has been

tested of late, BPA, has given rise to concern. Exposure of rodents to BPA in experiments has shown that the additive could have a cognitive effect on them, and affect their sexual behaviour.

Female rats were shown to avoid males which had been exposed to BPA, for example.

“We face a great dilemma in creating new molecules,” said the CANSA researcher. “How can we expose the public to chemicals when we don’t know the full impact of these on living systems?”

CANSA is recommending that polymers not be heated close to food or drink because monomers and/or plasticisers can be released and migrate into the food and then into the human body with unforeseen consequences. www.cansa.org.za

NOTES * Bisphenol A (BPA) is an organic, colourless compound that is soluble in organic solvents, but poorly soluble in water. Having two phenol functional groups, it is used to make polycarbonate polymers and epoxy resins, along with other materials used to make plastics. BPA is controversial because it exerts weak, but detectable, hormone-like properties, raising concerns about its presence in consumer products and foods contained in such products. Starting in 2008, several governments questioned its safety, prompting some retailers to withdraw polycarbonate products.

A 2010 report from the United States Food and Drug Administration (FDA) raised concerns regarding exposure of fetuses, infants, and young children. In September 2010 Canada became the first country to declare BPA a toxic substance. In the European Union and Canada, BPA use is banned in baby bottles.

Vinyls at London Olympics – PVC has had an interesting interaction at the Olympics of late: during the planning of the Sydney Olympics in 2000, a ‘PVC minimisation clause’ was imposed which restricted the use of PVC and vinyl construction materials for the event. This placed the Australian PVC industry under great pressure, but led directly to the creation of the Australian Vinyls Council. The organisation succeeded in getting the Olympic event’s planners to reconsider the restriction; it has also been very successful in changing the image of PVC in that country. Delanie Bezuidenhout said SAVA has been liaising with the Aussie council regularly since its formation. Following that success as well as the positive outcome of the Vinyls 2010 programme (a European PVC industry Product Stewardship Programme), the perception of the use of PVC at the London Olympics has changed significantly: now they have a PVC policy in place that allows for the use of ‘Best Practice PVC’. Several of the temporary stadia for the midyear event are clad with a PVC façade. This allows for the structure to be removed subsequently. Disposal/re-use/recycling programmes are also in place, so there will be no white elephants left once the Olympics leave town!

JUNE / JULY 2012 37

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ASSOCIATION NEWS

CANSA and cling wrap – the debate continues CANSA recommend that plastic wrap manufacturers should not continue to use DEHA or DEHP plasticizers

BY DR CARL ALBRECHT, RESEARCH ADVOCATE AND CANCER RESEARCH SPECIALIST, CANCER ASSOCIATION OF SOUTH AFRICA (CANSA)

MILLIONS of South Africans eat food daily that has been wrapped in plastic film containing man-made plasticizer molecules which make the PVC plastic pliable and soft. It is a fact that these plasticizers can migrate into foods like fatty cheese and meat and that this migration is speeded up considerably in the microwave oven.

We are told these plasticizers are safe and we need not worry because they are approved by the FDA, IARC of the WHO as well as other agencies. Nevertheless, scientists have found that the plasticizers such as DEHP and to a lesser extent DEHA can cause liver cancer in mice and rats.

Recent laboratory experiments have also shown that plasticizers can disrupt key metabolic genes, such as PPAR-alpha and PPAR-gamma which are involved with the molecular basis of biochemical regulation related to obesity, diabetes, atherosclerosis and cancer.

It is also a fact that there are plastic wraps that do not contain plasticizers and are claimed to be safe and non-toxic.

The Cancer Association of South Africa (CANSA) considers plasticizers to be a potential carcinogenic threat to the South African population at large, especially because they act on major gene controlling proteins. CANSA wants to see safer plastic wraps used to reduce the risk of plasticizerinduced carcinogenesis as close to zero as possible.

Calculations have shown that implementation of such a cautionary measure would have a minimal effect on cost of items per day, i.e. in the order of a cent per item.

CANSA maintains that clear, plastic films used to wrap food should be free of soluble, low molecular weight plasticizers such as di-(2-ethylhexyl) adipate (DEHA) which can migrate into fatty food such as cheese or meat.

Food wraps should rather consist of materials that do not migrate into food and that have no proven connotation with cancer in any organism. Furthermore, plastic wraps should not contain molecules that disrupt cellular and molecular control mechanisms that are related to cancer and serious meta38

JUNE / JULY 2012

bolic pathologies such as obesity, diabetes and atherosclerosis.

Problems with plasticizers Plasticizers such as DEHP and DEHA are controversial because at high doses they have induced tumours in rodent livers and testes. Most of the studies have been conducted with DEHP because this was the first plasticizer to be used on a large scale.

During the past decade, however, DEHA has replaced DEHP - the reasons for this are not clear. Nevertheless DEHA is not inert and has been shown to induce liver cancers in rats and mice like DEHP, albeit at a higher concentration. DEHA has also been shown to stimulate the key metabolic regulating PPAR -alpha gene.

Numerous other effects have been reported in recent peer-reviewed literature, including: • Six times more DEPH was found in the blood of girls exhibiting precocious puberty

than normal girls • Inhibition of apoptosis which could contribute to the induction of cancer • Dysregulates 34% of 2400 genes analysed including down-regulation of FGD1 and PAFAH1B1 genes which are related to essential brain development • Abnormal fetal development • Decreased testosterone in workers exposed to high levels of DEPH Arguments for and against Many arguments exist for maintenance of the status quo. These include the fact that there is no data available on any reproductive and developmental effects; genetic effects; toxic effects or cancer in humans with either DEHP or DEHA, and despite 5 to 7 billion patient-days of acute exposure and 1 to 2 billion days of chronic exposure to DEPH-plasticized medical products over the last 40 years, none of the effects seen in rodents at high doses have been seen and

Scheme showing the multitude of genes influenced by PPAR-alpha

reported in humans.

Arguments for excluding DEHA from the market place include the fact that DEHA is not an inert chemical and should have no biological effect. It should simply soften plastic and be readily excreted by the body with no side-effects if it migrates into food. Nevertheless, it has biological effects at the sub-cellular level such as causing the proliferation of peroxisomes and cancerous transformation in the livers of mice and rats.

It should be a matter of concern that both DEHP and DEHA can stimulate the PPAR genes. The PPAR genes (alpha, beta and gamma) are major controlling genes which regulate the processes of lipid metabolism and cell proliferation and these genes are intimately involved in diabetes, atherosclerosis, obesity and cancer.

It is better to be safe than sorry and prevention is better than cure. The full impact of DEHA on gene function may take at least another decade to unravel because of the complexity of gene action. Proactive prevention may be the best option under these circumstances.

A solution to the problem There are cling wrap products on the market that do not contain plasticizers. An example of such a product is Glad Wrap. A recent investigation of retail prices showed that Glad Wrap

was 80% more expensive compared to the cheapest DEHA-containing cling wrap.

However, in terms of wrapping a 350 g piece of cheese costing about R16, the extra cost involved in using Glad Wrap rather than a DEHA-containing cling wrap would be about one cent. It is conceivable that there are many more substitute food wraps not containing DEHA. It is proposed that even in the absence of currently proven pathological effects of DEHA and DEHP in humans, it is not prudent to continue to use DEHA or DEHP plasticizers because of signiďŹ cant theoretical risks for humans that may be found to be

real in the future.

Furthermore, because CANSA and industry have a great responsibility to the general unsuspecting public who expect bought food to be safe, it is proposed as a cautionary measure, that safer foodwraps are used in the future, even if this involves a higher cost which is relatively negligible compared to the cost of the high fat-protein food items involved.

(FOR THE FULL TEXT OF THIS PAPER, EMAIL DR CARL ALBRECHT AT CALBREC@IAFRICA.COM)

JUNE / JULY 2012

39

ASSOCIATION NEWS

Understanding pipe design

SAPPMA’s guest speaker, Vollie Brink, flanked

by Martine Goodchild (DPI marketing manager) and SAPPMA’s Louise Muller

of the pipe manufacturing industry, some from as far afield as Zimbabwe, and a smattering of consulting engineers.

Vollie covered diverse areas of pipe design from the points of view of the engineer, the contractor and the pipe manufacturer. His experience was evident in the ease with which he delivered valuable information with humour and knowledge.

Topics covered included understanding engineering design, selecting pipe materials, risk factors and how to manage them, quality assurance, institutional requirements and ‘green’ design, as well as building capacity for a sustainable future in design, construction, manufacturing and water efficiency.

repair without specialised tools; • A high level of expertise in terms of joining pipe and installation thereof; • Clear description of the pressure ratings of the pipes and the fluids it can handle; • Suitable technical support and quality of support from the manufacturer; • Delivery of piping and fittings on schedule; • QA support on site and honest reports and a guarantee that is worth the paper it’s written on!

• A representative that is part of the ‘team’ • A reliable, honest manufacturer that will solve any problems with the product; Construction & design engineering Discussing the risk factors related to ‘wet services’, Vollie explained that it was important to understand what is meant by ‘design engineering’ and ‘construction engineering’.

Wet services include sanitary drainage, rain and storm water drainage, domestic hot and cold water, hot water generation by electricity, solar, heat pump or gas and pump systems.

SAPPMA members and guests were recently afforded an excellent opportunity to gear up on their pipe design knowledge when consulting engineer Vollie Brink presented a brilliant full-day seminar in Cape Town.

The seminar was generously sponsored

by DPI Plastics and attended by members

What the engineer and contractor want from the pipe representative?

• Quality and a pipe that will last a minimum of 25 years without problems; • A pipe system that is suitable for application, is leak-free and suitable for working pressures; • A pipe system that is easy to maintain and

PIPE Conference in September!

SAPPMA donates bend tester for training at Plastics|SA

SAPPMA’S 6th annual conference will take place on 18 September at the Bytes Conference Centre in Midrand. This year’s Pipe VI Conference will focus on the importance of pipes in water distribution and will attempt to help design engineers and specifiers to make an informed decision when selecting material and products.

Dr Anthony Turton, an independent consultant and previously associated with the CSIR and the University of the Orange Free State, has been invited as keynote speaker.

Individuals interested in presenting papers at the conference are invited to submit their particulars and abstracts to Louise Muller at admin@Sappma.co.za before 30 June. Early bird offer to delegates: R750.00 for SAPPMA members and R1 500.00 for nonmembers for all bookings before 31 July. More information and electronic registration forms available on the SAPPMA website on

www.sappma.co.za 40

JUNE / JULY 2012

THE Installation and Fabrication Plastics Pipe Association (IFPA) and its parent body, the Southern African Plastic Pipe Manufacturer’s Association (SAPPMA), has made a bend testing machine available for training and testing purposes at the Plastics|SA Head Office in Midrand.

Bend testing is a quick and effective way of determining the quality of fusion of butt welds and was developed in Germany.

According to Jan Venter, CEO of SAPPMA, the bend testing machine is used for quality assurance of butt welds done by contractors,

IFPA and its parent body SAPPMA, recently made a bend testing machine available for training and testing purposes at the Plastics|SA Head Office in Midrand

as well as those done during training sessions hosted by Plastics|SA. “We have identified that a huge need exists for experienced butt welders in the plastics industry,” Venter said, who explained that a well-engineered pipe system is dependent on good design, high pipe quality as well as minimum standards at the downstream end, which includes looking at the quality of fabricated fittings and pipeline installation.

“SAPPMA realized what tremendous benefit it would unlock for the plastic pipe industry if we were to make a bend tester available that could practically test and judge the quality of butt welding on pipes manufactured from HDPE and PVC. Not only does Plastics|SA offer practical, handson training on the bend tester for their students, but they also make an operator available should any of our members wish to perform their own tests”, Venter added.

“The plastic piping business is a strategic industry and hardware needs to be reliable for extended periods of time. Long term product and installation quality is therefore fundamental. By making this investment into the future of the plastic pipe industry, we are confident that we will see a marked improvement in the quality of butt welds and therefore in pipe installations in general in the next months to come,” said Venter.

Johan Fouché and André Swart from Marley

Morne van der Merwe and Andrew Patience of Alprene

Engineering design of wet services has to be executed in compliance with specific institutional requirements, such as. SANS regulations and standards, SABS standards (not compulsory but voluntary), local bylaws including water services regulations, model water services bylaws and local water services bylaws.

Vollie pointed out that water services bylaws provide no guarantee of water actually being provided, or of the water pressure that will be applied, or the quality of the water.

The basis of engineering design is not one of mathematical calculations, rather one of assumption, degree of comfort and cost.

Risk factors The most critical elements of wet services include the selection of the pipe material, its suitability for the application, life of the pipe

Adrian Coetzee (WorleyParsons), Pieter Straiter (DPI Plastics) and guest speak Vollie Brink

system and its compatibility with the water quality or effluent.

Other important elements to consider include jointing, fixing, supports, anchoring, expansion, laying, testing, sterilisation, quality assurance, compatibility of the inner and outer diameters.

Vollie emphasised the importance of quality control: “This is the single most critical risk factor causing failure. QA is often regarded as an unnecessary extra cost and is therefore not budgeted for.

What happens then is that the engineer does the inspections at his own cost.”

The role of the pipe manufacturer’s representative in the QA process is crucial and should include inspections, advising the plumber, ensuring compliance with the manufacturer’s requirements and being able to issue a guarantee certificate on

completion of the project.

“It is vital that the manufacturers and users work together to build capacity for a sustainable future in design and construction competency, quality assurance capacity and awareness of the risk factors,” Vollie concluded.

Southern African Plastic Pipe Manufacturers Association (SAPPMA) Director Jan Venter p. 012 548 0149 c. 079 506 0484 e. janventer@3gi.co.za

SAPPMA partners 70% of the way to eliminating lead from all plastic pipes DPI Plastics is playing a major role together with its SAPPMA partners in entirely eliminating lead from all locallymanufactured plastic pipes.

SAPPMA successfully eliminated all lead stabilisers from members’ piping products in 2010 – five years ahead of the anticipated European Union (EU) targets.

Following this unprecedented success, SAPPMA and its members are now driving forward an initiative with the South African Bureau of Standards (SABS) to exclude lead stabilisers from all future SABS specifications.

DPI Plastics product manager, Renier Snyman said that an estimated 70% of plastic pipe manufacturers in South Africa have eliminated lead stabilisers from their products, replacing it entirely with calcium/zinc and organic-based stabilisers, resulting in a rise in demand, and consequent decrease in price, for alternative stabilisers. SAPPMA members have been in talks with the SABS since January 2012, and Snyman is optimistic that lead stabilisers will be completely eliminated from all SABS specifications within a matter of years.

The seminar even attracted delegates from Proplastics of Harare, Zimbabwe: Charity Zvokuomba (sales and marketing director), Netsai Chimombe and Nixon Matinika

Secretary Louise Muller p. 012 548 0149 c. 082 417 2977 e. admin@sappma.co.za

www.sappma.co.za

JUNE / JULY 2012

41

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ASSOCIATION NEWS

Enjoy the great outdoors!

New advertising campaign focuses on plastics in sport and leisure PLASTICS|SA’s new advertising campaign is as striking as it is informative; appealing to the South African public’s love of the outdoors.

“Plastics make our everyday lives possible – whether driving our cars, working in an office or climbing the next big mountain.

Without plastics, life as we know it would be virtually impossible,” said Douw Steyn, Sustainability Director for Plastics|SA and an avid outdoorsman in his own right.

“Take hiking boots for example: the lining and tongue can be made from a loosely woven polyester fabric that repels water and allows moisture to rapidly evaporate from the boot’s exterior, keeping the hiker’s feet dry in the wet and cool in the heat. For comfort and support, the mid-sole can be made from ethyl vinyl acetate (EVA), which provides lightweight cushioning. Polyester foam padding, on the other hand, provides extra comfort on the insoles,” Steyn explained. “Similarly, running shoes that weigh just a few grams yet provide the strength, support and suppleness that athletes demand as they power out of the running blocks, can make the difference between victory and defeat”.

In other sporting applications, carbon fibre composites are used for rowing skiffs; polypropylene and elastomer for masks and snorkels for underwater swimmers and divers and nylon runners for in-line skates; www.plasticsinfo.co.za

ABS protective helmets for footballers or space age composites for racing bicycles.

“However, wearing it or using plastics is only one side of the coin”, Steyn explained. “The sporting fraternity realises the impact of plastics on their lives and recreational activities. We need to spread the message that we all need to be responsible plastics users. We need to clean-up and recycle plastic products”.

Three of the four new Plastics|SA adverts – all dealing with an aspect of sport & leisure

Campaigning against plastic litter Sustainability and protecting the environment is one of the core functions of Plastics|SA and the organisation’s Clean-Up and Recycle theme for 2012 is Berg-2Beach.

“In partnership with SASOL, WESSA and the various polymer organisations within the plastics industry, we want to encourage all South Africans to help keep South Africa clean, from the mountains to the oceans,” said Steyn.

According to Steyn, this campaign will culminate in the annual Clean-Up South Africa month which takes place in September each year. During this month Plastics|SA

www.mywaste.co.za

encourages schools, clubs, businesses and the general public to clean-up and recycle where they live, play and work by initiating clean-up drives or participating in the annual International Coastal CleanUp Day on 15 September 2012.

“From now until the end of September, we are making a strong appeal to everybody using and enjoying the great outdoors – whether you are a mountaineer, hiker, canoeist, or part of the fishing and diving fraternity - to adopt a spot where you can help reduce the amount of plastic litter found in the environment through initiating a clean-up effort. Whilst the use of plastic products makes a positive contribution to our lives and wellbeing, we need to remember that plastics do not litter, people do!” Steyn added.

www.cleanup-SA.co.za/recyclingday-SA.co.za

New trainer for Plastics|SA Plastics|SA has appointed Andrew Murray as the new technical trainer for the Western and Eastern Cape regions with effect from 1 May. Andrew began his career in the plastics industry thanks to a bursary from Megapak which allowed him to complete his National Diploma in Polymer Technology at Technikon Pretoria.

His professional career started at Megapak in 1991 when he was appointed as the technical assistant to the divisional technical manager. He relocated to KZN in 1995 to become the production superintendent of injection and extrusion blowmoulding and was promoted through the ranks to become the divisional technical manager for Megapak.

“After more than 18 years I moved to Cape Town and joined the Hestico team as part of technical sales before venturing into 42

JUNE / JULY 2012

know-how to learners, in order to see the consulting to the plastics industry”, Andrew industry grow and flourish”, he said, adding said. that he is also looking forward to meeting Andrew said he was very excited about customers face-to-face as soon his new career at Plastics|SA as his induction period has and believed his years of been completed. practical experience gained Andrew is happily married to in the industry will stand him Carol, a teacher, and they are in good stead as he takes the proud parents of two boys, responsibility for training and Shaun and Cameron, aged 12 mentoring the plastics indusand 15. He loves spending time try’s leaders of tomorrow. with friends and family around “I have had the opportuthe braai and proudly admits nity to travel overseas and Andrew Murray, new that he is a faithful and avid to observe and compare technical trainer for Lions Rugby supporter after international best practices Plastics/SA Western and Eastern Cape regions spending 27 years in Gauteng. with what we’re doing in He also enjoys playing tennis, South Africa. I feel privileged to be part of a team that is passionate about squash and golf - “in fact, anything that involves chasing after a ball”, Andrew admits. imparting world class training and technical

ASSOCIATION NEWS

Let’s talk labour relations & conditions of employment

Executive Director Johan Pieterse p. 011 314 0019 c. 082 904 8274 johan@pcasa.co.za Regional Manager (KZN/E Cape) Garth Taylor c. 084 924 4551 garth@pcasa.co.za

PCA seminar outlines amendments and implications for employers LABOUR relations and basic conditions of employment were the order of the day at recent training seminars held around the country by the Plastics Convertors Association of SA (PCA).

The PCA’s chief executive officer, Johan Pieterse, explained that the seminars were part of the PCA’s commitment in preparing to make submissions on the proposed amendments to the Labour Relations Act (LRA) and Basic Conditions of Employment Act (BCEA). These two statutes, which form the cornerstone of South Africa’s labour legislation, have not been amended since 2002.

He said the seminars were designed to help members and employers fully understand the implications the changes to the LRA and BCEA would bring about, and how to manage these.

Discussing the BCEA, Jeanne-Marie Retief of NEASA (National Employers Association of South Africa) said that the most significant amendments proposed to the BCEA are to bring the provisions regulating child labour in line with international standards and to improve the mechanisms for enforcement of basic conditions of employment, including minimum wages.

Johan said that the changes proposed to both Acts would come into effect early next year once some Codes of Good Practice were clarified.

The proposed amendments to the Acts can be grouped as follows:

Plastics Convertors Association

Western Cape Andy van Tonder c. 084 543 1430 andy@pcasa.co.za Executive Officer Mike Bullock c. 082 888 9686 mikeb@pcsa.co.za www.pcasa.co.za

The PCA’s chief executive officer, Johan Pieterse, with Jeanne-Marie Retief of NEASA

1. responses to the increased informalisation of labour to ensure that vulnerable categories of workers receive adequate protection and are employed in conditions of decent work; 2. adjustments to the law to ensure compliance with South Africa’s obligations in terms of international labour standards; 3. ensuring that labour legislation gives effect to fundamental constitutional rights, including the right to fair labour practices, to engage in collective bargaining and right to equality and protection from discrimination; 4. enhancing the effectiveness of the primary labour market institutions such as the Labour Court, the CCMA, the Essential Services Committee and the

labour inspectorate; 5. rectifying anomalies and clarifying uncertainties that have arisen from the interpretation and application of these two statutes in the past decade.

FOR A COPY OF THE TWO AMENDMENT BILLS AND THEIR MEMORANDUMS, CALL CAROL KLOMFASS AT PCA TEL: 011 314 0019.

PET recycling on the move PETCO has sponsored Remade Recycling 10 x 28m³ bins to increase the collection of PET. The handover of the branded bins took place on the 11 March in Alberton.

“We are always looking for ways to increase the collection of clean PET for recycling and are delighted to be supporting Remade in their efforts” said Belinda Booker, PETCO. Remade, an associate member of PETCO, currently collects recyclables in Gauteng, Nelspruit, Hazyview and the Southern Cape Region. “We aim to continuously grow the volume of all recyclable material and keep the environment clean

while creating income opportunities,” said Director of Remade, Bryce Blum.

PETCO also supports projects with a strong focus on public and consumer based education and awareness programmes and these initiatives and activities contribute to the visible recycling of PET. Many of these programmes, such as beach clean-ups, trade shows, bailing equipment, bulk bag collection and training are initiated together with support from PlasticsISA. Workshops for members, on topics such as designing PET bottles and containers with recycling in mind to reduce contamination, are hosted by PETCO around South Africa. www.petco.co.za

44

JUNE / JULY 2012

Marius Basson, Financial Manager with J&J Fabrications (who made the bins) and Sean Connoway, Group Financial Manager of Remade Recycling look on while Bryce Blum, Director of Remade Recycling thanks PETCO’s Belinda Booker for sponsoring the 10 recycling bins

www.remade.co.za

Clariant Southern Africa (Pty) Ltd 329 Tungsten Road, Strydom Park Randburg. RSA Tel: +27 11 (0) 796 3400 www.clariant.com

ASSOCIATION NEWS

Plans to use recycled EPS

in low-cost housing Recycled EPS provided insulation, diverts product away from landfills TWO of South Africa’s most pressing needs – sustainable, low-cost housing and the need to divert recyclable materials away from the country’s landfills – have found an unlikely common solution in recycled expanded polystyrene (EPS).

Until recently the Polystyrene Packaging Council (PSPC) has been struggling to develop markets for used, post-consumer polystyrene.

“One of the biggest headaches we faced when talking to recycling companies and converters, was the need to wash and dry the contaminated polystyrene,” explained PSPC director Adri Spangenberg.

“However, the high cost of electricity and water in our country did not make it a viable financial option for smaller recycling plants to invest in infrastructure that would mechanise this entire process, resulting in much of the used polystyrene either being sent to landfills or exported to countries such as China and India for recycling,” she added.

Thanks to recently concluded research, design and development by Tower Technologies at the CSIR, the first series of

The first series of demonstration homes – the size of the standard threebedroomed house being built is 26m2 and weighs 1.6 tons.

It contains 5% EPS regrind (which equates to 75kg), thoroughly mixed with concrete to form walls that are almost indestructible

demonstration homes have already been built and undergone extensive testing, yielding positive results all around. The size of the standard three-bedroomed house being built is 26m2 and weighs 1.6 tons. It contains 5% EPS regrind (which equates to 75kg), thoroughly mixed with concrete to form walls that are almost indestructible.

“As a result of the breakthrough technology and applications developed by Tower Technologies, we will be in a position to harness the fantastic insulation properties

and other characteristics that make polystyrene unique low cost housing construction projects. Thanks to the fact that there is a readily available stream of used EPS in our country, we are able to provide more than enough material for the pilot phase of this initiative which will see low-cost homes being built around the country,” said Spangenberg. www.polystyrenepackaging.co.za

Entries now open for SAPRO ‘Best Recycled Product’ competition THE South African Plastics Recycling Organisation (SAPRO) has opened entries for its third annual “Best Recycled Plastics Product of the Year” Competition, hosted in collaboration with Plastics|SA. SAPRO Chairman, Douglas Greig, said the winners of the 2012 competition will be announced at a gala dinner which will form one of the highlights of the plastic industry’s national Clean-Up South Africa Week, on 13 September.

“This competition has grown in leaps and bounds since we introduced the awards for the first time three years ago. We are purposefully aiming to create what has been called the ‘Oscars of the Plastics Recycling Industry’ as we acknowledge products that are made from post-consum-

er recycled materials and encourage brand owners and industrial designers to consider recycled plastics as a material of choice”, Greig explained.

The organisers are inviting submissions in four product categories: 1) Products made from 100% recyclate 2) Product containing a certain percentage of post-consumer recycled content 3) Products made from a mixture of postconsumer recycled materials 4) Novel or artistic articles made from recycled plastic A panel of plastics experts will be judging entries based on the following criteria: • Life expectancy of product • Sustainability, long-term demand and market acceptance for product (i.e. will it still sell in 5 years’ time?)

• Tonnage (potential tonnages) diverted from landfills and converted into a product replacement of alternative materials • Technical achievements in manufacturing excellence to overcome recycled material challenges • Measures taken to ensure product consis-

Last year’s overall winner and recipient of the PACSA Trophy for the Best Recycled ‘Product of the Year’ was Polypet’s entry of a 1.5-litre cooldrink bottle manufactured for Woolworths 46

tency and customer satisfaction despite recycled material content “Although various weighting could be used to judge products objectively, we are overall looking for products that will help us focus attention on the quality of products and innovation that we have come to associate with the local plastics recycling industry,” Greig said.

Any company in the SADC region may enter, provided that the recycled material originated in South Africa. Products that were entered in previous years but did not win, can also enter again.

Entry forms, rules and competition information can be obtained from the SAPRO website (www.sapro.biz), the Plastics|SA website (www.plasticsinfo.co.za) or can be requested from the organisers directly by emailing: Annabe@absamail.co.za The closing date for entries is Friday, 24 August.

• Entry forms can also be found in this issue of the magazine. www.sapro.biz

where quality is action

A-PET

ASSOCIATION NEWS

Cost effective training for rubber sector is an option for all ONE of the stalwarts of the rubber industry, Dr Dave Duncan, gave a presentation on the topic ‘Cost Effective Education and Training in the Rubber Industry – an option for all’ at the IOM³ KZN branch’s annual general meeting at the Westville Country Club on 15 March.

Dave, who has retired from ‘active service’ as such but continues to make a contribution in the area of training and skills development, explained how the BEE/ education structure that the IOM³ Education Fund Committee has been working on for the past two years has progressed.

TPE’s lecture from Carst & Walker There was a somewhat festive atmosphere at the lecture on thermoplastic elastomers given by Dr Kathy Garde to a meeting of the PISA KZN branch on 8 May. Who knows why?

Maybe Kathy’s very entertaining, and besides that she’s one of the top authorities on TPEs in South Africa. Those in attendance, some 35, left well informed, and judging by her easy manner in answering questions from the floor, Kathy got her message across to the audience. KZN branch wishes to thank Carst and Walker for sponsoring the evening.

C&W supplies a range of TPEs, including ‘Dynaprene’ (a PP/EPDM-type) from Nantex, and ‘Taipol’ (styrenic block copolymer, SBS, SEBS) and ‘T-Blend’ (a styrenic TPR – i.e. PP/ SBS and PP/SEBS blend) from TSRC.

48

During the interesting presentation, Dave pointed out particularly that the industry needs to build and restore the technical expertise required in such a specialized sector.

Elections took place prior to the lecture, with Jaco Smith of Carst & Walker being elected chairman. Also elected on to the committee were André Cornelius (Orchem Trading), Des Royappen (Aberdare Cables) and Crighton du Preez (Anchor Chemicals).

Thanks are due to the sponsors for the evening, who were, West African Group and its principal Centrotrade.

New chairman – Jaco Smit of Carst & Walker was elected chairman of the IOM³ KZN branch in March

Dave Duncan outlined plans to improve training for the industry … although he wasn’t actually wearing a bowtie on the night

PISA dates to remember ü PISA Northern branch will host a Golf Day on 21 September at Blue Valley Golf and Country Club, Midrand. Members will be provided with more info nearer the time. If you have any queries, contact Lowrie Sharp, tel: 011 793 4691 or lowrieplasticsmedia@ absamail.co.za; Horst Seute, tel: 083 676 0278, or Elmarie Botha at elmarie.botha@plasticssa.co.za ü The National PISA AGM takes place in Gauteng on 19 July at the Plastics|SA premises.

PISA subs now R400 THE annual subscription for PISA has been increased to R400. The subs had been R375 for a number of years. All members will have received a subs renewal invoice during May and, if you wish to continue your membership of the Institute, the best option is to make payment at once.

JUNE / JULY 2012

#/34 #/-0%4)4)6% /. ',/"!, 3#!,% s 0RESS TOOLS s #OMPONENT PRODUCTION SUPPLY s $EEP DRAWING TOOLS s 4HIN WALL HIGH PRECISION THROUGH HARDENED MOULDS s 3ILICONE MOULDS

#/.4!#4 53 /Fl CE +27 (0)31 765 5720 #HINA -OBILE 0086 151 685 69018 -OBILE +27 (0)82 821 4775 %MAIL brian.miraclemould@gmail.com

IOMÂł conference in Cape St Francis in March 2013 21st edition of national rubber conference THE Institute of Materialsâ&#x20AC;&#x2122; national rubber conference â&#x20AC;&#x201C; the 21st edition of this highlight of the regional rubber industry calendar â&#x20AC;&#x201C; is to be held in March 2013 at at the Cape St Francis Resort & Conference Centre, located in the quiet village of Cape St Francis, one hourâ&#x20AC;&#x2122;s drive from Port Elizabeth, in the Eastern Cape.

The conference has proved successful and enduring over the close to half-century that theyâ&#x20AC;&#x2122;ve been held, which in itself is an impressive achievement again by the IOMÂł personnel â&#x20AC;&#x201C; bearing in mind that

most of the preparation work is done on a voluntary basis.

A call for papers has been issued, and if you have any technical queries about that, contact Coen Burger, the conference chairman, on 082 456 6656 or at coenburger@axxess.co.za.

For all other enquiries, contact Wendy Knott Craig of the PR Junction on 041 360 4415 or at wknottcraig@vodamail.co.za.

For more information about the resort, visit www.capestfrancis.co.za

Institute of Materials: Southern Africa Region National Chairman Hans Strydom p. 011 425 3241 c. 082 449 5920 hans@rubbernano.co.za Eastern Cape Coen Burger c. 082 456 6656 coenburger@axxess.co.za

KwaZulu-Natal Jaco Smith c. 082 808 4703 jaco.smith@carst.co.za Northern Spike Taylor p. 011 928 4172 c. 082 456 5734 spiket@multotec.co.za

Secretary Diane van Rooyen p. 041 486 1505 diane@snrubber.co.za

www.iom3.org www.iom3.co.za

Complex additives, liquid dosing technology topics summarised Shaun Bouwer of Performance Colour Systems and Peter Rappard of BASF ďŹ&#x201A;ank PISA Northern chairman Pixley Makhubo following their presentations at Plastics|SA in Midrand in April. Peter gave an outline of BASFâ&#x20AC;&#x2122;s vast range of additives, many of which originated from Ciba group â&#x20AC;&#x201C; which BASF purchased in 2011. Peter in fact worked for Ciba before, and has become one of SAâ&#x20AC;&#x2122;s top plastic additive experts. Shaun summarised PCSâ&#x20AC;&#x2122;s liquid dosing technology, which presents several advantages, including quicker colour changeover, reduced need for stockholding, and lower addition rates. Combining the presentations as a â&#x20AC;&#x2DC;double headerâ&#x20AC;&#x2122; probably did both speakers an injustice, as their topics were vast and complex, but both Peter and Shaun were happy to answer questions and engage with converters in the following â&#x20AC;&#x2DC;happy hourâ&#x20AC;&#x2122;. Thanks are due to BASF and PCS for sponsoring the function.

Plastics Institute of Southern Africa National Chairman Alain Berichon p. 031 461 2990 c. 082 888 2429 e. alain@neupack.co.za

National Vice-Chairman Martin Wells p. 021 712 1408 c. 082 822 8115 e. martin@summitpub.co.za

www.pisa.org.za

National Secretary David Rule p. 011 452 6940 c. 082 552 0726 e. david@plasticolors.co.za

KwaZulu-Natal Garth Taylor c. 084 924 4551 e. garth@pcasa.co.za

Northern Pixley Makhubo p. 011 458 0719 c. 083 628 5215 e. pixley.makhubo@sasol.com

Western Cape Billy MacMillan c. 082 453 7070 e. billy@superthene.com

JUNE / JULY 2012

%80%2)%.#% s &,%8)"),)49 s 30%%$ s !UTOMOTIVE MOULDS s -EDICAL COMPONENT MOULDS s YEARS EXPERIENCE s )3/ CERTIl ED TOOL ROOM s (OUSEWARE MOULDS s 0 % 4 PREFORM MOULDS BLOW MOULDS s )3/ CERTIl ED INJECTION MOULDING AND TESTING FACILITY s /PTIMISED FAST CYCLING MOULDS s #OST EFFECTIVE s 2APID PROTOTYPING AND #.# PROTOTYPE MANUFACTURE s &INITE ELEMENT STUDIES UNDERTAKEN

350%2 15!,) )/2 49

49

PEOPLE

ON THE MOVE

Vic puts half-century of experience to good use at design college There’s no substitute for hands-on experience

Performance Colour Systems has made a number of new appointments to consolidate its drive to be world class competitive.

Lurika Joubert, who has been with Performance group for the last five years in a predominantly HR function, has been promoted to sales and marketing manager with effect from May. Due to growth shown by the business an opportunity to join the commercial team came about and Lurika grabbed it with both hands. Her new role is both exciting and one that allows use of her marketing background Shannon van der Merwe joined the Performance team in January as technical manager for the Johannesburg operation.

Shannon has an extensive background in chemistry and has fitted in well with the accountability culture that is developing within the Performance stable.

Shannon takes over from technical director Riccardo di Blasio who now also takes on the branch manager responsibility for the Performance plant in Cape Town and relocated.

Riccardo and his family relocated during April to take up the challenge of maintaining the growth numbers seen from Cape Town in the last 18 months.

Ronita Stroebel joined the internal sales team in March and has been a welcome addition. Ronita has worked in the plastics industry since the 1990s.

Ronita takes over from Thabang Lechalaba who has been promoted to an internal sales position in Cape Town.

AFTER an incredible 52 years in the plastics business, Vic Beaumont retired from M&S Plastics last year and found, surprisingly, that he had quite a bit left in the tank. Still energetic, and with halfa-century of experience, he decided to continue operating as a consultant.

Then, unexpectedly, an opportunity came up to work part-time as a lecturer at the CAE Group private design college in Edenvale, Johannesburg. He initially gave a 3-hour lecture on plastics materials and applications, which seemed to go down well. Shortly thereafter the college management decided to incorporate a module on plastics as a subject in the syllabus, and Vic was invited to lecture in both plastics and engineering.

The main focus at the CAE Group college is CAD draughting (using AutoCAD and Inventor programmes), including standard projection drawing and 3D modeling. With the emphasis on design, and plastics being one of the materials most exploited in contemporary design, there was an obvious need for the

Vic Beaumont is imparting knowledge and know-how gained during over half-a-century in the industry to students at a design college in Johannesburg

students to learn more about the industry, so Vic was in the right place at the right time.

Two 20-week courses are presented a year, from February to June and July to November.

• CAE COLLEGE CAN BE CONTACTED AT TEL: 011 452 6233 OR VISIT WWW.CAEGROUP.CO.ZA

Carried away on bucket list Bucket list – Stephen Mountain, former MD of the Chemserve company Plastamid, is working on his ‘bucket list,’ one item of which literally got him carried away. On board the USS Carl Vinson, a nuclear powered aircraft carrier in the Pacific on a 5-day trip from Hawaii to San Diego, Mountain participated in deck drills such as observing ‘launches and recoveries’ (take offs and landings), simulated drills for aircraft fires and ‘crash’ recoveries. Oh, and he also ‘played’ golf on a rest day on the 4.5 acre deck.

Orion Engineered Carbons’ golf day

Plastomark th 5 Major

ORION Engineered Carbons hosted its customer golf day, followed by an evening function, at the Ebotse Golf Club, Benoni on Friday 11 May. Team winners on the day were Graham Kennedy (Heneways), Kerry-Lea Kirkman (Orion Engineered Carbons), Pierre Fourie (PJF Transport), Wendy Arries (Orion Engineered Carbons) and Herman Steyn (Dunlop Industrial Products). Brent Hean absent

PLASTOMARK’S 5th Major golf invitation held on 15 May at the River Club in Johannesburg was a great success. Winner on the day was Don Searle of LD Plastics, flanked by Plastomark’s Greta Croll and Wolfgang Raffalsky.

Azwi Ramulayi, who has completed his polymer technology studies, works closely with Igor on the formulations side.

Igor Komljenovic was appointed during November 2011 to support the growth experienced in the group’s Liquid Technology division. As project manager for the innovation, Igor is responsible for all aspects of the operation, from equipment through to packaging and ultimately for the commercial aspects as well.

50 JUNE / JULY 2012

IDC – a new path to development Since 1940, the Industrial Development Corporation, South Africa’s largest development finance institution, has helped to build the industrial capacity that fuels the country’s economic growth, by funding viable businesses.

As the government’s key partner in revitalising the economy, the IDC focuses on priority economic sectors that offer the greatest potential to unlock job opportunities.

Our vision To be the primary driving force of commercially sustainable industrial development and innovation to the benefit of South Africa and the rest of the African continent.

Our mission The Industrial Development Corporation is a national development institution whose primary objectives are to contribute to the generation of balanced, sustainable economic growth in Africa and to the economic empowerment of the South African population, thereby promoting the econo omic prosperity of all citizens. The IDC achieves this by promoting entrepreneurship through the building of competitive industries an nd enterprises based on sound business principles.

What we do

Chillibush6703IDC

Through partnership, the IDC C provides funding in support of industrial capacity developm ment by: t Proactively identifying an nd funding high-impact projects t Leading the creation of viable new industries t Using our diverse indusstry expertise to drive growth in priority sectors t Taking up higher-risk fu unding in early-stage and high-impact projects

Telephone: 086 069 3888 Email: callcentre@idc.co.za To apply for funding online visit www.idc.co.za

What we offer you The IDC assists start-up and existing businesses with a minimum funding requirement of R1 million and a maximum of R1 billion.

Funding is offered across its mandated sectors under the following Strategic Business Units: t Agro-Industries t Chemicals and Allied Industries t Forestry and Wood Products t Green Industries t Healthcare t Information and Communication Technology t Media and Motion Pictures t Metal, Transport and Machinery Products t Mining and Minerals Beneficiation t Strategic High Impact Projects and Logistics t Textiles and Clothing t Tourism t Venture Capital Special funding schemes are available that address transformation and d entrepreneurial t i ld development l t (TES) (TES); ttopping i up equity it contributions from entrepreneurs (TES & RCF); and sector-specific schemes (horticulture, forestry, clothing and textiles, hospitals).

The IDC Gro-e-Scheme provides funding for projects from R1 million to R1 billion at prime less 3% for up to five years.

The IDC’s business support programme prog addresses non-financial support to entrepreneurs. eneur Assistance is provided with capacity building to improve mpro project viability.

If you have a project that can contribute to building South Africa’s industrial capacity and creating jobs, visit www.idc.co.za to find out in how the IDC can help build your opportunity.

PEOPLE

ON THE MOVE Bert Green has joined SES as national sales representative in technical sales. Bert started out as an injection moulding machine setter in 1982, working for companies like SA Tupperware and BIC SA. Before joining SES, Bert spent 16 years with Adron.

Cape Town-based Cibapac, has made two senior appointments to its management team: Caspar Elbers as manufacturing executive; and Keith Wawn as key accounts manager.

Caspar Elbers, a native Hollander who has been in SA since 1992, brings mechanical engineering, an MBA and years of packaging industry experience to Cibapac. He has overall responsibility for Cibapac’s three factories - its rigids plant for EPS trays, its expanding flexibles plant and that of Unsgaard & Samson which Cibapac acquired last year.

Also based in Cape Town, Unsgaard supplies waxed and coated papers, baking papers, filter papers, tray liners and soaker pads, as well as unique wipes materials.

Keith Wawn’s responsibility is to grow Cibapac’s flexible division, focusing on its key customers in the meat, poultry and cheese sectors. He is an ‘old’ packaging hand, having been in the game for some 35 years, with the last 21 of them as national sales manager for Colpak. www.cibapac.com Brett Clark has joined Mpact as chief financial officer designate and executive director for the recently listed paper and plastics packaging group. He will officially assume the role of chief financial officer at the beginning of July. Clark will replaces Mpact’s current CFO, Les Leong, who retired at the end of June. Clark joins Mpact from Absa Capital Private Equity where he held the position of principal since March 2006.

Digital dentistry!

DemaPlasTech recently hosted a fascinating seminar on digital dentistry. Pictured at the seminar were DemaPlasTech MD Jacques Kleynhans and guest speakers Gennadios Skalenko of 3shape, Avi Cohen of Objet and Owen Peringuey of GEMC

www.demaplastech.co.za 52 JUNE / JULY 2012

Astrapak at ZITF Bulawayo show – Charles Muller and Ramon Scheepbouwer of Astrapak manned the group’s stand at the Zimbabwe International Trade Fair (ZITF) in Bulawayo in April, where they were the only SA plastics and packaging exhibitor present. Although their presence did help reinforce Astrapak’s brand in Africa, the majority of the inquiries were not of great substance, said Charles. They did, however, meet with a number of high-profile individuals, including the German and Malawian ambassadors to Zimbabwe. Zimbabwe is trying desperately to revive its economy and people are friendly and keen “to make it happen,” said Charles, but he feels that, as long as they persist with implementation of their Indigenisation Act, it will not be a country that attracts serious investors. The supermarkets and shops are full of products where you can buy almost anything you want, and restaurants serve good food – however, everything is in US dollars!

www.zitf.net

Farewell to jolly Rob Rodger worked from 1987-96. That phase WE ARE sad to report that ‘Mr coincided with the introduction Cheerful’, Rob Rodger of Namof PET containers, which was pak, has passed away. probably one of the most exciting Widely regarded as the periods for the industry in South epitome of the true gentlemen Africa. and one who, quite literally, was Following that Rob was always cheerful. Rob died in Rob Rodger had appointed director of Nampak March. He was 63 and had been a rare combinaPolycyclers in Olifantsfontein from working in the industry for 39 of tion of affability 1997, where he remained. those years. and kind-heartRob wasn’t one for shying Rob’s family came from edness with extensive industry away from voluntary work: his Scotland originally and he was knowledge and involvement included roles as born in Australia, but the family non-executive director of PETCO; later moved to SA. He obtained a experience affiliate member of PISA; and diploma in industrial engineering member of the boards of the Plastics from Wits Technical College in the early Converters Association (PCA), SA Plastics 1970s and started as a trainee industrial Recyclers Organisation (SAPRO) and the engineer at the Metal Box Plastics Division Federal Council of PlasticsSA. in 1973. From there he moved to Metal He was also a director of the newly Box’s beverage can division from 1975-80, formed POLYCO. where he was project planner and controlAlways affable and kind hearted, Rob ler. He was soon back in plastics, however, brought humour and respect to gatherings when he was appointed commercial manof these bodies, mixing that with his extenager of Metal Box Custom Plastics, where sive industry knowledge and experience – he worked from 1981-86. an important and useful combination.

Metal Box was in the process of being Besides that, Rob loved golf (he was a assimilated into the Nampak group, with member of Randpark Club) and enjoyed the purchase being completed in two photography and getting out into the bush. tranches, half in 1984 and the rest in ’87, There was a large contingent from so Rob effectively only ever worked for the industry, mainly from Nampak, at his one employer: he was appointed plant funeral in Irene. He leaves his wife Di. manager of Petpak in Isando, where he

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DESIGN

Inventive product design Thermoforming Parts Competition attracts diverse range of entries THE European Thermoforming industry’s main even of the year, the 8th European Thermoforming Conference in Venice from 26-27 April, was two days of expert presentations and workshops. A combination of excellent technical presentations, discussion workshops and an exhibition of associated technologies which ran in parallel, all contributed to ensure the event was relevant and informative to the international participants.

The Thermoforming Parts Competition attracted a diverse range of entries which offered the visitors a unique insight of how innovative product design combined with modern materials and processes can produce inspirational structural, cosmetic and highly functional parts. There were several examples of how thermoformed parts can support demands in completely new market sectors.

HEAVY GAUGE AUTOMOTIVE

Winner: Walter Pack (Spain).

Part: Window for Renault Twizy

The winners of this year’s Parts Competition were:

Jury´s comment: Processing highly complex polycarbonate sheet material free from moisture and dust contamination on an industrial scale which requires high level of processing control, careful logistic management and well-designed tooling.

This is a lightweight and innovative product for a demanding environment.

HEAVY GAUGE NON-AUTOMOTIVE

Winner: Solera Thermoform Group (Italy). Part: Long Chair Avus Jury´s comment: Originality of design, clever use of cosmetic materials, and an excellent example of a high performing light weight structure produced using the twin sheet processing technology.

www.walterpack.com

www.soltherm-group.com

THIN GAUGE

Winner: Generation Tech (France) Part: Paint Tray multi-layer Jury´s comment: Thermoforming 5 layers simultaneously, also using recycled material; the product is not only environmentally friendly, but also potentially opens up new application areas for the thermoforming industry.

• THE NEXT EUROPEAN THERMOFORMING CONFERENCE IS SCHEDULED TO TAKE PLACE IN APRIL 2014. WWW.E-T-D.ORG

Accolades for roto-moulded dog bed & kennel ITALIAN A’ Award and Competitions have awarded South African designer Tom Kerpert the prestigious Silver A’ Design Award for his ‘K9 Shut Eye’ dog or cat bed, as well as the Bronze award for his ‘Dog Kennel’ in the Pet Supplies and Products for Animals Design Competition.

Kerpert explained that the dog bed is manufactured by roto-moulding in HDPE and designed for ergonomics, easy cleaning and maintenance. It is safe for the

animal and long lasting as well as 100% recyclable. The unit is a single moulding with a metal tag attached to the back of the bed on which the pet’s name can be engraved.

The project started in in 2007 in Johannesburg with initial concept designs and went into production towards the end of 2008 in Johannesburg.

Meanwhile, Kerpert’s ‘Dog Kennel’ was awarded the Bronze A’ Design Award at Pet Supplies and Products for Animals Design

The award-winning K9 Shut Eye’ dog or cat bed and dog kennel designed by Tom Kerpert of Design Development Implementation for Accelerate Design

ddi.design@telkomsa.net

Competition.

Designed by D.D.I. (Design Development Implementation) for Accelerate Design, the dog bed and kennel are ergonomically designed for easy cleaning and maintenance, safe, long-lasting, 100% recyclable, manufactured from HDPE using roto-moulding.

Design Development Implementation is a design studio active mainly in the plastics industry working from concept to final tooling with clients. The client is a rotomoulding company distributing under its own name to the pet industry and producing general roto-moulded parts like tanks and barriers.

Kerpert said all work was done using 3D modelling software. Roto-moulding was chosen to manufacture the product at an early stage in the design process and the design was optimized for this particular process.

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JUNE / JULY 2012

PRODUCTS

VISI key in shovel development

New applications, new synergies for lifting bags

STATE of the art software helped to deliver a new collapsible shovel. With its two-hinged handle, the collapsible shovel is designed and manufactured by plastic moulding experts Senior and Dickson with the help of specialist CADCAM tools from Vero Software.

While the shovel is primarily aimed at motorists because of its handy folding design, the manufacturers also expect it to become an essential tool for helping householders keep their property clear of debris with its unique interchangeable shovel and fork heads.

Senior and Dickson are specialists in plastic injection, rubber moulding and die casting. By linking their experience of injection moulding, tool making and rapid prototyping, they readily develop ideas from concept through to working prototypes and on to production tooling – as demonstrated by the shovel project.

The VISI suite of CADCAM software was instrumental in designing the head configurations, specialist handle and 3D tooling, along with the CNC toolpaths.

The shovel handle and folding mechanism are produced using a high performance polycarbonate and the shovel head is produced using a recycled polypropylene.

Partnership between Trelleborg business areas steps up to take lifting bags to new places FOR the past 30 years Trelleborg’s lifting bags have been used by emergency services. A new synergy between Trelleborg Engineered Systems in the Netherlands, where the bags are made, and Trelleborg Wheel Systems France has opened up a different and highly successful market with agricultural and forestry tyre customers.

Lifting bags have been a huge success among Trelleborg customers, starting with a key account, Chouteau, an important tyre dealer based in western France.

Luc Parey, sales manager of the agricultural business of the Chouteau Group, commented: “In 2009, I saw an article on lifting bags, and I was very interested. Very soon I had put in a significant order. Agricultural tyres are extremely heavy to raise. Lifting bags are safer and easier to use than jacks, offering us significant gains in terms of productivity and security. We are all extremely satisfied with Trelleborg’s lifting bags.”

Trelleborg’s lifting bags are made of natural rubber reinforced with aramid fibres, which are stronger, lighter and more flexible than steel. They are suitable for lifting, moving, distributing and fixing loads. Available in eight sizes, the lifting bags can lift loads of up to 67 tons (at a compressed air pressure of 8 bar) to heights of between 80 and 520 millimetres.

www.vero-software.com www.senior-dickson.co.uk

Trelleborg’s lifting bags are made of natural rubber reinforced with aramid fibres, which are stronger, lighter and more flexible than steel

Trelleborg’s lifting bags can lift loads of up to 67 tons (at a compressed air pressure of 8 bar) to heights of between 80 and 520 mm

www.trelleborg.com

Metal replacement in high heat thermostat application Moulding in polyamide offers benefits in terms of both weight and cost

VISI cadcam suite was key in the development of a new shovel designed to fit in the boot of a car.

Designed and manufactured by plastic moulding experts Senior and Dickson, the compact, collapsible shovel has a two-hinged handle 56

SINCE February of this year, thermostat housings moulded from Ultramid® A3WG6 HRX are in use at Volkswagen.

The new polyamide specialty from BASF, which is now available worldwide, was developed specifically for applications requiring high hydrolysis resistance in conjunction with high strength. Production takes place at Veritas AG, headquartered in Gelnhausen, for the VW engine factory in Salzgitter (both in Germany).

The coolant control module’s cover, which is moulded from the new material, must withstand demanding conditions – a pressure of several bars at a peak

temperature of up to 130°C – and exhibit minimal deformation, as this would reduce the module’s efficiency.

Compared to its all-aluminum predecessors, the housing cover moulded from the polyamide specialty offers benefits in terms of both weight and cost: in contrast to the metal component, the moulded plastic component does not need to be finishmachined, and the desired dimensional accuracy, especially of sealing surfaces, is easier to achieve.

Supports, holders, valve seats and other functions can be integrated into the moulded component without effort.

Advanced air portable fuel containers enter service New manufacturing process reduces container weight by 25%, cost by 30% GKN Aerospace has been awarded a £2m, five-year contract with the UK Ministry of Defence for its latest Mark 5 Air Portable Fuel Containers (APFCs). These are being used to transport fuel to inaccessible points such as forward airstrips, helicopter landing zones and forward operational areas.

These latest fuel containers are 25% lower in weight and 30% lower in cost than previous generations of APFC. This is due to the introduction of an innovative new manufacturing process, developed by GKN Aerospace, which replaces the established slow and solvent-heavy, rubber-based production with a process which sprays a polyurethane compound paint onto nylon wire. This new

process is much faster, lower cost and is virtually VOC (volatile organic compound) free, so far more environmentally friendly.

GKN Aerospace APFCs are extremely rugged: able to function effectively at temperatures as low as -26˚C and as high as 71˚C – and will survive down to -46˚C. The containers are para-droppable, towable and aerodynamically designed to offer optimum flight conditions when underslung on a helicopter. They are qualified for use in cargo aircraft such as the A400M and C-130.

www.gknaerospace.com

Preparing the spray booth in the Air Portable Fuel Container (APFC) factory at GKN Aerospace in Portsmouth

Radiant good health at first glance

www.greiner-gpi.com

GREEN, fresh and healthy – the new Benevita Margarine packaging clearly demonstrates the product’s health benefits with Greiner Packaging achieving a balanced combination of decoration variants for the sleeves and labelling. The side walls of the polypropylene cup for the 225 gram contents are shrink-sleeved. Greiner Packaging has brought further decoration strength to the optical design of the cup bottom and the slip lid. A label with the printed product information and barcode is on the bottom of the cup. The label on the slip lid reinforces the message of the side wall decoration and supplements it with additional information. The slip lid cover is coloured in the same shade of green that gives the entire package its healthy appeal.

In addition, the high surface quality of the plastic is important, since it counteracts abrasion by the coolant.

Great attention was devoted to optimal positioning of the gates.

This made it possible to shift the unavoidable weld lines with their reduced strength to regions of the housing that are subject to lower loads.

Ensuring long-term tightness of the component under the seal and thermostat loads as well as the internal coolant pressures presented Veritas with an additional challenge. With the aid of BASF’s universal simulation tool Ultrasim®, it was possible to analyze the creep behaviour of the component in advance and optimize design accordingly. www.ultramid.com

The upper half of the thermostat housing for the new TSI 1.4-litre gasoline engine from VW is made of the new, especially hydrolysisresistant grade Ultramid® A3WG6 HRX from BASF and withstands not only hot water up to peak temperatures of 130°C, but also high pressures

57

PPSU replaces steel in solar panel system First use of a thermoplastic for thermal boilers in pressurized solar panel system SOTERNA S. Coop., based in Navarra, Spain, has developed the first solar panel system with an integrated thermal boiler for quick installation and reduced cost. The thermal boiler is made of Radel® polyphenylsulfone (PPSU) resin from Solvay Specialty Polymers USA, LLC, which provides long-term hoop stress resistance along with resistance to prolonged exposure to hot chlorinated water.

Soterna’s decision to go with PPSU instead of the traditional stainless steel represents the first use of a thermoplastic for thermal boilers in a pressurized solar panel system. Powered by a photovoltaic solar cell, the integrated solar thermal system uses solar energy to produce hot water. The 80 kg thermal complete system

Rotomoulded boats PERSICO Rotomoulding and Marine Divisions collaborated on designing the final product, as well as manufacturing the production equipment (rotational moulds) for the new Pioner 14 Active craft made by Cipax, a boat maker with sites in Norway, Sweden, Estonia and Finland.

The Persico Rotomoulding Division has been a Cipax Group supplier for many years. Initially Persico provided just the moulds, but over the years it broadened its offering to include rotational moulding equipment (moulds, cooling jigs and foaming tools) and know-how, helping Cipax to develop and improve its mathematical models for rotational moulding products. In 2011 Cipax decided to begin

- measuring 2 029 mm by 1 020 mm by 240 mm – withstands high pressure 600 kPa and hot 95°C chlorinated water.

It consists of two extruded profiles with injection moulded end caps which are welded onto the profiles. The profiles are connected to each other and hold a total of 150 litres of water.

The integrated thermal system reduces installation time by 50% and cuts cost due to the elimination of piping from the boiler to the panel. Targeted for residential use, the compact solar thermal system takes up no space in the dwelling and requires no maintenance.

www.soterna.com

The 80 kg thermal complete system – measuring 2 029 mm by 1 020 mm by 240 mm – withstands high pressure of up to 600 kPa and 95°C chlorinated water

www.solvayspecialtypolymers.com

www.persico.com

an intensive collaboration with Persico on a new 14-foot boat, starting from product design up to mould manufacturing, with the targets of a short development time and a reasonable final product market price.

Starting from the first-draft drawings of the craft, Persico addressed the main requirements of Cipax’ marketing strategy: developing a competitively priced product targeted at a wide customer base. Once all the functions and characteristics were defined, Persico integrated all the features into a mathematical model through the latest generation 3D modelling software.

The craft was launched at the Tanumstrand trade show held in Sweden in September 2011 and was well received by the public. Persico and Cipax are now working on the development of a large boat suitable for a wide range of end users and applications.

The new Pioner 14 Active craft

Cardia launches world first bio-container CARDIA Bioplastics has launched the world’s first food contact compliant and fully recyclable Biohybrid™ container for the nutritional supplement market and cosmetics industries.

Cardia is implementing a marketing strategy to launch the Bio-Containers globally and is currently working with both a US

manufacturer of plastic containers and a major nutritional supplement company to launch the new Bio-Containers into the US market.

Cardia Bioplastics has produced ‘biocontainers’ for packaging tablets and cosmetics using its new food contact approved Biohybrid™ resins. The Cardia Biohybrid resins are fully recyclable and comply with the US Food and Drug Administration and EU regulatory requirements on materials The new environmentally sensitive Bio-Container uses Cardia Biohybrid™ resins technology

www.cardiabioplastics.com

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and articles intended to come into contact with food.

Bio-Containers offer excellent physical properties and shelf life for the stored products. In addition to their excellent performance, Bio-Containers require less oil to produce and have a more favourable environmental profile and carbon footprint than conventional plastic containers.

Cardia Biohybrid proprietary technology combines renewable thermoplastics with polyolefin material to reduce dependence on finite oil resources and to reduce carbon footprint.

JUNE / JULY 2012

PRODUCTS

DuPont nylon and PPA used for charge air coolers Lightweight plastic helps improve fuel economy, reduce dependence on fossil fuels TATA TOYO’S has used DuPont™ Zytel® PLUS nylon for three hot- and cold-side charge air coolers used on four vehicles of a major Indian auto OEM across passenger car, utility vehicle and light commercial vehicles.

Tata Toyo selected Zytel® PLUS to replace specialty nylon resin product for added protection against the harsh elements associated with turbo-diesel systems and now has an eye on replacing metals in other applications.

“Weight, performance and cost are critical in our components and systems,” said Rajiv Kulkarni, head of engineering at Tata Toyo, a leading heat-exchange technology supplier based in Pune, India. Charge air coolers quickly cool hot air generated by the turbocharger before it is forced through the induction system. Cooler air improves combustion efficiency.

“Improving powertrain efficiency is critical to improving fuel economy and reducing dependence on fossil fuels,” said Patrick Ferronato, director of automotive, DuPont

Performance Polymers. “Turbo systems are one of several technologies the industry is quickly adopting to boost the performance of smaller, more efficient engines. The environment these power-boost technologies create is challenging the capabilities of many existing engineering thermoplastics.”

Last year DuPont introduced the family of high-performance nylon and PPA materials that deliver long-term resistance to heat, chemicals and pressure. Unlike specialty nylon resins, Zytel PLUS retains processing ease typical of traditional nylon resins. This family is targeted primarily at automotive underhood and engine applications.

DuPont this year invested in several new collaboration facilities, including the India Innovation Centre in Pune, India. The facility is focused primarily on the automotive segment with a goal of connecting globally on materials and solutions that improve sustainability, performance, safety, comfort and design while reducing weight and enabling alternative-drive vehicle systems.

Weight, performance and cost are critical in charge air coolers which quickly cool hot air generated by the turbocharger before it is forced through the induction system. Cooler air improves combustion efficiency

www.dupont.com

JUNE / JULY 2012

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EQUIPMENT

BKG CrystallCut process wins award Spherical PET pellet offers double the energy savings A PLANT with a production capacity of 600 tons per day may achieve an almost unbelievable energy savings of 25 gigawatt hours of energy during one year of operation using the CrystallCut technology developed by BKG, Bruckmann & Kreyenborg Granuliertechnik, in place of existing pelletizing and crystallizing technology.

This has been acknowledged by Plastic Technology China in cooperation the Vogel Media Advertising Co. Ltd and nominated for the prize of the most innovative, energy-saving plastics processing equipment of the last decade.

CrystallCut is a pelletizing and crystallization process in which the crystallization of the PET is achieved using the latent heat energy already present in the pellets.

The equipment line-up is similar to a traditional polymerization and extrusion line.

However, the critical difference lies in the cooling of the polymer after it exits from the extruder die.

During the first two seconds the plastic melt loses two-thirds of the latent heat energy. Because of this it is very important that the residence time of the pellets in the process water be kept to an absolute minimum to later attain the highest possible degree of crystallization.

CrystallCut equipment is therefore used with an underwater pelletizing system.

The pellets exit from the dryer and enter the crystallization conveyor at an average temperature of more than 135 ˚C. Here the superficially cooled pellets are kept in constant motion triggering the crystallization process which proceeds without

the need for any additional energy. Only the latent heat energy present within the pellets is used, crystallizing from the core to the outside and resulting in a 40% degree of crystallization.

With CrystallCut, compared to conventional extrusion equipment for the manufacture of PET pellets, an energy savings of around 20% is achieved. A further energy cost savings of around 5% is realized during the subsequent processing of the pellets in the injection moulding machine.

Because of the microstructure that results from the crystallization action in the conveyor, significantly less energy is required to re-melt the pellets. This results in an overall energy savings, when compared to conventional processes, of around 25-30%. In turn this accounts for about 25 gigawatt hours per year at a plant having a capacity of 600 tonper-day.

Finally, the CrystallCut technology provides yet another advantage during further processing in injection mouldwww.kreyenborg-group.com

Stretch film recycling THIS year’s Stretch & Shrink Film Conference in Weissenbach, Austria, during April was highlighted by a visit to the technical centre of Starlinger recycling technology where visitors could watch the recycling process of stretch film production scrap.

The main feature was the recycling unit recoSTAR basic 85, shown in operation with

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ing machines. The performance of the injection moulding machine increases by 5% when working with spherical pellets due to the fact that this form of pellet is more readily re-melted when compared to conventional strand-cut granulate.

• SA AGENT IS PLASTIC & CHEMICAL TRADING TEL: 011 483 3015

www.bkg.de

www.starlinger.com

nip roll feeder for recycling of stretch film production scrap on reels. The equipment works in automatic mode for in-line applications, featuring stand-by mode and automatic start-up, and in semi-automatic mode for off-line and mixed applications.

During the recycling process the polyethylene melt is treated with great care,

resulting in a high-quality end product: The regranulate can be used at a rate of up to 100% in the production of new film. In most applications the mixing ratio is, however, up to 80% regranulate plus 20% virgin resin.

• Starlinger is represented in South Africa

by Starlinger SA

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‘Goldfish’ 2012 by Neil Pauw of The Parlotones

EQUIPMENT

Engel ‘Green Cap’ venture for caps for China TO MEET the specific needs of the Chinese market more effectively, injection moulding machine manufacturer Engel has joined forces with mould manufacturer Plastisud. Under the name Green Cap, the joint venture partners are offering turnkey solutions for the production of sealing caps for water and soft drink containers in China.

Around the globe, demand for caps and closures is expanding by around 5% per year – and China is the world’s largest market in terms of volume. The world’s most populous country is imposing increasingly stringent requirements on packaging products and their manufacture: the weight of packaging needs to be reduced, quality needs to be raised and uncompromising performance must be delivered with maximum energy efficiency.

energy consumption of just 0.75 kWh per kilogram of granules, delivering far better energy efficiency than similar systems on the market can offer.

The system solutions save cooling water as well as electricity, making a lasting contribution to environmental protection. Other features of the production systems include robust and hard-wearing components, high process reliability and maximum availability. Green Cap solutions come with 32 to 96 cavities moulds as standard along with machine clamping force of 200 to 420 tons; as a further option, 500 ton machines are available. www.plastisud.com

The all-electric Engel e-cap 3440/420 injection moulding machine with a 96-cavity mould made by Plastisud made nearly 130 000 sealing caps per hour, reaching a cycle time faster than 2.8 seconds

Maximum process reliability and availability Plastisud and Engel unveiled their new concept at the Chinaplas 2012 trade fair (18-21 April in Shanghai). At the Green Cap stand an all-electric Engel e-cap 3440/420 injection moulding machine with a 96-cavity mould made by Plastisud made nearly 130 000 sealing caps per hour, reaching a cycle time faster than 2.8 seconds.

With cycle times of under 3 seconds and injection speeds of up to 460 mm per second, Engel’s all-electric e-cap injection moulding machine is designed to handle the highest output rates with maximum efficiency. Green Cap total solutions promise

EFFEX – efficiently achieving economic and ecological goals Combines technical sophistication, economic viability EFFEX is the name for Gruber Extrusion’s sustainably efficient extrusion solutions.

With its new FX line, the company once again takes a leading role in the field of plastic profile extrusion. Its design targets increased efficiency in all areas.

“Our business goes well beyond manufacturing energy-saving window profiles, it is also aimed at saving energy costs in the production process. To us, efficiency means the combination of three factors: increased production figures, lowered energy consumption, and safe and environmentally compatible production methods”, said general manager Richard Füßlberger.

The Gruber Extrusion engineers concentrated on a targeted extrusion solution with no over-engineering. Gruber Extrusion focuses on the finished product and offers 62

JUNE / JULY 2012

it at an unmatched price/performance ratio, in high-end quality. Products of the FX line are distinguished by a low level of complexity. This leads to higher reliability and lower waste in production.

The FX line offers a wide range of outstanding features: Vacuum Energy Saving Kit (VESK) as a standard feature of all FX products for automatic vacuum control.

Standardised production steps largely improve both the product quality and productivity of your extrusion line.

The FX line is the conclusive result of broadening the EFFEX product group. This combination enables customers to achieve maximum yield while also

reducing their energy consumption. Customers using Gruber’s FX line benefit from a reduction of up to 80% in energy costs compared with traditional extrusion lines. www.gruberextrusion.com The new FX line by Gruber Extrusion helps to cut energy costs by up to 80%. At the same time it boasts excellent efficiency, reliability and a clear-cut design. The FX line enables finished products of ultimate quality – at an unmatched price/performance ratio.

PHOTO: GRUBER EXTRUSION

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E-MAIL: info@cabletech.co.za

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EQUIPMENT

High Tech co-extrusion for pipe, profile & siding CON 40 piggy back version on TTS 88 profile extruder with the new clamp system

HIGH Tech Extrusion, consisting of the companies Theysohn, Technoplast, Topf and Extruder-Komponenten Salzgitter, is an ‘all-in-one’ provider which has developed a unique series of extrusion lines, tools and pipe heads over more than 10 years.

Now the group offers three different and advanced solutions for the industry.

The conical extruder (CON 40 or 50) or the CO.32 single screw coextruder is mounted on the main extruder. With the newly developed clamp system for the piggy back solution the adjustment of the coextruder is possible in all directions (up, down, side and angular). This piggy back solution can also be mounted on non-Theysohn extruders. Recently High Tech Extrusion was technically challenged by British customers as they were interested in modifying their old extrusion lines into co-extrusion lines. High Tech Extrusion accomplished this by mounting a conical extruder CON 50 ‘piggyback’ on the existing extruder. The requested output was achieved and due to the unique ‘piggyback’ system, shortage of space at the plant was no longer a problem.

The guaranteed output with the CON 50 conical extruder as coextruder is 125 kg/h for PVC window profiles and for rigid-PVC profiles 150 kg/h.

For this type the extruders are positioned next to each other and the coextruder is mounted on a pillar. High Tech Extrusion offers solutions for the single screw coextruder CO.32 as well as the conical extruders CON 40 and 50, and is working on a construction for the CON 63 of course.

Both extruders are positioned next to each other and the coextruder is mounted on wheels and can be moved easily. This solution is suitable for all existing extruders in various combinations. The maximum output for PVC siding coextrusion is approx. 1400 kg/h (1500 kg/h is possible depending on the type of profile) with the lines extruding 45 m/min respectively. Depending on the combination of extruders, pipe head, pipe dimension, pipe material and formulation an output from 400 to 1600 kg/h can be achieved at PVC pipe coextrusion.

The CO.32 single-screw extruder can

be used for profile- and pipe extrusion with rigid-PVC, soft-PVC, PA, PMMA and thermoplastic elastomers (TPE). www.ht-extrusion.com

Co32 Coextruder piggy back version on TTS Theysohn Twin-Screw Extruder

SINGLE expands production capacity Specialist temperature control and cooling systems expands production floor, creates new jobs SINGLE Temperiertechnik GmbH of Hochdorf/ Germany has started operations at its new site and has expanded its production capacity. The well-established manufacturer of temperature control and cooling systems has added a new production hall and offices in close vicinity to the company’s headquarters in Hochdorf near Stuttgart. The company is also looking for new personnel.

SINGLE has been developing, producing and selling high-performance temperature control systems for more than forty years. The

company’s product portfolio consists of water and oil-operated, high-quality temperature control systems, cooling technology as well as tailor-made and customised solutions.

Additional 1 000 m2 of production space and 150 m2 of office space have been created in the vicinity of the company’s headquarters in Hochdorf. Thanks to the new production and storage hall, production and freight management can now be handled separately, which avoids shortage of space

Additional SINGLE site in Hochdorf/Germany PHOTO BY SINGLE TEMPERIERTECHNIK GMBH

during busy periods and optimises workflows in both production and logistics. The results of business excellence projects have identified additional optimisation potential, which can now be strategically implemented thanks to the expanded floor space.

The addition of floor space and strategic expansion are the cornerstones for more growth. SINGLE currently employs 120 people at its headquarters in Hochdorf and plans to increase its personnel by up to 25% in the short to medium term.

• DEMAPLASTECH MACHINERY (PTY) LTD IS THE SA AGENT FOR SINGLE www.single-temp.de www.demaplastech.co.za

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Advanced dental implantology solutions

EQUIPMENT

Implant models printed by the Objet 3D printer are delivered with exceptionally fine details and an outstanding surface finish

ORATIO BV, a leading dental industry company in the Netherlands, has developed a complete in-house digital workflow for fabrication of models for dental implants with the help of an Objet 3D printer. The addition of 3D printing into Oratio’s workflow has turned Oratio into a fully digital dental provider, allowing it to significantly expand its implantology practice while offering higher accuracy and faster turnaround times.

Oratio identified the use of digital solutions for implantology as a potential growth opportunity. However, the company did not want to increase staff or costs, nor compromise its high standards. According to Siebe van der Zel, chief operating officer at Oratio: “Digital dentistry could enable a new level of implant models and allow us full control of the complete process – from the dentist’s initial order, to designing the restoration, through final manufacturing.”

Leveraging its strong experience in producing dental parts from CAD design imagery, Oratio chose to integrate the Objet Eden260V 3D Printer into its workflow. Since installing the Objet 3D Printer, Oratio has digitised the entire design and manufacturing process for dental implants. This has significantly improved the productivity of dental technicians by allowing them to focus on higher-level tasks. Implant models printed by the Objet 3D Printer are delivered with exceptionally fine details and an outstanding surface finish – to the full satisfaction of Oratio’s dentist customers. Dentist clients are also benefitting from improved turnaround times, enabled by the in-house rapid manufacturing process. www.oratio.nl

Brazilian company Fermolplast Components has 24 injection moulding machines installed on a 5 200 m² production floor, of which 15 have come from Battenfeld. These machines are used to produce housings for electrical appliances such as hair dryers and automotive parts

Miqueli Mascaro, owner-manager of Fermolplast Components displays an example of the hair dryer for which housings are produced on the EcoPower

Extraordinary efficiency FERMOLPLAST, a Brazilian Battenfeld customer of longstanding, installed its first EcoPower from Wittmann Battenfeld at its São Paulo plant in 2011. Fermolplast has also purchased automation and peripheral equipment from the Wittmann group.

Since its foundation in 1982 as a mouldmaker, Fermolplast has gathered a wealth of experience in manufacturing high-quality injection-moulded parts with state-of-the-art European injection moulding machinery.

The company specializes in high-precision moulds for plastics injection moulding and supplies complete solutions in this area, including product planning and development, mould-making and manufacturing of the end product as well.

Today, the company has 24 injection moulding machines installed on a 5 200 m² production floor, with clamping forces ranging from 50 to 400 t, of which 15 have come from Battenfeld.

The Battenfeld machines currently installed at Fermolplast are mainly hydraulic machines from the reliable HM series and toggle machines from the TM series. In March 2011, Wittmann Battenfeld supplied the first all-electric machine from the PowerSeries, an EcoPower 180, which is used,

www.ObjetDental.com www.demaplastech.co.za

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JUNE / JULY 2012

for example, to produce housing components for hair dryers.

The EcoPower’s precision and high speed are mainly due to the direct drive of the injection unit via a circulating ball spindle, which minimizes transmission loss and enables exact control and repeatability of the metering and injection processes.

The precise, efficient toggle drive of the clamping unit features high dynamism, positioning accuracy and energy-efficiency as well.

The extraordinary degree of energy efficiency is reached by using the braking energy of the drives, normally returned to the power supply network by an elaborate process, completely within the machine to provide the necessary voltage for the control system and for barrel heating.

Depending on the application, the savings potential of this machine lies between 50 and 70%, compared to modern hydraulic machines. www.wittmann-group.com

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INDUSTRY NEWS

Direct Digital Manufacturing Rapid Prototyping The need for prototype components led to the development of Additive Fabrication Systems. The original technologies were based on laser-cured resins.

Produce parts rapidly, cost-effectively using Additive Manufacturing Technology Conventionally speaking, parts are machined out of a large billet of material. Usually carried out by means of CNC (computer numerical control), it’s called subtractive fabrication. Using this method, as much as 90% of the original material may have to be removed to produce the finished part.

There’s a new approach that not only saves time, but also saves money – and provides digital accuracy.

Stratasys additive manufacturing produces dimensionally accurate parts by adding thermoplastic in layers based on a 3D CAD (computer-assisted design) model.

The part is built up in precise layers by using an accurate CNC profile for each layer.

Stratasys fused deposition modeling (FDM) Stratasys developed and manufactures the patented Fused Deposition Modelling

(FDM) systems that manufacture real parts composed of production grade thermoplastics. Because FDM uses real production thermoplastics, parts manufactured are stable and have no warping, shrinkage or moisture absorption like resins and powders in competing processes.

No matter how complex, the 3D CAD geometry, Stratasys FDM systems allow you to produce accurate production quality real parts – parts that can be assembled, tested and installed in products for end use.

The possibilities are endless.

The Fortus Systems produce fixtures, assembly tools and parts in ABS Polycarbonate Blend, ABSi medical and food grade thermoplastic, ABS ESD7 Electro static dissipative, polycarbonate, Ultem 9085 (Aircraft Grade Material) and Polyphenolsufone for high-temperature applications. The Dimension 3D Printers are the office friendly systems that ‘print’ parts in a high strength ABS Polycarbonate blend Thermoplastic.

To achieve dimensionally accurate and

highly detailed models requires the following environment: ü A hot envelope. Hot material deposited in a cold or ambient environment leads to shrinkage, warping and delamination of layers. ü High strength production grade thermoplastic. ABS is a brittle material but a high temperate ABS polycarbonate blend produces an extremely tough model that allows for custom parts and low volume production parts to be built. ü Soluble support technology. Parts produced using additive manufacturing technology requires support structures for complex parts. To produce finely detailed and dimensionally accurate parts require removal of support structures without damaging the model. Manual removal of supports leads to model damage and in complex models is impossible to remove. Soluble support material is simply removed by placing parts in a hot water alkaline solution. ü A CNC tool path. To achieve dimensional accuracy a CNC type tool path is required. Using a matrix of nozzles or inkjet type technology operates like a dot matrix printer and this will not produce a closed profile that is required for precision parts. For example, a water jet cutter uses a CNC profile to cut an accurate part.

• 3D SOLIDS ADDITIVE MANUFACTURING TECHNOLOGY: TEL (012) 345 5112

No matter how complex, the 3D CAD geometry, Stratasys FDM systems allow you to produce accurate production quality real parts – parts that can be assembled, tested and installed in products for end use

Simulation software for plastic injection moulding PRETORIA-based Esteq, a leading supplier of engineering eimulation solutions in South Africa, has recently launched the Moldex3D eDesignSYNC R11.0, the latest simulation software for plastic injection moulding.

Moldex3D is embedded in leading 3D CAD software, including NX , Creo , Solid Edge and SolidWorks. Moldex3D eDesignSYNC provides engineers with easy-to-use, multi-functional and cost-effective solutions that enable synchronized design changes

68

and evaluation of manufacturability directly in their familiar CAD system. Designers are able to predict and avoid potential moulding problems during the tool development process.

CAE simulation solutions are proven to assist mould makers to discover the optimal process conditions. There is a need to quickly try different tool design scenarios to solve moulding defects rather than spending time and costs on process condition optimization.

“The integration between design and simulation brings a high-performance design platform that allows designers to examine and optimize part and mould designs seamlessly. It will enhance product quality and reduce the costs of building common communication knowledge through each phase of the design-to-manufacturing process,” said Dr Venny Yang, President of CoreTech System, creators of Moldex3D. www.esteq.co.za

EQUIPMENT

GET this!

Mouldplas market state of the art General Extrusion Technology blown film extrusion equipment

Bubble cage and cooling systems Advanced cooling allows for high speed, AirKage is contact free, no marks and no strips. Easily retrofitted to any existing extrusion line

production, from 50 mm up to 90 mm, MOULDPLAS has discovered yet all designed for high speed extrusion at another ‘star’ in the blown film extrusion lower energy consumption. equipment market in Chinese company, General Extrusion Technology (GET).

Air ring system GET was launched by Jian Peng, a GET’s air ring system is designed former GM of Battenfeld China, and a to maximize both external colleague. and internal cooling The 7-layer coof the bubble. GET extrusion high-barrier offers single lip, dual blown film production lip and double stack line from GET can air ring systems. produce high-barrier All three systems film which is high qualcan be equipped ity and symmetrical with Auto Profile in structure, such as Control (APC) for m-PE/Tie/PA/EVOH/ precise web gauge PA/Tie/m-PE or unsymcontrol. GET’s newly metrical high-barrier developed fully films such as PA/Tie/PE/ motorized dual lip air Tie/PA/Tie/m-PE. Online ring (patent pending) exchange of film layer allows the operator structures can be done to to precisely control reduce costs and improve New tooling upper lip and perforated barrier performance. developments and chimney positions via The 7-layer co-extrusion designs allow for the competitive stepping motors. blown film production line edge in the market GET’ auto profile air is equipped with seven GETring features segmented air ring 60-30S smooth barrel extruders, design. Ultra-fine air chambers on the GET-500-7 low-mould spiral mandrel, circumference of the air ring allow air seven-layer co-extrusion dies, air rings flow over the bubble in a more precise with 116 control zones for automatic film and even manner, resulting in more acthickness control, and a barrier film thickcurate film thickness control. ness gauge.

GET’s blown film extrusion system Profile control system is controlled by a ACS 5300 Navigator The Plast-Control profile Control System developed by Plast-Concontrol system trol of Germany. The Navigator operauses a gauge tor concept allows a simple but central control device graphic control of all line components, to sense the such as extruder drives, temperature web gauge. controllers, auto profile, haul-off, treater, The date calibration basket, collapsing frame and collected is IBC via a touch screen. sent to an ACS The company offers a complete 5300 system for range of extruders, for blown extrusion 70

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calculation, after which the correct control commands are sent to the segmented cartridge heaters for adjustment.

The internal bubble cooling system significantly affects the line speed of a blown film extrusion system. The design of GET’s IBC units results in high cooling and venting efficiency which is vital for high line speeds.

GET’s bubble cage features all extruded aluminium structures, motorized up and down height adjustment and electrical actuator bubble diameter adjustment. All cage arm surfaces are synergistic coated, super hard, have a very low COF and high temperature resistance. www.mouldplas.co.za www.get-extrusion.com

GET standard extruder – Smooth bore units available from 40 to 120mm with outputs ranging from 40 to 490kg/hour (LDPE)

MATERIALS

Clariant launches ColorForward colour forecasting guide CLARIANT has launched ColorWorks™ and its ColorForward™ colour design tool.

ColorForward is a dedicated colour forecasting service in the plastics industry, now in its seventh edition.

Colour is a powerful communications tool and in a world filled with conflicts and pressures, the impact of colour, whether conscious or subliminal, can positively influence mood. In knowledgeable hands, valuable guidance can be provided for applying colour to real-world challenges to achieve desired outcomes. In the world of plastics, that guidance comes from Clariant’s ColorWorks and its ColorForward colour design tool.

ColorForward’s colour predictions are based on intensive research of the most influential societal trends around the world.

Each ColorForward forecast package is based on a year-long effort that involves

hundreds of plastics industry and trend analysis experts from around the world.

Colour specialists from industries as diverse as architecture, textiles, packaging, housewares, automotive and fashion all participate in the process.

The colour selections for 2013 are based on four powerful societal trends that are deemed to have the strongest global impact in the near time frame. The worldwide Clariant ColorWorks team has developed a range of colour palettes that harmoniously resonate with each trend’s influence.

The colour palette for Sciensational represents the growing sense of optimism we have in the capabilities of science and technology to find the best solutions for the planet.

Foodture’s palette is very organic and brings to mind a bright, fresh, healthy and

tasty salad. We live in a global society where what we eat, how it’s grown, and where it comes from are important issues.

People are feeling a need to join together with others who share the same interests and values. This is a drive to create communities of kindred souls that Clariant has named Communination. These social networks, aided by rapidly growing communication technologies, will be both local and global. Communination offers a warm palette that’s clean, direct and grounded.

Today’s new generation feels they can enjoy life more by having less. This global shift from collecting stuff to choosing what we feel is essential, is a trend Clariant titled Enough … is Enough! The downturn in the world economy, the ‘green’ revolution, the desire for a less pressured lifestyle – all contribute to the new attitude against conspicu-

Clariant spotlights FDA-compliant polymers for food contact applications Also developing future solutions for stabilization of agricultural film CLARIANT’S additives business unit, a major supplier of products for functional effects in plastics, coatings and printing ink, showcased several innovative additive products at the recent NPE show in Florirda, USA, including four FDA-compliant grades of Licocene® metallocene polymers for polyolefins; Nylostab® S-EED multi-functional additive for polyamides; Hostanox P-EPQ® processing stabilizer for thermoplastics; and Exolit® non-halogenated flame retardants.

“Customer demand and the worldwide growth of our technologies – particularly for our Licocene polymers, Hostanox antioxidants and Exolit flame retardants – is very strong, and we are developing future soluClariant spotlights FDA-compliant Licocene® performance polymers for food contact applications PHOTO: CLARIANT

tions in the stabilization of agricultural film with our Hostavin® NOW XP product line.

Our Licocare® SBW 11, a renewable highperformance lubricant for PVC under development, also holds great promise,” said Michael Harris, head of sales for the Clariant Additives Business in North America.

Clariant’s FDA-compliant Licocene PP polymers for food contact applications are excellent dispersing agents for colorants, other additives and fillers. Designed for polypropylene used in packaging and containers, three of the Licocene PP grades – 1302, 1502 and 2602 – function as carriers in compounds and concentrates and they can streamline handling and processing of clarifying agents.

Hostanox P-EPQ is a highly effective processing stabilizer for polyolefins and engineering thermoplastics. By protecting against degradation from thermal oxidation, this technology maximizes yield and avoids waste. Hostanox P-EPQ ensures constant melt viscosity and colour stability. It is especially valuable when working with recycled content.

Nylostab S-EED is a multi-functional additive technology designed especially for polyamides, which goes beyond conven72

JUNE / JULY 2012

tional light stabilization. By improving melt processing, the product preserves polyamide resin integrity throughout the cycle.

Exolit non-halogenated flame retardants enhance sustainability Clariant Exolit non-halogenated flame retardants enable manufacturers to comply with global environmental regulations, including the EU’s Restriction of Hazardous Substances (RoHS) directive and Waste Electrical and Electronic Equipment (WEEE) directive, as well as leading eco labels.

Clariant offers a full portfolio for different types of resins and applications: Exolit OP grades for thermoplastics feature a proprietary organophosphinate formulation without red phosphorus or heavy metals; Exolit EP grades for epoxy thermosets and laminates provide highly effective protection at low dosage levels; and Exolit AP grades for polyolefins, based on ammonium polyphosphate chemistry, are characterized by extremely low smoke density.

www.clariant.com

ous consumption. The colours of Enough... is Enough! foster a sense of quality and durability.

The colour palettes of these trends are quite varied and will give designers much to think about. “But that’s the idea,” says Cristina Carrara, designer at ColorWorks Europe and a member of the Clariant Masterbatches global ColorForward team. “The colours are conceptual ideas.

They are meant to inspire the imagination.” Carrara also points out that the colours can be mixed and matched, and freely adapted to the needs of local markets or blended with regional influences.

Anyone interested in learning more about ColorForward can visit www.colorworks.clariant.com and click on the Color Trends tab. www.colorworks.clariant.com

Rise of plastic cladding in architecture GRP extremely durable, offering combination of properties seldom found in other materials ORIGINALLY developed in 1938 for use in insulation, GRP is extremely durable, offering a combination of properties seldom found in other materials: excellent impact strength, low weight, dimensional stability, weatherability and energy efficiency.

GRP was introduced into the International Building Code (IBC) in 2009 and has already been used with great success in projects such as the new 3 050m² Masscash Holdings Trading Warehouse, contracted to Scheltema. The trading warehouse with an apex height of 12m which gives the client flexibility with its racking layout and allows for bulk storage of up to 6m, and was one of the first large-scale projects in the Western Cape to make use of non-fragile GRP sheeting known as Modek GRP Walk-on.

Internationally the British Oval Cricket Ground, Emirates Stadium, Twickenham Stadium and Dubai international airport have all made use of GRP cladding, rooflights and canopies.

“In the long run, plastic cladding offers an attractive appearance that is much easier to clean than brick or wood,” said Christo Pienaar, marketing director of Modek and www.modek.co.za

Ampa Plastics. Both companies supply GRP sheeting to the construction industry.

“It is strong and can withstand a great deal of stress, as well as extreme temperatures, marine conditions and strong winds. GRP is also excellent for use in buildings where chemicals are used.”

The industrial cladding industry in particular is challenged by corrosive chemical fallout and acid rain, which makes metal cladding unsuitable. Modek produces opaque GRP sheets using high grade isophthallic chemically resistant polyester resin for such industries, including battery manufacturing plants, refineries, poultry farms and galvanizing works.

Modek supplied over 7 400m² of isophthalic sheets to the Skorpion Zinc mine in Namibia to replace their polyethylene cladding that corroded due to chemical degradation and are currently working on a similar project with Namdeb.

Other benefits include its high thermal resistance, moisture- and mildew-resistance, mechanical strength and the reduction of installation time because it is easy to cut, drill, fit and carry on site.

www.ampaplastics.co.za

Dubai International Airport is just one of the new international constructions that make use of GRP cladding, rooflights and canopies

JUNE / JULY 2012 73

MATERIALS

Borealis & Borouge showcase global weight-reducing automotive innovations

Xmod™ GD301FE for pedal and frontend carriers creates a minimum 15% weight saving and 10% lower system cost compared to a polyamide (PA) solution.

The high performance, high stiffness, 30% glass fibre reinforced PP offers improved processing and no pre-drying step

BOREALIS and Borouge demonstrated their support for the automotive industry’s drive to reduce vehicle weight and emissions with the very latest in lightweight material solutions when they exhibited at the VDI International Conference ‘Plastics in Automotive Engineering’ in Mannheim, Germany from 21-22 March.

Cutting-edge components and underthe-bonnet applications used by BMW and Fiat/ General Motors were showcased by Borealis and Borouge to demonstrate the added value of pioneering Xmd™ short glass fibre reinforced polypropylene (PP), Nepol™ long glass fibre reinforced PP and Daplen™ materials. Their mechanical properties, sound-dampening advantage, weight reduction potential and processing performance provide global automotive original equipment manufacturers (OEMs) and Tier One suppliers with a viable alternative to traditional, higher density engineering plastics.

Exemplary weight-saving and efficiency benefits in the spotlight included: • Xmod™ GD301FE for pedal and frontend carriers creates a minimum 15% weight saving and 10% lower system

cost compared to a polyamide (PA) solution. The high performance, high stiffness, 30% glass fibre reinforced PP offers improved processing and no pre-drying step • Xmod™ WB300UB for automotive engines is a hybrid (glass fibre and mineral filled) reinforced PP chosen by Fiat for air filter housings. It meets the performance, stiffness and impact strength as well as good surface properties of a PA-based alternative at a lower cost and 16% lower weight, creating an improved sustainability profile Borealis and Borouge also showcased a success story with Nepol™ GB215HP, a long glass fibre reinforced PP, used in the instrument panel carrier of the BMW 1, 3, 5 and 7 Series models. The use of Nepol GB215HP enabled a weight reduction of 20% compared to the previously used material as well as 20% lower system costs.

It was also important for the customer that the material supported the BMW SGI integral foaming injection moulding process.

www.borealisgroup.com

Off-the-shelf optical train is first for CPV modules Bypasses the tooling process to save time and money EVONIK is launching a complete acrylic lens package, Plexiglas® Solar Pre-Fab lens panels, designed to provide access to Concentrated Photovoltaic (CPV) optics while also saving customers costs in advance and several months manufacturing time. These new lens panels are part of the well-known Plexiglas Solar product portfolio which consists of specialty PMMA moulding compounds and sheet products for solar applications.

Plexiglas Solar Pre-Fab acrylic lens panels are combined with a Secondary Optical Element (SOE) to create a complete optical train package for assembly directly into Concentrated Photovoltaics (CPV) modules. This allows customers to bypass buying the tooling device needed to create the product, which is very expensive and requires a time-consuming installation process of several months.

“This is a great example of how we continuously enhance our products to deliver our best value and performance to our customers,” said Peter Marks, new busi74

JUNE / JULY 2012

ness development manager of Evonik’s Performance Polymers – Acrylic Polymers business line. “The package’s complete offering allows us to deliver world-class performance to our customers while bypassing the tooling process to save both time and money. We are also offering the product in small quantities of as little as 10 panels to be used in prototypes.”

The Plexiglas Solar Pre-Fab lens panels serves as the Primary Optical Element (POE), which collects light over its entire area. This POE is coupled with Evonik’s SAVOSIL®, the Secondary Optical Element (SOE) that focuses light over a

smaller area homogenizing the light in order to maximize its usefulness to a solar cell.

The Plexiglas Solar Pre-Fab lens panels are produced through Evonik’s proprietary processes for manufacturing acrylic CPV lens panels. These lens panels also take advantage of the precision tooling and prescription replication capability of 10x Technology LLC, a developer of microstructured polymer products.

Plexiglas Solar Pre-Fab is offered in three sets of quantities – 10 panels, 50 panels, and 300 panels. www.evonik.com

Plexiglas® Solar Pre-Fab lens panels, designed to provide access to Concentrated Photovoltaic (CPV) optics while also saving customers costs in advance and several months manufacturing time

SOUTH AFRICA Polymers Division

O U R W I N N I N G F O R M U L A S E T S U S A PA RT Carst & Walker has developed sustainable partnerships with leading international suppliers and valued customers for more than 70

Rubber and Plastic industries.

Within the Polymers Division, the following business units provide the customer with the ultimate polymers solution:

ELASTOMERS

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customized solutions innovative technology

Johannesburg: Bill Taylor Jenny Warner Kevin Clark Tel: +2711 489 3600 Fax: +2711 489 3601 Durban: Jaco Smith Ron Dunwoodie Paul Rose Tel: +2731 313 8500 Fax: +2731 313 8518 Website:www.carst.co.za

world class quality products

Cape Town: Tel: +2721 506 4560 Fax: +2721 506 4561

sales support

Port Elizabeth: Kathy Garde Tel: +2741 397 3600 Fax: +2741 397 3601

service excellence

A HOBART COMPANY

technical expertise

leading international manufacturers

MATERIALS

New Purgex 602 Plus commercial purging compound for clear PC, PS NEUTREX of Texas, USA, has introduced Purgex 602 Plus, a new commercial purging compound (CPC) developed specifically for rapid changeovers from coloured to clear or clear to coloured polycarbonate and polystyrene.

The new CPC will process PC and PS and their copolymers at temperatures ranging from 182° to 288°C while removing any residual contamination in injection moulding machines and providing efficient cleaning of hot runner systems.

Neutrex states that Purgex 602 Plus can be used in a wide range of industries processing clear PC or PS including automotive/ transportation, electrical/electronic, medical, packaging, furniture and appliance manufacturing, building and construction materials, sporting goods, and consumer products.

According to the company, new Purgex 602 Plus is a ready-touse blend consisting of non-toxic,

non-abrasive active ingredients with a polystyrene carrier. It provides dual-cleaning action, with mechanical cleaning properties plus a unique expanding/foaming turbulence to clean plastics processing machinery thoroughly and safely.

All active ingredients consist of USA Food and Drug Administration (FDA)-approved materials used in food and pharmaceutical applications. The purge material can be processed safely through hot runner gates as small as 0.75mm and is easy to remove from the machine upon completion of the purge.

Purgex 602 Plus is the latest addition to the Purgex line of CPCs for cleaning thermoplastic injection moulding, extrusion and blow moulding processing machinery.

New Purgex™ 602 Plus enables rapid changeovers from coloured to clear or clear to coloured polycarbonate or polystyrene when purging injection moulding equipment

www.PurgexOnline.com • PURGEX™ IS SOLD IN SOUTHERN AFRICA BY CHEMIMPO.

First ever thermoplastic hand pallet truck Highly ergonomic, light, silent and manoeuvrable TECHNYLSTAR® advanced polymers from Rhodia Engineering Plastics have enabled the designing and launching of a revolutionary thermoplastic hand pallet truck (HPT) called the I-ton.

Developed in close collaboration with the Italian company Lifter (a subsidiary of the Pramac Group) a leading, imaginative creator and manufac-

turer of innovative materials handling equipment, the new I-ton thermoplastic HPT has the toughness of steel, yet is elegant due to the greater design freedom and part surface aesthetics provided by metal-replacing TechnylStar advanced polymers.

“I-ton is a highly ergonomic, light, silent and manoeuvrable hand pallet truck almost entirely manufactured from polyamide thermoplastic materials weighing half as much as a standard steel hand pallet truck, yet capable of lifting 1000kg,” said Federico Piersimoni, CEO of Lifter.

“This ambitious project was made possible thanks to our strong commitment in research and development of innovative technologies and the collaboration with Rhodia Engineering Plastics, whose know-how and high performance polymers’ formulation enabled us to substitute steel, the conventional material used in traditional fork lifting equipment,” he added.

TechnylStar® offers processors and moulders significant cost, time and energy saving advantages speeding up the manufacturing process of the revolutionary thermoplastic I-ton hand pallet truck.

In addition, the end-of-life products are recyclable.

Rhodia Engineering Plastics, a member of the Solvay group, creates new materials in response to its customers’ needs through a global network of customer support centres equipped with cost-effective predictive simulation services. TechnylStar, the high-fluidity range based on PA6 and 6.6, exists in various reinforced versions, from the mid-reinforced TechnylStar S and AF ranges to the highly reinforced TechnylStar SX and AFX ranges. www.rhodia.com www.solvay.com

The revolutionary thermoplastic hand pallet truck (HPT), called the I-ton, manufactured from advanced polymers from Rhodia Engineering Plastics 76

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Extraordinary Colours

153 Haring Road Wadeville Ext 2 21 YEARS Established 1990

For all your colouring requirements of masterbatch and pigments.

We have the latest computerised colour matching facilities and 21 years expertise.

Impossible just won’t do!

DEKRA EN ISO 9001:2000 CERTIFIED

Johannesburg: Tel: (011) 824 0350/1/2 • Fax: (011) 824 0353 • email: aussie@mercuryplastics.co.za Durban: Conrad Pillay 082 358 4727 • Cape Town 021 552 4433 •

EQUIPMENT

Mouldplas represents Wittmann in SA

Bryan Webb, MD of Mouldplas Marketing with Michael Wittmann, MD of Wittmann Kunststoffgeräte GmbH

www.wittmann-group.com

Styron confirms success of improved pricing process for polystyrene STYRON Europe GmbH has been able to settle prices for 90% of its PS EMEA monthly negotiated business within the first 10 days following its recent proposal for changing pricing settlement.

On March 16, Styron made an appeal for an improved process to settle contract pricing for polystyrene at the beginning of the month, effective as of May. In mid-April more than 20 of Styron’s key customers had already endorsed the proposal to change the timing to the beginning of the month, no later than May 11. Today, the result is an early pricing settlement of 90% of Styron’s PS EMEA monthly negotiated business. Moving forward, Styron is confident that with the broader support of the industry, this process will be maintained in June and become a more established industry practice over the coming months. This will bring the European Polystyrene pricing process in line with other regions and polymers.

“We obviously recognize that the new practice is not fully operational and that it will take time for the industry to adopt this progressively but this result brings us one step closer to our goal of bringing more clarity and consistency on polystyrene pricing in the future,” said Paul Moyer, Styron’s vice president and general manager for plastics.

Styron is committed to the proposed change for pricing settlement because it will provide improved visibility and timely information to facilitate decision making for both buyers and sellers during the month of delivery, particularly when it comes to managing volumes, financials and production. www.styron.com 78

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AS from March this year, Mouldplas Marketing, based in Randburg, represents the entire product portfolio of the Wittmann group in South Africa, including injection moulding machines for the plastics industry plus automation and the complete range of peripheral equipment.

Mouldplas was established by Bryan Webb in 2009 to supply the South African plastics packaging industry with complete solutions - from individual machines to turnkey production lines.

With highly qualified technical staff from the plastics industry, Mouldplas is in an excellent position to provide the necessary customer support and maintenance services.

Among other activities, Mouldplas is the preferred supplier of the Astra Pak group for a range of processing equipment, where it has an exclusive contract with selected international suppliers over the next three years. With the agency for the product range of the Wittmann group, Mouldplas intends to expand its business in the injection moulding sector and aims to become the market leader in the area of machinery and service within the next three years. The company currently employs 18 people and plans to hire additional staff, primarily technicians. www.mouldplas.co.za

Rise of the trilobes TPE materials treated with advanced injection blow moulding processes are being used to manufacturer a competitive, reliable and environmentally friendly seal. Trelleborg has manufactured dynamic sealing systems for years. One such system takes the form of a rubber boot, or ‘trilobe’, a bellowed triangular seal that sits over a moving part such as a driveshaft, or a circular boot made of thermoplastic elastomer, or TPE, with an additional trilobe insert. Today, automakers such as Peugeot, Citroën, Ford, Renault, Dacia and Daimler are increasingly sealing their driveshaft joints with trilobes made of TPE.

www.trelleborg.com

MATERIALS

1st Commercial biovinyl flexible compounds Lifecycle analysis shows 41% reduction in CO2 versus conventional vinyl TEKNOR Apex Company has developed flexible vinyl compounds with plasticizers based on renewable resources for applications as diverse as automotive window encapsulation, medical tubing, and footwear, and it is prepared to supply the compounds to manufacturers seeking to reduce the carbon footprint of their products.

New BioVinyl™ flexible vinyl compounds have already found commercial uses. Three of these are a line of fashionable ‘flip-flop’ sandals produced in the U.S. by Okabashi Brands, Inc.; a range of shoe welting manufactured by custom extrusion processor Barbour Plastics, Inc.; and a new series of Tuff-Seal interlocking floor tile from Flooring Adventures.

BioVinyl compounds incorporate phthalate-free Dow Ecolibrium™ bio-based plasticizers, which are manufactured using plant by-products by Dow Electrical and Telecommunications (Dow E&T), a unit of The Dow Chemical Company. Under a recently announced Joint Collaboration Agreement, Teknor Apex has been granted the exclusive right to market in North America flexible vinyl www.dow.com/ecolibrium

compounds containing Dow Ecolibrium biobased plasticizers in certain applications.

Life cycle analysis tests conducted by Dow and reviewed by a third party indicate that every ton of vinyl compound made flexible with Dow Ecolibrium helps the industry reduce carbon dioxide equivalent emissions by 0.7 ton, or 41%.

Applications for which Teknor Apex is prepared to supply commercial quantities of BioVinyl compounds include: • Automotive window seals, interior and exterior trim, and instrument panel skins.

• Medical tubing, masks and collection bags.

• Consumer products such as footwear and toys.

Development work continues on compounds for other applications, such as blood bags and wire and cable jacketing.

In work on formulations incorporating Dow Ecolibrium, Teknor Apex researchers developed and tested

BioVinyl grades for a number of standard flexible vinyl applications, such as building and construction seals and gaskets and irrigation tubing.

The most pronounced property change that was discovered in comparison with conventional phthalate-plasticized compounds was an improvement in heat stability, enabling extrusion processors to carry out longer product runs without prohibitive levels of polymer degradation.

• ADVANCED POLYMERS IS THE SA AGENT FOR TEKNOR APEX COMPANY

www.teknorapex.com

Potential commercial and industrial applications of Teknor Apex Company’s newly developed flexible vinyl compounds with plasticizers based on renewable resources

80

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Lanxess Isithebe renews Responsible Care Commitment THE Lanxess Isithebe Rubber Chemical site renewed its commitment to the Responsible Care Guiding Principles during a signing ceremony held at the site recently.

Two signing ceremonies were conducted, with one undertaken in the presence of invited guests from relevant institutions and organisations within the locality, and the other in the presence of Lanxess Isithebe employees.

Speaking during the signing ceremonies, Chemical and Allied Industries Association (CAIA) representative, Louise Lindeque said she was pleased to realize

that Lanxess management did not make a private commitment but instead pledged their support for the principles in full view of its key stakeholders.

Addressing employees during the ceremony, Managing Director for Lanxess South Africa, Dr Karl-Rudolph Gassen said it was the responsibility of every employee to ensure that the site observed Health, Safety and Environmental standards to the latter.

Site Manager, Morgan Govender said the plant has been signatories to the guidelines for several years and relied

on them in the day to day activities at the plant.

Responsible Care is the chemical industry’s unique global initiative that drives continuous improvement in health, safety and environmental (HSE) performance, together with open and transparent communication with stakeholders. In 1994, CAIA launched Responsible Care in South Africa to respond to public concerns about the manufacture, storage, transport, use, and disposal of chemicals. www.lanxess.com

Lanxess Isithebe site manager Morgan Govender, CAIA representative Louise Lindeque and Lanxess SA managing director Dr Karl-Rudolph Gassen after the signing Lanxess Isithebe employees proudly display their Responsible Care certificates

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Pelletron De-dusters clean pellets which increase output, profitability and the quality of the end product • • • •

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P1 mini de-duster cleans up to 65 kg per hour

Applications: Polyester HDPE PTT Styrene Polypropylene Glass & material Filled

P5 cleans upto 225 kg per hour

Solutions for: • Injection moulders • Blow moulders • Recyclers • High end products • Medical equipment • Automotive equipment • Protective gear • Screens and high quality surfaces • Optical equipment

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LETTERS

Colour effect pigments training

The seminars will be held in: Johannesburg 9 May – Cosmetic Seminar 10 May – Industrial Seminar (packaging • FOR MORE INFORMATION, TEL: 031

The funding of education & training

and masterbatch) 11 May – time available for us to visit individual customers if required.

Durban 14 May – combined cosmetic and industrial seminar Cape Town 16 May – combined cosmetic and industrial seminar 17 May – time available for us to visit individual customers if required.

TRAINING

CORAL Chem in conjunction with its principal, Geotech International BV, will host a training seminar in Cape Town, Durban and Johannesburg during May 2012 about colour effect pigments (glitters, pearlescents, glass and aluminium pigments).

The seminar will cover all aspects of colour effect pigments, ranging from their make-up, type, colours and particle sizes available, formulating with them, their use in different solvent systems, as well as care needed when using them in production.

The seminars are free of charge and will start at 09h00, ending at about 16h00, and will include refreshments and lunch.

266 0307 OR EMAIL INFO@CORALCHEM.CO.ZA

in the rubber industry

IOM Rubber Division’s Education and Training Fund qualifies for socio-economic development element of Broad-Based Black Economic Empowerment Act

Extensive in-house training has in fact been carried out in rubber sector that the companies involved have been I refer to the article in the May edition of satisfied with the standards of training your publication by Dr D Duncan (on the delivered and have in fact benefited from Funding of Education and Training in the this training.

Rubber Industry, page 96) which I feel It is pertinent to note that today over cannot be allowed to pass without 100 learners are attending training courscomment. es being presented by one or other of the Since 2000, in-house training has been two companies. The same cannot be said carried out at factories across the country of either the IOM³ or MERSETA! by mainly two companies, Polymer Turning now to the involvement of the Educational Services and Rubber ConIOM³ with the MERSETA and the Unit sultative & Training Services. These two Standards implemented by the MERSEcompanies have during this time trained TA, again this many hundreds process has been of learners both at It is pertinent to note that notable by the abinternal venues within today over 100 learners sence of the IOM³. In companies and in are attending training 2009, the MERSETA formal educational courses being presented set up a committee situations. The two of ‘experts’ and spent companies have carby one or other of the approximately one ried the flag of skills two companies. year examining and training across South revising the Unit Standards in place for Africa from Phalaborwa to Durban. This skills training in our industry. The existing training has been carried out without the Unit Standards left a lot to be desired in assistance or cooperation of the Institute respect of the content of the standards. of Materials (IOM³) and at times in the In addition, much of the content was irrelface of direct opposition from that body. evant to shopfloor operatives: would you, To claim that the ‘level of education and for example, expect an extruder operator training in the rubber industry’ offered by to be able to understand an electrical these companies is ‘poor’, as stated by circuit drawing and further to install an Dr Duncan, is patently untrue. During this electrical distribution network (as implied time many companies have returned to one or other of the two bodies listed above in Unit Standard 13136 Level 2)?

It should also be noted that SAQA for further in-house training. Additional Qualifications for Levels 2, 3 and 4 were training at levels 4 and 5 has taken place restricted to mixing or extruding or mouldin Pretoria, Johannesburg, Howick and ing or calendering.

Durban. This repeat business infers

NO-ONE can deny that the level of education some support to get it underway. This fund and training in the Rubber Industry a company can achieve 15 and 25 in South points was tested against the principles of BBBEE Africa is poor. The consequence of respectively in terms of the enterprise this is indeveland found to qualify for the socio-economic creased production costs and lower opment element of BBBEE. profitability. development element of the Act. This gave an Numerous interventions to resolve this In other words; by contributing 3% of problem immediate points score under profits BBBEE of 25 for have been attempted over the years, after tax, a company can achieve 20 but have or 50 an SMME and 5 points for a big company. always foundered on the issue of funding. points respectively towards their BBBEE We than approached the subject from the In 2010, the IOM undertook an initiative rating, simultaneously providing skills training economic development element of BBBEE to facilitate the skills training of the workforce which will ultimately enable the company and investigated ways of training people to in the in the rubber industry of South Africa. improve both the quality and productivity Apindustry within the definition of this element of proaches were made to Plastics/SA of their operation. (50 points is a level (formerly 6 BBBEE the Act. We found that the formation of a workers accreditation for an SMME. The Plastics Federation) to assist through An SMME is dethe co-operative, in which the co-op members use of their regional facilities and teaching would fined as earning less than R35 million turnover skills. be educated in a classroom and then trained in They agreed and this gave us training per annum). facilities a commercial operation in a factory environment in Midrand, Durban, Port Elizabeth At the end of the day, this initiative is and Cape only would fulfill the conditions of the Act. This conTown. as good as the number of skilled people cept was introduced to the Industry it at the IOM The SETA (Merseta) relevant to the can deliver. We now have in place, rubber in-house Conference in April 2011. industry had qualifications and unit and through strategic alliances, the standards ability to Since then the Rubber Industry Workers in place and so all we had to do, in educate - from ABET to PhD. We can order to get Co-operative Limited train has been registered the process up to speed, was find students by the from sweeper to factory manager and DTI. The registration number and then go is 2012/002753/24. on to develop fund them. the business skills for entrepreIn order to create a positive attitude neurship. to the Implications for the industry include: cost benefit that a company will achieve by un- • By contributing 1% of after tax profits to the dertaking training on an industry basis, FOR MORE INFORMATION CONTACT: the idea IOM3 Rubber Division’s Education and of linking the costs to the skills development Training ANTON HANEKOM, TEL: 011 653 4785, Fund a company can achieve 5 and EMAIL: ANTON.HANEKOM@PLASTICSA. 25 points portion of the Broad-Based Black Economic CO.ZA respectively in terms of the socio-economic TONY HESP, TEL: 082 452 7842, Empowerment (BBBEE) legislation was muted. development element of BBBEE. EMAIL: HESPFUTURENET.CO.ZA The IOM Rubber Division’s Education and • By contributing 2% of after tax profi DAVE DUNCAN, TEL: 082 491 0619, ts to The Training Fund was set up in 2011 and received Rubber Industry Workers Co-operative Limited, EMAIL: DDJD@IAFRICA.COM

After about a year’s deliberation, several revised Unit Standards were finalised.

Later it was reported by the MERSETA that these revised standards were vetoed by the Plastics Federation as being not suitable and never issued for further comment. Thus a year’s work by representatives from the Industrial Rubber Goods Industry travelling from as far afield as Durban, Port Elizabeth and Gauteng was tossed aside by a body not even involved in our industry. It should be remembered that the Unit Standards referred to by Dr Duncan are still those which were considered as unsuitable for use in 2009. To use these standards as the basis for future training courses would be folly indeed.

Those companies considering training based upon the current Unit Standards are advised to carefully consider the contents of these standards before committing themselves to training courses based upon these standards.

Finally, doubts are present in my mind as to the long-term viability of the IOM³.

In the Gauteng area the Institute seems to be moribund. The number of meetings held in the past year can be counted on the fingers of one hand. Is this then the body to oversee the education and training of learners in our industry?

DW Ransom Rubber Consultative and Training Services (Note: The letter has been edited)

Biodegradable, photo-degradable or oxo-degradable?

I want firstly to congratulate you and your team for the quality journal you produce. I read the article in page 44 of April/May 2012 and I have some opinions on the contents. I think in the article it should have been stated clearly that using an additive that perhaps is biodegradable partly or totally does not make polyethylene biodegradable.

If something is claimed to be biodegradable, I would expect the standard used is included in the article. I have attached a copy of an article* that comes from a well-known institute in Sweden where they have many years’ experience in biodegradable polymers as well as degradable polyethylene. In my mind you need to state clearly in similar articles if the polymer is biodegradable, photo-degradable or oxo-degradable to prevent any confusion. I would also prefer that the additive is called pro-oxidant if there is no evidence that the additive is biodegradable.

Eino Vuorinen (PhD, Pr Sci Nat) R & D Metrologist: Metrology in Chemistry, NMISA, Pretoria

82 JUNE / JULY 2012

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Major Indian plastics producer counts on

Erema’s TVEplus technology Heavily printed plastics pose new challenges to recycling systems PACKAGING films are colourful and chemically complex and represent an ever-growing challenge for recycling systems. Erema’s TVEplus technology makes it possible to produce high-quality recycled material even from waste film that has multiple layers of print. By using TVEplus recycling technology, innovative plastics producers such as the Indian company Uflex help to protect resources and also handle them responsibly.

The Indian company Uflex Limited, a subsidiary of the international Uflex Group, has been a pioneer in the production of plastic packaging (BOPP, BOPET, laminated and metallized films etc.) since 1983.

The company also makes the multilayer printed and strikingly colourful packaging for many applications. However, the production waste does not land in the bin.

Instead, a newly developed recycling system means the company can process the plastic waste and make high-quality recycled material. TVEplus technology from Erema has been in use with great success at Uflex Group since 2010, enabling the sustainable use of packaging materials.

www.erema.at

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TVEplus recycling technology is suitable not only for production waste but also for post-consumer and means plastic waste can be processed and high-quality recycled material manufactured

material in a single pass, even from waste film that is covered with multiple layers of print.

Strength and sustainability When processing heavily printed multilayered plastic waste, previous recycling Gaining quality technology often reached its performance Uflex Group uses TVEplus systems from limits. Binding agents and other additives Erema and produces a high-quality end that are always found product even from TVEplus technology in the inks, for example, materials which are are a problem as they difficult to process. The developed by Erema melt at the processing recycled material is offers efficient filtration, temperatures of the then used in the prohomogenization and plastic matrix and break duction of high-grade degassing at the down in parts. injection-moulded TVEplus technology parts. highest level developed by Erema ofAdditionally, the fers efficient filtration, homogenization and ecoSAVE design of the EREMA systems degassing at the highest level and makes is particularly energy-saving and environit possible to produce high-quality recycled mentally-friendly. The positive result for

UFLEX: greater efficiency with less energy consumption.

Recycling with sustainability TVEplus recycling technology is suitable not only for production waste but also for post-consumer material, where appropriate collection systems are of significance. India is also working on improving and optimizing waste management and recycling infrastructure. In October 2011 Solicitor General Gopal Subramanium spoke out in favour of improving the nationwide collection system to ensure homogeneous material flows for the recycling process.

• RELLOY REPRESENTS EREMA IN SOUTH AFRICA

New design, proven technology THE official soccer ball of this year’s European Soccer Championship, the ‘Tango 12’, is the result of long-standing, proven collaboration between Adidas and Bayer MaterialScience. A special feature of the Tango 12 is the texture of the surface, reminiscent of the structure of denim. The outer shell of the Tango 12 consists of five polyurethane layers based on raw materials from Bayer’s Impranil® product line. The innermost layer is an adhesion coating that connects the textile substrate to the layers above. On top of this is a syntactic foam layer, roughly 1 mm thick, made up of millions of gas-filled cells. The ball is finished off with three compact polyurethane layers of various thicknesses. They make the surface highly resistant to external factors and abrasion, but also highly elastic, ensuring the ball retains its unique appearance over the long term.

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MATERIALS

Songwon doubles capacity

of OPS products Commissions an additional 7 000 tons capacity

Songnox® OPS delivers a wide variety of complex additives in a convenient and accurate form for safe and cost effective processing.

(PHOTO: SONGWON INDUSTRIAL CO., LTD.)

www.songwonind.com

EDM open house!

EDM Shop, suppliers of machine tools from various manufacturers, including Accutex, Huron, Wele (Toyoda), Sure First, Aristech and Frank Phoenix, as well as Welltec and Long Chang moulding machines, will be hosting an ‘open-house’ show at its premises at 17 Aschenberg Street, Chamdor, Krugersdorp, on 18 and 19 July (Wednesday/Thursday), from 10am to 4pm on both days.

SONGWON Industrial Group, the global number two supplier of polymer additives, has extended its lead in the delivery of OPS (One Pack Systems) products by commissioning an additional 7 000 tons capacity.

Songwon acquired Additives Technology Greiz (ATG) in Germany in December 2011, making Songwon a leading supplier of OPS product solutions.

“The new capacity doubles the current volume to 14 000 tons”, said Jongho Park, chairman and CEO of Songwon Industrial Group. “We made a promise when we acquired ATG to extend the capacity of our Songnox® OPS products up to 12 000 metric tons. However, the reaction we have had from our customers has led us to commit additional investment such that we can now deliver an additional 7 000 metric tons of product to meet their demands.”

The Songnox High Heat OPS range offers customers a complete toolbox for designing tailor-made solutions to meet the requirements of longer service life and

The star of the show will be a new model Sure First high-speed closed-bridge machining centre. Features of the CM-565 machine include: • a 30000rpm, 6.4kW built-in motor, spindle; • a 1:5 spindle support ratio (a design breakthrough); and • an exclusive design on the X-axis Also being exhibited in live demos, a CNC EDM machine featuring a quick change tooling system, an Accutex WEDM machine and a 1500mm x 800mm travel machining

Roquette showcase plant-based plastics THE Roquette Group, a leader in the field of starch and its derivatives, have launched Gaïalene®, an innovative and sustainable solution for the plastics industry.

Gaïalene is a complete range of plant-based plastics designed and developed by Roquette for the plastics technology sector and compounders. Bio-based and not biodegradable, the Gaïalene resins have a very low carbon footprint and contain over 50% of renewable matter. Gaïalene resins are available in industrial quantities for film extrusion, injection moulding, extrusion blow moulding of small bottles and compounding. The resins can replace plastics such as PE, PP and ABS, and can be used directly on conventional production lines and at the end of their service lives are fully recyclable.

www.gaialene.com

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JUNE / JULY 2012

durability under harsh conditions for enduse applications such as in the automotive industry.

OPS products combine a wide variety of complex additives into an integrated dust free, pellet form, can be custom formulated and offer a number of key advantages such as uniformity and certified composition. OPS are also extremely cost effective as they reduce the actual dosage of individual additives due to more accurate feeding as well as simplified quality control procedures.

Songnox OPS offers a combination of additives in a convenient and accurate form for safe and cost effective processing. This is ideal for the automotive industry where Songwon is gaining ground and finding favour due to the high quality and performance that Songnox High Heat OPS offers.

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centre featuring a Renishaw automatic job setup system, as well as static displays of other machine tools and accessories.

CAD/CAM and measuring arm demos

by Aztech will also be conducted during the course of the two days.

FOR FURTHER INFO, CALL SUZIE ON 011 762 5231 OR EMAIL SUZIE@EDMSHOP.CO.ZA

www.welltec.co.za

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Physical foaming products for communication cable insulation Meeting the demand for higher quality transmission improvement in electrical properties. Since was subsequently developed to improve then this technology has progressively been cable performance. adopted by the wire and cable industry The reason for this is that gases like air where it is now widely used. and nitrogen have very low relative dielectric In chemical foaming azodicarbonamide is constants and therefore offer outstanding mainly used as the blowing agent. However, insulation properties. this creates carbon oxides and ammonia Typical applications for communication decomposition products while foaming. Gas cable insulation include: injection technology is more attractive from • Multipair telephone cables, smaller coan environmental point of view as nitrogen axial cables, such as Community Antenna or carbon dioxide is normally used as the Television Cables (CATV) and data cables expansion medium. produced by chemical foaming and having expansion degrees of Communication up to 50%.

PE is the material of cable applications • High expansion (up choice for insulation The main applications to 80%) physically in telecommunication for communication foamed insulations. applications because its cables with a metal • 3G mobile phone optimal combination of conductor are: antenna systems, • Pair cables, telecomusing 50 Ohm coaxial electrical, physical and munication cables, demanding Chemically and physically foamed processing properties • Data cables minimal losses. insulation compounds gives it an ideal fit • CATV cables These cellular insulation compounds are with the performance • Mini coaxial cables By combining gas with optimised to generate uniform and evenly • Radio Frequency PE (which also has a distributed cells that enhance transmission requirements.

(RF) cables properties. In addition, improved flow proper- low dielectric constant) Solid or chemically blown insulations are through foaming, an even better insulation ties, melt elasticity and purity allow for high the main choices for pair cables and data material that enables the reduction of cable line speeds in combination with minimised cables of the twisted pair type. However, size, as well as giving improved transmiscapacitance variations. sion, is created. Initially, creating a sealed cell there is a significant increase in the use of PE is the material of choice for insulation structure was achieved by chemical foaming physical foaming for pair cables as well as in telecommunication applications because for CATV cables on account of the better its optimal combination of electrical, physical of the material through the incorporation of a electrical properties they offer. and processing properties gives it an ideal fit blowing agent in the compound formulation.

For RF cables such as antenna systems A later advance came with the introduction of with the performance requirements. Historiin mobile telephone networks, physigas injection technology, allowing PE to be cally, the first use for PE in telecommunicacal foaming is the most commonly used tion was as solid insulation. Cellular insulation physically foamed and bringing another step THE exponential growth of internet and mobile phone use globally is emphasising the need for accurate and fast transmission of large volumes of data, voice communication and pictures. The increasingly higher operating frequencies used have accelerated the demand for enhanced electrical properties of the insulation materials in communication cables. The insulation performance improvements should also be matched by improvements in processability and material consistency.

To satisfy these dual objectives, Borealis and Borouge have further developed their extensive range of chemically and physically foamed polyethylene compounds. These developments offer improved transmission properties for the end user and easier processibility for the cable manufacturer.

Processing Typical temperature profiles for different products are hard to recommend as adjustments in process settings have to be made according to the cable size, construction, extruder type etc. In general, higher processing temperatures are required when manufacturing smaller diameter cables or when using higher line speeds.

Thus, temperatures close to 200ºC can be used for high speed extrusion of data cable insulation. A lower temperature profile is recommended for cables processed at line speeds lower than 500-700 m/min (ap-

88

proximately).

It is recommended to start with a low temperature to supply energy to the material via the screw for good homogenisation. To obtain optimal activation of the nucleating agent, the temperature should then be increased at the point where the gas is injected. It is very important to achieve good homogenization of the polymer and gas at the gas injection point.

Normally physical foam processes are used for the manufacture of 100Ohm data cable or large 50 or 75 Ohm coaxial cable insulations. The manufacture of data cable

TECHNICAL

technique, and it has been a prerequisite in the evolution of more efficient systems operating at the highest frequencies.

Historically, the materials used for physical foaming have often been in-house mixtures based on Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE) and a nucleating agent, made by the cable manufacturer directly at the cable line. The main advantage of this procedure is that for each cable size, the LDPE/HDPE ratio can be optimised in order to achieve the lowest possible attenuation while maintaining good foaming properties.

Hence, optimised blends of LE1120 and HE1123, correctly processed, will meet top level requirements for cables with extra high attenuation demands. An alternative possibility is to use ready-made blends such as HE1106 and HE4873. These two compounds for physical foaming have been optimised to meet different demands and the needs of a variety of applications.

frequencies. By dry blending the pellets prior to extrusion it is possible to optimise the HE1123/LE1120 ratio for each insulation thickness in order to give the lowest possible attenuation. A variety of nucleating agents developed for gas injection applications can be used in combination with HE1123/LE1120. Nucleating master batch Hydrocerol® NUC5532 from Clariant, containing endothermic blowing agent, has Recommended insulation products shown good performance in these applicaBorealis’ and Borouge’s chemically and physitions. cally foamed cellular compounds exhibit a high For symmetric cables and coaxial cables degree of foaming and deliver very low dielectric with an outer diameter of up to approxilosses. It provides a single source of solutions mately 3 to 4 mm, HE4873 is recommendable to satisfy the full spectrum of communicaed. With stricter requirements of attenuation tion cable demands. for small size and medium size coaxial HE1106 is a fully formulated compound based cables, HE1106 can be used. mainly on HDPE and a nucleating agent. This grade is designed for use in small to medium Borealis and Borouge – Dedicated coaxial cable constructions (type RG) as well as to wire and cable solutions standard demand RF cables.

Borealis and Borouge are the world’s leadThe components are selected to give low ing providers of innovative, value creating attenuation over a wide range of frequencies. plastics solutions for the wire and cable HE1106 can be expanded to slightly above industry. Their solutions are customer80%. HE4873 is a fully formulated compound driven and designed to satisfy the industry’s for gas injection of cellular data cable insulation. continuously evolving demands for higher The components have been chosen to achieve technical performance. Consequently, they superior processing properties which enable can be found in the most challenging EHV high line speed in combination with good cell and HV cable applications, as well as MV structure and minimised capacitance variation. and LV energy transmission and distribution The main use is in twisted pair data cables and cables, building wires, and communications small coaxial cables, typically not exceeding an cables. outer diameter of 3 to 4 mm. HE4873 can be In answer to the need for production, expanded to above 60%. installation and cable-system lifetime enLE1120 and HE1123 are designed to be used hancements, Borealis and Borouge create as insulation for radio frequency cables having the innovation links that secure worldextra high demand on low attenuation at high class, step-change solutions and benefit

is a high-speed process normally using >30 L/D extruder of 60 or 80mm. In general, such lines are equipped with conductor and insulation skin extruders (triple layer).

Line speeds in excess of 1500m/min are common. Modern lines have sophisticated electronics giving fully automated process control and for most established commercial insulation materials the required temperature settings are programmed into the control software. Additional information on temperature settings is available on the material technical data sheets.

Physical foam extruders for coaxial cables

are much larger (100-150mm). Typically the extruder barrel is very long (40L/D).

This is because the polymer must be heated in the first part of the screw to a temperature in excess of the kicker decomposition temperature, and then subsequently in the second part of the extruder, to cool the melt to increase the melt stability. Often this is accommodated by two extruders in cascade, the first smaller extruder serving to melt and homogenise the polymer and the second much larger machine to cool and incorporate the gas.

the whole wire and cable value chain.

Through the introduction of unique polymer technologies, which include Supercure™, Visico™/Ambicat™, Borcell™, Borstar®, and Casico™, they continue to pioneer the development of advanced insulation and jacketing systems for both energy and communication cables.

Built on more than 40 years’ experience, Borealis and Borouge have a well-established track record in serving customers’ needs with the consistently high quality products expected of global leaders.

Putting customers’ needs at the centre of our planning is reflected in the commissioning of expanded XLPE production capacity in the second half of 2007 and Borealis’ €370 million investment in a new 350 000 ton/year LDPE plant in Stenungsund, Sweden.

Furthermore, Borouge’s expansion of Borstar® capacity in the Middle East allows the company to satisfy growing customer demand for wire and cable products in emerging markets.

Through ongoing research and development, investment in the future and a dedicated team with solid industry knowledge, Borealis and Borouge aim to remain fully responsive to their customers’ needs throughout the world.

• CONTACT YOUR LOCAL BOREALIS REPRESENTATIVE, CHEMIMPO, REGARDING SPECIFIC RECOMMENDATIONS FOR PROCESSING CONDITIONS

www.borouge.com www.chemimpo.co.za www.borealisgroup.com

Insulation skinning to protect the foam during the cooling process is necessary and for highly expanded insulation a conductor skin is necessary to achieve a sound conductor/foam interface.

Borealis and Borouge offer a full set of products for physical foaming. Together they cover the complete range of cable insulation solutions with this technology.

Optimally mixed, these Borcell products offer superior processing properties and minimised attenuation, in addition to improvements with respect to environmental considerations.

89

TECHNICAL

Removing the guesswork from mould manufacture ‘Preventative analysis’ detects potential manufacturing issues

The moulded cover is produced using 30% glass long fibre filled nylon

PATENTED injection moulding analysis ahead of tool production ensures that a number of components in a revolutionary water powered rock drill are manufactured to the degree of absolute precision required by mining operations around the world.

Leicestershire-based Dudley Associates produce a polymer cover that plays a vital role in enclosing the drill’s rotary drive mechanism and protects the workings from damage and contamination at the working face of the mine, up to 2km underground.

Work Director John Churchard says accuracy of the cover, which is manufactured from 30% long fibre glass filled polyurethane, is critical: “The flatness aspects are particularly important. As the component has the drive gear running through it, any distortion or warpage would cause

VISI Flow’s database has more than the whole drive to bind and 7 500 polymer grades thereby have a detrimenWhen it comes to analysing how moulds tal effect on the drill for components such as the rock drill cover efficiency.” will perform, Design Engineer Kevin Steele He says weld uses the tools within VISI to validate part lines and weak thickness and remove any features such points were also as small fillets or engravings to ensure crucial factors optimum flow simulation. Once satisfied in making the with the part quality, the gates are added. moulded cover For all but the most complex gating, this is robust enough easily done by sketching the centreline of to cope with the runner/gates and applying the relevant the conditions features. Then the model is prepared for underground analysis. while drilling blast The material is selected from VISI Flow’s holes. It was theredatabase of more than 7 500 polymer fore imperative that the grades, and the moulding parameters aluminium tool used in the are set. injection moulding process was Any required parameter changes are typical of the high spec, high precision made and the analysis is run again until work that makes Dudley Associates spethe results are acceptable. For this project, cialists in high grade aluminium tooling for VISI Flow confirmed Kevin Steele’s use of a range of industries including automotive, a four-position multiple gate going through medical and electronics. the centre, but where Before they start to necessary it will flag “The flatness aspects are create such techniup that the gate size cal moulds, Dudley particularly important. or position must be use VISI Flow (plastic As the component has adjusted. “For many injection analysis and the drive gear running parts that’s as far as simulation from Vero through it, any distortion the analysis is taken, Software) to optimise but when we need to the tool design and or warpage would cause know more, I’ll set up moulding process the whole drive to bind a holding analysis. parameters. This and thereby have a VISI Flow suggests ‘preventative analysis’ detrimental effect on the holding and cooldetects a wide range ing times, but the fill of potential manufacdrill efficiency.” analysis can also be turing issues such as analysed to look at which areas of the part warpage, weld lines, air traps, filling issues are frozen off at what time.” This is followed and hot spots, while determining the optiby the shape analysis, which he says mum gating position.

VISI Flow confirmed the use of a four-position multiple gate

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VISI is used to validate part thickness and identify potential issues

normally requires no further information unless there is a feature such as a steel insert in the moulding which limits movement. â&#x20AC;&#x153;The part can then be studied to see where it will distort, and by how much. When comparing different process variables itâ&#x20AC;&#x2122;s useful being able to export an STL ďŹ le of the distorted part into the CAD system and overlay it, giving a useful visual comparison of the options.â&#x20AC;?

Using VISI Flowâ&#x20AC;&#x2122;s host of features in this way gave Dudley Associates a full picture of how the tool would perform in the moulding machine, and gave them the conďŹ dence to commit to making the high grade aluminium mould, which now produces the covers on an Engel Victory 300 tonne moulding machine with robot arm.

Dudleyâ&#x20AC;&#x2122;s parent company, Peterstow Aquapower, manufactures the drill in South Africa, which operates on untreated water without the need for conventional oil hydraulics or pneumatics. With changing many of the drill components from metal to moulded plastic, it has become extremely compact, portable and manoeuvrable. The closed loop system does not need oil or harmful chemicals, and the specialist Peterstow Aquapower technology eliminates the need for much of the underground infrastructure required for competing technologies, making it signiďŹ cantly more efďŹ cient and cost effective.

Dudleyâ&#x20AC;&#x2122;s Work Director, John Churchard, with Engel 300T moulding machine

Post production analysis As well as the pre-production analysis that proved to be so valuable in creating the perfect mould for the drill cover, Kevin Steele also uses VISI Flowâ&#x20AC;&#x2122;s Post-Production Analysis capability when an older mould is already in production and not performing as expected.

The company also has the optional overmoulding module, which recently

helped them produce the perfect mould for an electronic bingo computerâ&#x20AC;&#x2122;s casing, which houses the screen players use to mark off their numbers. The casing is PC/ ABS with a TPE overmould. www.peterstow.com www.vero-software.com JUNE / JULY 2012

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Shanghai Hongshen

MAGNETITE ENGINEERING POLYMERS REWORKED AND REPALETIZED MATERIALS

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Johannesburg (Head OfďŹ ce) Tel: 011 894 3937 Fax: 011 894 3954 sales@hi-techelements.co.za www.hi-techelements.co.za

KwaZulu Natal Tel: 031 701 1053 /63 Fax: 031 701 1062 ashwan@hi-techelements.co.za www.hi-tech.edx.co.za

HEATING ELEMENT DESIGN & MANUFACTURE

TRAINING

International materials experts share in SA’s training load als technology since 1990, IAM prides TOP European experts in polymer technolitself on its international standing as a ogy have been presenting sections of centre of excellence and, to that end, has the course-based honours programmes co-opted international experts to share in at the Institute of Applied Materials at the its training offering, as well as to participate University of Pretoria over the years. This in research at the Institute. year will be no different with In 2011 Prof Hans-Joachim Prof Christian Bonten, head of Radusch of the Martin Luther the Institute of Polymer TechnolUniversity of Halle-Saale, Gerogy (IKT) at Stuttgart University; many lectured in rapid prototyplecturing in polymer engineering ing and rapid manufacture, also as part of the polymer processas part of polymer processing ing course. The IKT works in course. Dr Bruno Ameduri, a the fields of materials science, fluoro-polymer expert from the processing and development of Prof Christian Institute Charles Gerhardt in plastics parts.

Bonten, head of the Montpellier, France, has also The two-day ‘Designing with Institute of Polymer participated and plans are Plastics’ course by Prof Bonten, Technology (IKT) at already underway to include will take place on 2-3 August Stuttgart University, will lecture polymer Prof Rene Androsch, also (Thursday-Friday). For more engineering as from Halle-Saale, to lecture in details phone 012 420 5015; or part of the polymer polymer materials as part of email: info.ce@up.ac.za. The processing course the polymer materials science course fee is R3500 per person. at the Institute of module in 2013.

The Institute of Applied Applied Materials at the University of The Institute is currently Materials (IAM) is an interdiscihome to four professors. They plinary materials research group Pretoria include Prof Brian Rand, a at the University of Pretoria world leader in carbon materials research with participation from the Departments of and part-time chair holder of the SARChI Physics, Chemistry, Chemical Engineering Chair in Carbon Technology and Materials, and Materials Science and Metallurgical as well as Prof Philip Crouse, chair holder Engineering. IAM is associated with two of the SARChI Chair in Fluoro-materials SARChI Chairs conducting research in Science & Process Integration. The other carbon and fluorine materials respectively. two are Prof Walter Focke, director of the Offering postgraduate courses in materi-

Prof Walter Focke, director of the Institute of Applied Materials at the University of Pretoria

Institute and Prof Ncholu Manyala of the Department of Physics.

IAM also has an advanced thermal analysis capability and work is performed for industry on an ad hoc basis at commercial fees. All analyses are performed and interpreted by trained technicians.

Analytical methods include: • Thermomechanical analysis (TMA) • Simultaneous differential scanning calorimetry (DSC) and thermogravimetry (TGA) linked to gas analysis by mass spectrometry (up to 1500 °C); • Thermogravimetry (TGA) linked to Fourier transform infrared spectroscopy (FTIR) spectroscopy; • Dynamic mechanical analysis (DMA) (up to 600 °C). www.iam.up.ac.za

Borealis scientist honoured with Giulio Natta Award 2012 Sirius technology allows for better regulation of polymerisation reactions

Dr Peter Denifl (middle) received the Giulio Natta Award at a function in Ferrara, Italy, on 19 May

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THE MASTERMIND behind Sirius, Borealis’ groundbreaking new polyolefin catalyst technology, has been awarded the prestigious Giulio Natta Award for 2012.

The accolade recognises the significant contribution of Dr Peter Denifl’s scientific activity in catalyst development, in the field of polypropylene products. Proprietary Sirius catalyst technology from Borealis is spearheading the development of polyolefins with cutting edge performance and sustainability benefits. For example, it is supporting the innovation of cast film polypropylene grades which offer step change purity and optical properties, and faster, more energy-efficient processing for recyclable and sterilisable food contact applications.

The Sirius technology platform has been quoted as the biggest change in industrial

polyolefin catalyst technology since the development of high-yield Ziegler Natta (ZN) catalysts several decades ago. It has raised considerable interest in the global polyolefin community due to its ability to improve control of the active site distribution in ZN polymerization catalysts in a single-step process, resulting in better regulation of polymerisation reactions.

Also ‘single site’ catalysts can be made using the Sirius technology, with benefits in productivity and homogeneity across the catalyst particle.

The G Natta Award was introduced in 2003 to celebrate the scientific achievements of Prof Giulio Natta, recipient of the Nobel Prize in Chemistry (1963) for the discovery of polypropylene. www.borealisgroup.com

MATERIALS

Steeling the show First joint industrial activity for injection moulded plastic parts with steel cord reinforcement

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TOGETHER with its partners Bekaert (Belgium) and Voestalpine Plastics Solutions (Netherlands), BASF is working on the development of thermoplastic components that are reinforced with steel cord fabrics and produced by means of injection moulding. The three companies have joined together to use and further develop this new EASI technology with partners in the automotive industry. (The abbreviation EASI stands for Energy Absorption, Safety and Integrity).

In contrast to known types of reinforcements like continuous ďŹ bre-reinforced laminates or other carbon or glass ďŹ bre fabrics, the steel cord inserts ensure the integrity of the moulded partâ&#x20AC;&#x2122;s function in a crash situation. This creates an entirely new performance class.

Bekaert, Voestalpine Plastics Solutions and BASF have been investigating steel cord reinforced injection moulded parts since 2010. The ďŹ rst production part using the predecessor technology was based on compression moulding with GMT (glass mat reinforced thermoplastics), and received the AVK Innovation Award in 2008.

Working together, the three companies are now focusing on classical injection moulding of parts with steel cord reinforcement.

The steel cord reinforcement employed in the EASI concept ensures that an injection moulded part retains its structural integrity. Thus, while EASI parts may be damaged in a crash, they are still able to absorb energy and lead it further into the structure. www.basf.com www.voestalpine.com Injection moulding and steel cord reinforcement â&#x20AC;&#x201C; The steel cord reinforcement employed in the EASI concept ensures that an injection moulded part retains its structural integrity

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USEFUL INFO ON THE INTERNET

PLASTICS|SA WEBSITE REDESIGNED Redesigned site allows for ‘social media’ interaction Plastics|SA has re-launched its website. The goal of the current overhaul is to provide a more functional, user-friendly navigation experience.

A lot has changed in the electronic world in the five years since the site was last designed in 2007, so it allows for more ‘social media’ interaction via Facebook, RSS Feeds or YouTube.

The new design features a members-only section, allowing members of Plastics|SA’s associations access to important industry information and opportunities. The news section provides current industry news and an events calendar outlines important dates.

Education and training receives special attention, with info about the latest learning programmes being prominent.

The website displays a section titled ‘Plastics part of your Life’ that elaborates on the role that plastics plays in packaging, medical and health, transport, building and construction, electrical and electronics and also sport and leisure. The site is also aimed at members of the general public, many of who may not fully understand polymer technology. Topics covered include how are plastics made; where do plastics come from, how safe is BPA and much more.

Since one of the most frequently received inquiries is where to recycle, an interactive portal allows the users to type in the area where they reside and find the closest recycling/dropoff sites. Sections are also devoted to energy efficiency and plastics and toys.

Members of the industry are encouraged to use the on-site interactive poll and comment about the site, visit: www.plasticsinfo.co.za

PERPETUAL MOTION ON THE SKYLINE INNOVATIVE solutions from the chemical industry help to enhance the performance and efficiency of modern wind turbines. That is the message of the new ‘Perpetual Motion on the Skyline’ film of roughly four minutes that BASF has released in the ‘Creating Chemistry’ series. The video also provides interesting insights into the activities of Enercon GmbH, a BASF customer and a major wind turbine manufacturer headquartered in Aurich, Northern Germany.

Be it in the use of epoxy systems for heavy-duty fibre-reinforced components, coatings for wind turbine blades, foams for the internal strengthening of rotor blades, special grouting mortars or concrete additives for the production of ultra-high strength foundations and towers, or lubricants for gearboxes – BASF’s chemistry comes into play everywhere. BASF supports the manufacturers of wind turbines with a broad range of products and solutions that it keeps enhancing in close cooperation with its customers.

“We have been relying on and trusting in

our cooperation with BASF for some years because it enables us to develop and improve products to meet our specific needs.

We get optimum results in this way,” said Ruth Brand-Schock of Enercon GmbH. The strains and stresses that a wind turbine is exposed to are immense: With top speeds reaching up to 300 kilometres an hour, powerful forces act on the whole plant.

They may make blade tips bend by more than a metre. In addition, weather factors such as snow, rain, heat and UV radiation take their toll on the wind power plant.

PARKINSON TECHNOLOGIES LAUNCHES ALL-NEW WEBSITE PARKINSON Technologies, Inc. has launched an all-new website that consolidates the company’s numerous brand offerings under the Parkinson Technologies Inc. umbrella, and provides an easier platform for customers to navigate, inquire and place orders.

“In addition to consolidating our technology platforms in one place, our new website makes a fresh and more obvious connection to the diverse industries and markets we serve,” said Peter Termyn, President and CEO of Parkinson Technologies. “The developers did a great job making it easy to navigate between our many brands while still emphasizing our other critical service offerings such as our extrusion and biax orientation lab.”

The new website database has enabled the company to provide more uniform product specifications to site visitors, and in turn, allows customers to send more detailed inquiries in a more organized manner.

Parkinson Technologies Inc. is an industry leader in the development, design and manufacturing of web processing machinery for the plastics, nonwovens, paper and specialty materials industries.

Product brands include Parkinson winders, Dusenbery® Converting Systems, Marshall and Williams biaxial plastics orientation lines and Key Filters plastic extrusion melt filtration equipment. With a world-class pilot plant facility, Parkinson Technologies also offers its customers complete flexibility to conduct sheet/film plastic extrusion and plastics orientation R&D and to produce commercially viable marketing samples. Parkinson Technologies’ customers include a broad range of companies, from venture-backed startups to Fortune 50 enterprises, all of whom demand innovative solutions for their plastics orientation and web processing challenges. www.parkinsontechnologies.com

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www.youtube.com/basf

BOOKS

Thermal stability of polymers IN recent years numerous research papers have been published on the changes in chemical structure and in physical properties of polymers when they are exposed to heat over a range of temperatures.

These changes can occur at any time during the injection moulding of the plastic, in the subsequent processing and in its end-use application when exposed to elevated temperatures.

This book reviews in nine chapters the measurement of these properties in the main types of polymers in use today. Numerous techniques are discussed ranging from thermogravimetric analysis, differential scanning calorimetry, infrared and nuclear magnetic resonance based methods to pyrolytic techniques such as those based on pyrolysis, gas chromatography and mass spectrometry.

The book is aimed at those engaged in the manufacture of polymers and the development of end-use applications. It is essential that students of polymer science should have a thorough understanding of polymer stability and an additional aim of the book is to help in the development of such an interest. www.polymer-books.com

High performance drives growth for agricultural films LEADING plastics industry consultants Applied Market Information Ltd. (AMI) has highlighted the increasing importance of plastics in the area of agriculture and horticulture with a new in-depth report on the agricultural films market in Europe. This first of its kind report details the €2 billion agricultural films market which accounts for over half a million tons of polymer-based films every year.

Over the past 60 years, agricultural output and productivity has significantly increased and plastic agricultural film for silage, mulch and greenhouse applications has made a substantial contribution to this development. The use of plastic films has been notable in the horticultural industry, as well as the beef and dairy sector, contributing to continuously increasing yields.

The market is mainly in the Mediterranean region with Spain and Italy taking the lead particularly in consumption of greenhouse and mulch films. In the long term, however, demand for agricultural films is expected to grow more strongly in countries in Northern Europe where climate change will contribute to more favourable conditions for agriculture and ongoing push for higher yields will drive demand for agricultural films. www.amiplastics.com 98

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Leading masterbatch producers thrive through downturn A NEW report from Applied Market Information Ltd (AMI) has analysed the performance of Europe’s 50 largest companies.

The report details the size, strategy and performance of Europe’s leading masterbatch producers updating earlier research carried out in 2006.

A number of companies have refined and changed their market position in the last three years. Some of the players that feature in the Top 10, such as Schulman and Ampacet have widened their product ranges to include much more specific colour matched product, while other companies such as Tosaf and Plastika Kritis have grown their business through expanding their sales geographically.

For the first time AMI has included the Russian and Ukrainian plants of the lead-

ing producers in its analysis. Leading players operating in Russia include Clariant, Plastika Kritis (Global Colors) and Gabriel Chemie while in the Ukraine Tosaf is the leading manufacturer. www.amiplastics.com

Global PVC Market: Demand Is Increasing Steadily CERESNA Research expects the global PVC market to reach revenues of more than US$65 billion in 2019. Now that the global recession has ended, the construction industry will again boost demand for PVC. The average annual growth rate of 3.3% seen in the past eight years is likely to be

surpassed in future. The market experts from Ceresana forecast PVC demand to increase at an average annual rate of 3.9% over the next years.

Ceresna’s report gives a concise overview of the different production methods and processing techniques of PVC; a presentation and analysis of the global PVC market; countries are analyzed in detail: PVC demand, revenues, production, and imports & exports during past eight years; and an in-depth analysis of the individual application areas of PVC.

www.ceresana.com/en/market-studies/plastics/polyvinyl_chloride

www.ustech.co.za

Accurate: Fast: Reliable: Plastic identiďŹ cation Thermo ScientiďŹ c microPHAZIR PC Handheld Plastics Analyzer Thermo ScientiďŹ c microPHAZIR PC is a handheld NIR material analyzer designed for rapid on site plastic material identiďŹ cation.

The 2.75 lb (1.25 kg) analyzer is battery powered and completely selfcontained for portable analysis. Ergonomically designed for the expert and non-technical user alike, microPHAZIR PC utilizes the power of nearinfrared spectroscopy to save you time & money.

IdentiďŹ cation of common plastic types, including: PLA, PET, PP, PS, ABS, PI, PSO, PE, PPS, TPV, PTT,PC, PMP, PBT, PA (nylon), PETG, SAN, EVA, PB, PPO, CA, PMMA, PUR, PI, PVC, PLA, Ionomer, Styrenic terpolymer, Elastomer, POM, Nylon+ABS

Key BeneďŹ ts Include: Save Time: Rapid and accurate results displayed within seconds.

Easy to use: Designed for non-expert users, the analyzer is fully automated and requires no user input.

Portable: Small and lightweight for fast identiďŹ cation of materials in the ďŹ eld or at the sorting facility.

Safe: No sample preparation or burn test necessary, NIR is fast, safe and nondestructive.

For more information please contact Anna Tshwene at United Spectrometer Technologies EMAIL INFO USTECH CO ZA Â&#x201E; WEBSITE WWW USTECH CO ZA #APE 4OWN Â&#x201E; *OHANNESBURG 4EL

DISTRIBUTOR

WORLD NEWS

Recycled PET moulded in SPI’s International Plastics Design Competition THE award winners in the 2nd International Plastics Design Competition (IPDC) sponsored by SPI: The Plastics Industry Trade Association, spanned a wide range of applications, many of them demonstrating innovative use of technologies in support of sustainability goals. Culminating at NPE2012, the competition attracted 32 product entries. An international panel of nine judges evaluated the entries in advance of NPE2012 and in a special exhibit at the show itself. In addition to awards presented by the judges, there was a ‘Peoples’ Choice’ award based on online and at-show voting. For full details on all the winning entries, visit

Best in Show

www.plasticsdesign.org

GENESYS FLUID PUMP

able Sustainrt Pa

Designed by Millennium Mould Design for brand owner Multi-Duti Manufacturing, moulded by Ci-Dell Plastics with material from Bulk Moulding Compounds and tooling from Moldcraft.

ing Emerg logy Techno

3D IML WITH MUCELL

A 3D in-mould labelled packaging tub injection moulded from expanded PP using the MuCell process.

Brand owner, designer, and moulder was PACCOR Packaging Deutschland. Netstal supplied the machinery and Plastisud the tooling.

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s’ Judge Award

CALIBOWL FOODWARE By brand owner and designer Simplewave, with materials, moulding, and tooling supplied by Jatco and machinery from Toyo Injection Moulding Machines.

TIGRIS AIRLINE CATERING TROLLEY

otive Autom ns& Tra on portati

Designed by ProMolding, moulded by Bemis Manufacturing using tooling from VinylTech International, machinery from Milacron, and resin from Solvay Advanced Polymers. The product also received the Innovations in Plastics award and the Project award.

PURIST HYDROFLO WATER BOTTLE Designed by Harbor Fluid Products for brand owner Specialized Bicycle Components.

mer Consu cts u d o r P

chairs top winners BASF received four awards in the International Plastics Design Competition (IPDC), including the Best in Show Award for the 111 Navy Chair.

Accepting for BASF was Susan Jackson, shown here with IPDC chairman Robert Janeczko

111 NAVY CHAIR Designed by Emeco and gasassist injection moulded from recycled PET supplied by BASF. The product also won the Buildings & Furnishings award and the Sustainable Consumer Product award.

PRODUCT DESCRIPTION To show the value of recycled soda bottles, the rPET chair was engineered to match the iconic 1940’s era all-aluminium chairs produced for the U.S. Navy. The all post-consumer recycled plastic chair was engineered to meet meticulous cosmetic and rigorous performance requirements while minimizing material and optimal cycle times.

Approximately 111 soda bottles are used per chair, thus the name.

The chair has a subtle ‘velvet’ feel and is available in six earth inspired colours, each made from a paint-free moulded in-colour process. The chair is creatively moulded in a single cavity using gas assist technology to optimize cycle time and reduce overall chair weight. Extensive use of mould filling analysis was made to confirm knit line location, minimize warpage and gas traps. High end gas assist simulation software confirmed gas penetration and optimized the injection moulding cycle times. Non-linear finite element analysis was used in the design phase to confirm the chair’s structural integrity. A six-axis robot demoulds the chair and positions it for automatic degating and subsequent assembly. The chair’s structural H-brace, also made from PETRA recycled PET, is ‘press fit’ into place. This press fit requires no additional fasteners and the entire chair uses only four simple screws.

Single Part

INJECTION MOULDED COMPONENT FOR A WATER OUTLET ASSEMBLY

s’ Judge Award

Designed by Tech Mould, CBW Automation, and Moldmasters, with machinery from Milacron and materials from PolyOne.

MOBILEGS

ing

Packag

Moulded by Arta Plast from material supplied by Spartech Corp., for brand owner The Better Bean Company. Machinery for the project was supplied by Packline West.

POLY-LACTIC FOAM ARTICLE

able Sustainess Proc

By brand owner and designer Sekisui Plastics, also responsible for materials, machinery, tooling, and moulding.

Designed by MPC for brand owner Nissan, using material from Solvay, machinery from Demag and tooling from Industrial Moulds.

IML SYRINGE BARREL

1-SEAL CONTAINER AND LID

l& Medica fic Scienti

ZIP ZESTER

s’ People e Choic

For removing zest from citrus fruits; designed by Grass Roots Industries for brand owner Zip Zester; moulded by Cashmere Moulding using Battenfeld equipment, materials from EMS Grivory, and tooling by Questech Unlimited and China Monicom.

An alternative to the traditional crutch for disabled people, designed by Studio + Weber for brand owner Mobi.

BASF supplied the resin, and Illinois Tool Works did the toolmaking and moulding.

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BMW unveils i8 Spyder

AROUND THE WORLD BASF ACQUIRES B.C. FOAM

FOLLOWING the presentation of the BMW i3 and BMW i8 concept cars, BMW Group has now unveiled a third i model – the BMW i8 Spyder two-seat sports car.

This also features a carbon fibre reinforced plastics passenger cell.

Like the i8 coupe model, the BMW i8 Spyder is a plug-in hybrid powered by a high-performance electric motor and petrol combustion engine. The lithium-ion battery supplying the motor with power can be recharged in a short period of time from a domestic power socket.

Compared with the i8 concept, the Spyder has a slightly shorter wheelbase and overall length. The car features upward-swivelling, windowless doors and a transparent glass panel at the rear.

BASF has purchased the PET foam business of the Italian company B.C. Foam S.p.A., headquartered in Volpiano. The companies have agreed not to disclose the purchase price for the transaction. The acquisition includes production facilities and intellectual property rights, as well as a special extrusion process which enables the production of high-performance PET foams with very high densities. www.basf.com

MEXICHEM BUYS WAVIN FOR €531M MEXICAN chemicals giant Mexichem has purchased the Dutch pipe making company Wavin for €531-million, creating one of the world’s biggest plastic pipe manufacturing businesses with a turnover in excess of €4bn. The transaction follows two unsuccessful attempts by Mexichem to buy Wavin late last year. www.mexichem.com

The sports car is based around the LifeDrive architecture used in the other models, combing the carbon fibre reinforced plastic (CFRP) Life module (a lightweight passenger cell) and the Drive module, made primarily from aluminium, which brings together all the car’s operational driving functions, such as the powertrain, chassis and safety structure.

The BMW i8 Concept Spyder from 0 to 100 km/h (62 mph) in 5 seconds and has a top speed of 250 km/h (155 mph). It uses 3 litres of petrol per 100 km (equivalent to fuel economy of 94 mpg imp) in the European test cycle.

With its battery fully charged, the BMW i8 Concept Spyder can cover up to 30 km (19 miles) on electric power alone.

SABIC, Siniopec to build

PLASTIC OMNIUM SIGNS SWEET DEAL FOR BRAZIL BINS

polycarb plant in Tianjin

FRANCE-based Plastics Omnium is set to provide rubbish bins made with sugarcanebased PE to the United Nations’ Rio+20 Conference on sustainable development in Brazil. The contract is for 50 000, 240-litre bins, which were first launched at the Salon Pollutec show in Lyon, France, last year.

They are made with plant-based PE derived from non-alimentary sugarcane. Plastic Omnium developed the material Sigmatech R&D centre in La Plaine de l’Ain, near Lyon. www.plasticomnium.com

THE foundation for a polycarbonate production complex with 260,000 metric tonnes per annum capacity in Tianjin, China, was laid on 3 April. Set up by the Sinopec SABIC Tianjin Petrochemical Company (SSTPC), the venture is the second by partners China Petroleum & Chemical Corporation (Sinopec) and Saudi Basic Industries Corporation (SABIC).

SSTPC’s first venture, the construction and commissioning of an ethylene plant with an annual capacity of one million metric tons, began production in January 2010.

With a total investment of RMB11 billion (US$1.7-billion) and covering a ground area of 67 hectares, the polycarbonate production complex was approved by China’s National Development and Reform Commission (NDRC) on 13 January 2012.

With two sets of phosgene-free production

ENHANCING MUCELL® PROCESS PRODUCTIVITY CORETECH System (Moldex3D) Company and Trexel Inc have entered into a joint development agreement for enhancing MuCell® process productivity. Trexel is the worldwide leader in the development and commercialization of the patented MuCell microcellular foaming process for injection and blow moulding process systems, and CoreTech System (Moldex3D) is the ‘True 3D’ injection moulding CAE simulation solution innovator. www.moldex3d.com; www.trexel.com

www.sabic.com

systems, with an annual capacity of 130 kilo metric tonnes each, to be built, the new polycarbonate is expected to be operational in 2015. It will be able to produce four major classes of polycarbonate, including the mixed, extrusion, optical and moulding grades.

The Tianjin deputy-party secretary Huang Xingguo said: “This is another big project following the Tianjin one million metric tonnes of ethylene and the ten million metric tonnes of oil refining projects by Sinopec and SABIC. It deepens the cooperation between China and Saudi Arabia, and accelerates the development of Binhai New Area and is strategically important for the construction of state-level petrochemical industry base. We will put full effort to provide quality services and create the environment to safeguard the smooth project implementation.” www.sinopec.com

BAYER EXTENDS PC SHEET BUSINESS BAYER MaterialScience has acquired Arkema’s polycarbonate sheet business in the USA. With this deal, Bayer MaterialScience will further strengthen its position in the North American market and its global sheet activities. The acquisition will include Arkema’s Tuffak® line of products used in areas such as aerospace, transportation and heavy equipment. In addition, production equipment from Arkema Inc. will be transferred to the sheet business of Bayer MaterialScience LLC in the NAFTA region. www.bayer.com

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The ceremony was officiated by Prince Saud bin Abdullah Al-Saud, chairman of SABIC

WORLD NEWS BMW i8 CONCEPT SPYDER • Length/height/width: 448 cm/120.8 cm/192.2 cm • Wheelbase: 265 cm • Kerb weight: 1630 kg (EU) / 1555 kg (DIN) • Top speed: 50 km/h (155 mph) electr. governed • Acceleration: 0-100 km/h (62 mph) 5 s, 80-120 km/h (50-75 mph) 4 s • System output: 260 kW / 550 Nm • TwinPower turbo engine 164 kW / 300 Nm • Fuel consumption (EU cycle): 3 l/100km / 94 mpg imp • Electric range approx: 27-30 km (17-19 miles) • Battery charge time standard: 1.45 h for 100% charge

The recently unveiled BMW i8 Spyder two-seat sports car is based around the LifeDrive architecture used in the other models, combing the carbon fibre reinforced plastic (CFRP) Life module (a lightweight passenger cell) and the Drive module, made primarily from aluminium

South Korean supermarket launches world’s 1st virtual store ACCORDING to international studies of worker productivity, South Koreans spend more hours on the job than workers in many other countries. That means many find it hard to make time for even the most basic of chores, like grocery shopping. In Seoul, a Korean supermarket chain has developed a ‘virtual’ store that allows consumers to do their shopping with smartphones.

And on the subway platform inside Seoul’s Seolleung station stand illuminated

billboards with hundreds of pictures of food products, including instant noodles, bottled beverages and bunches of bananas. This is a virtual store, created by the supermarket chain Homeplus, an affiliate of British firm Tesco.

All shoppers have to do is scan the black and white Quick Response Code (QR) under the picture of the product they want to buy. The product appears on her phone’s screen and the shoppers selects

the size and quantity of the product. It’s then transferred to the shopper’s virtual ‘shopping cart’.

The App then requests where the products should be delivered and prompts the shopper to enter their billing information.

The product is delivered shortly after the shopper arrives home.

There are plans to create more of them in other subway and bus stations, especially in areas close to universities. And it may only be a matter of time before Tesco starts creating virtual stores for its franchises in other countries too.

Using a smartphone to shop for groceries is no longer an Orson Welles fantasy!

PlasticsEurope supports call for a ban on landfill

PLASTICSEUROPE has come out in support of the European Parliament’s adoption of MEP Gerben-Jan Gerbandy’s proposal for a general ban on waste landfill.

“This proposal is really encouraging,” said Jan-Erik Johansson, programme director for resource

efficiency at PlasticsEurope. “We believe that a landfill ban is key to manage waste as a resource.

Every year 10 million tons of plastics are still buried in landfills in Europe.

In May 2011, PlasticsEurope called on policy makers to support its aim of enforce zero landfill

of plastics by 2020. Seven EU member states, plus Norway and Switzerland, already landfill less than 10% of their plastics waste.

However, a further 15 countries landfill more than 60% of their end-of-life plastics. According to PlasticsEurope this is a result of poor legislative enforcement.

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103

DIARY

NPE’s move to Florida proved successful Event was most international yet

One of the halls at the NPE show

THE NPE 2012 plastics exposition, which took place April 1-5 in Orlando, Florida, substantially exceeded NPE2009 in size and attracted more participants from outside the United States than any previous edition of the show.

Taking place in a venue that marked a dramatic shift after four decades in Chicago, NPE2012 attracted 1933 exhibitors, more than in each of the three previous NPEs. The total exhibit space occupied of 87,300m² was 23% greater than in 2009. There was a 26% increase in attendance, with 55,359 professionals from 19,283 companies present.

One-third of the international visitors came

from Latin America.

There was also an increase in the number of exhibitors from outside the United States, with the approximately 750 international exhibitors representing 40% of the total. China sent the most international exhibitors by far: over 300, or 16% of all exhibitors, were from China. Canada sent 72 exhibitors, the second-largest country total after China.

The 28 exhibitors from Mexico and South America represented the largest contingent ever from Latin America. www.plasticsindustry.org

‘SoftGate’ advanced sequential control

Successful EPTA World Pultrusion event

‘SoftGate’ – Incoe of the USA introduced its SoftGate® advanced sequential control technology at NPE. Initially introduced in Europe during K2010, the SoftGate hot runner valve pin velocity control system has performed exceptionally well in numerous challenging applications, particularly in improved part and surface quality. SoftGate valve pin velocity control technology resolves process challenges related to conventional hydraulic sequential moulding. Poor flow characteristics leading to part inconsistency, flow hesitation lines or blemish marks are reduced.

The gradual pin actuation, precisely timed as needed for optimized melt flow velocity to the mould cavity, provides a key process control advantage for moulders.

DELEGATES from 14 European countries as well as from the USA, Russia, Saudi Arabia and China enjoyed an overview of the global market development of composites and pultrusion at the 11th World Pultrusion Conference in Istanbul from 22-23 March.

The conference, which takes place every two years, is organised by the European Pultrusion Technology Association (EPTA). For a day-and-a-half, 16 speakers presented information about innovative raw materials and technolChairs made using ogies as well as about a unique thermonew applications. plastic pultrusion Delegates were also process able to visit the nearby Metyx plant.

www.incoe.com

104 JUNE / JULY 2012

www.avk-tv.de

2012 EVENTS ARGENPLÁS IN JUNE Applications for the new Lexan grades include consumer electronics and appliances, where the trend is to shrink in both size and thickness, calling for new materials that can provide excellent FR performance at ever-thinner gauges. For example, covers for notebook computers are typically 1.5 mm, and tablet covers are even thinner at 0.8-1.2 mm. Lexan CFR advanced copolymer fills an unmet market need by giving consumer electronics and appliance manufacturers a clear material with superior flame resistance at very thin gauges compared to competitive products

Efforts to raise the continuous operating temperature of LED lights for increased light output are placing new demands on plastics used in these applications. Long-term colour stability and retention of light transmission performance under the influences of heat and light are becoming more critical. The Lexan LUX resin portfolio, for covers of LED bulbs and tubes, addresses this challenge. The grades utilize new technology that offers improved initial color, colour stability and light transmission during heat aging compared to standard polycarbonate

SABIC expands Lexan polycarb line SABIC’s Innovative Plastics business introduced a number of new Lexan™ polycarbonate grades at the NPE 2012 show in Florida in April, including flame retardant and LUX resin grades.

Lexan CFR (clear flame retardant) copolymer addresses rising consumer electronics and appliance manufacturer demand for a clear, sustainable flame retardant (FR) material, and the new Lexan LUX resins of-

fer an excellent solution for light emitting diode (LED) applications such as light guides and lenses. The new materials underscore how the company continues to increase polycarbonate performance to meet customers’ environmental, high-performance, aesthetic and regulatory requirements.

SABIC’s portfolio of customer-relevant polycarbonate materials is one of the broadest in the PC market globally.

Styrolution showcases post-consumer polystyrenes STYROLUTION America showcased a line of polystyrene products containing post-consumer recycled (PCR) polystyrene at the NPE show in April. The product line includes three product grades, each with 25% PCR content, supplied by NextLife. a collaborative manufacturer of sustainable plastic resins for use in a variety of applications.

These grades are FDA-compliant for food

contact and designed for injection molding and extrusion applications requiring consistent resin properties. The resins, which process the same as 100% virgin polystyrene, target injection moulded opaque applications, such as cutlery, housewares, office accessories and appliance components.

“This product line proves that polystyrene is absolutely a recyclable product,” said Ed Barnes, VP of Styrolution.

ARGENPLÁS, Argentina’s national plastics show, takes place from 18-22 June. The Argentine industry appears to be slightly larger than that in South Africa, with annual consumption of polymer in 2011 estimated at 1,74 million tons, with 1,35-million of that being locally produced polymer – which in both cases is slightly more than the comparative stats for SA. Like SA, the Argentine industry also imports significantly from China (of both capital equipment and finished goods), but the industry’s main feature is its high level of exports to Brazil, of both polymer and finished product. Its activities are strongly related to the Mercosur region (including the countries Argentina, Brazil, Paraguay, Uruguay).

About 17,000 visitors are expected to attend Argenplás, which is notably higher than average attendance at SA’s top show, Propak Africa. The other obvious difference is that of trading hours: the Buenos Aires show runs from 14:00 to 20:30 … so the guys have got a chance to visit the factory first.

This will be the 14th edition of Argenplás; the main sponsor is Standard Bank. www.argenplas.com.ar

BRICS FORUM AT SAITEX THE vast, largely untapped potential for BRICS (Brazil, Russia, India, China) intra-Africa trade will get a boost through the newly-launched BRICS Africa Export Import Forum, which will run alongside SAITEX (the Southern African International Trade Exhibition) from 15-17 July at Gallagher Convention Centre, Midrand.

The BRICS Africa Export Import Forum is the only event that is dedicated to showcasing the range of services and support available for BRICS trade into and around Africa trade.

A number of co-located events designed to stimulate trade will be staged. The Johannesburg Chamber of Commerce and Industry (JCCI) in association with BRIC trade consulates and the Department of Trade and Industry is convening a series of trade opportunity presentations and seminars aimed at opening dialogue between trade representatives from BRIC countries and African business visitors. www.exhibitionsafrica.com JUNE / JULY 2012 105

2012 EVENTS GREEN BUILDING EVENT IN LATE-JULY The Green Building conference/exhibition takes place as part of Sustainability Week at the Sandton Convention Centre in Johannesburg from 24-29 July.

The focus will continue to be on solutions for adaptive interventions aimed at creating more climate resilient cities and communities into the future. www.greenbuilding.co.za

DIARY

SPE AUTOMOTIVE COMPOSITES CONFERENCE THE 12th SPE Automotive Composites Conference and Exhibition takes place from 11-13 September at the MSU Management Education Center in Troy, Michigan, USA. Now in its twelfth year, the SPE ACCE has become the world’s leading forum for automotive composites and draws exhibitors, speakers, and attendees from 15 countries on five continents.

“With the global automotive industry growing again after several difficult years, and with a host of tough new emissions and fuel-economy standards looming for the industry to meet, interest in lightweight materials like polymer composites is at an all-time high. Fortunately, the composites industry has a broad portfolio representing a wide range of cost, performance, and processing options from which to choose. Whether automakers are working on low volume/performance platforms, or high volume/economy platforms, they will find materials and process options that will meet their needs. And the best way to keep on top of the very latest technology innovations in this field is to attend the annual SPE ACCE show,” said Creig Bowland, the 2011 and 2012 SPE ACCE conference chair. www.4spe.org

PHOTOVOLTAIC MATERIAL PERFORMANCE IN ARIZONA SUN ARIZONA is regularly selected for weathering testing of photovoltaic materials and modules owing to its dry, sunny climate. It is also one of the optimum locations for solar energy farming. In view of this, the next AMI international conference on Plastics in Photovoltaics 2012 will be held on 19/20 September in Phoenix, AZ, USA. The event starts with a review from Professor Dauskardt of Stanford University on the challenges for plastics in photovoltaics, followed by Solaria describing research data from polymer aging studies. www.amiplastics.com

Record attendance at ChinaPlas THE 26th edition of ChinaPlas, from 18-21 April in Shanghai, was a marvelous success for the organisers: the 109,858 visitors represented a 16.8% increase on last year’s figure.

Of that figure, 28,110 visitors were from outside of China, representing 25% of total visitors

Chinaplas involved over 2700 exhibitors from 35 countries, occupying 210,000m² of space. There was also an increase in the number of country pavilions, with 13 present this year, including: Austria, Canada, France, Germany, Italy, Japan, Korea, Taiwan, Thailand, Turkey, UK and USA.

New business flows from Chinaplas Milacron China sees substantial orders for all-electric injection moulding machines INJECTION moulding machine manufacturer Milacron China received an order for 85 Elektron machines in the first quarter of 2012. The machines ranged from 500 to 1550 kN in size.

Following a successful exhibition at Chinaplas this April, the order has been expanded with 28 additional 2600 kN machines. The complete purchase now comprises of 113 all-electric injection moulding machines.

The first 85 Elektrons will be delivered to two locations of a Chinese customer in the second quarter of 2012; 30 of those machines have already been delivered.

The second set of 28 machines will be shipped in the third quarter of 2012.

Labeled buckets, produced on an ELEKTRON 450

The smaller Elektron machines will be used to produce electronics components for a well-known American manufacturer of computers and entertainment devices.

The larger Elektron models will be used in the manufacture of household items.

The customer already has around 40 K-TEC multi-component machines from Ferromatik Milacron in service.

As a direct result, Milacron China has hired new personnel, increasing the total workforce at the facility to 120. This order has led to the company’s best quarter since its founding in 2004. Around 90% of the Elektron machines produced in stay in China, where they are contributing to that country’s burgeoning manufacturing sector. Two years ago, the machine series received the CE mark and has since been available from Ferromatik Milacron in Europe where sales have been growing. www.ferromatik.com

MEDIPLAS 2012 MEDIPLAS, to be held in Birmingham, UK, from 25-26 September, is a uniquely focused event for the highly specialised area of manufacturing plastic parts for the medical industry. The exhibition will cover all areas of the medical plastics supply chain.

It differentiates itself from general plastics shows, as it brings to the forefront aspects and considerations of medical device manufacturing that do not feature in production for other industries. It is also distinct from existing medical device events because it specialises in plastics - the new material of choice as biocompatible plastics and polymer compounds continue to replace metal and ceramics in the medical industry. www.mediplasuk.com 106 JUNE / JULY 2012 ELEKTRON 450: the newest and largest model in the all-electric machine series from Milacron with a clamping force of 4500 kN was exhibited at Chinaplas

THE POLYMER SOLUTIONS COMPANY Plastamid, a member of the Chemical Services Group, has brought premier polymer solutions, extensive application development and technical service to the local and international polymer markets for over 35 years.

Plastamid plays a leading role in the manufacture and supply of thermoplastic compounds to a diverse range of industries.

Automotive

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Experience PR E MI E R P OL YM ER SOL UTION S w ith exten siv e A PPL I C A TION DEVEL OP M EN T and expert T E C H N IC A L SER VIC ES Visit www.plastamid.co.za for further information.

CPT 021 MEH MNHF I JHB 011 922 1600 I DBN 031 701 9546 I PE 08000 75 278

Good result for Plast show ITALY’S Plast show, which ran in Milan from 8-12 May, achieved a positive result with increases in the number of exhibitors and international visitors.

That was slightly offset by a decline in overall attendance, but this was neverthe-

less a good result in the present economic climate – and the Italian suppliers will be encouraged by the increase in the number of international visitors – up from 17,500 in 2009 to 18,200 this year.

The number of exhibitors rose from

1478 at the 2009 event to 1514 on this occasion. That trend was also reflected in the increase of the number of countries represented, from 45 to 58.

Overall attendance this year was 50,593 – down from 55,175 in 2009.

Lights on at Plast show Tail lights for a Lancia model were manufactured from PMMA in a 2-cavity mould supplied by Olsa SpA of Italy on the A Wittmann stand at the PLAST show in Milan in May. Wittmann manufactures the ‘PowerSeries’ injection moulding machines with its partner company Battenfeld. One of the highlights for the group was its new MacroPower 500 machine, representing an extension of the its large machine series down to a lower clamping force range. The compact machine series is now available with clamping forces ranging from 500-1100t. A Wittmann W823 robot was used to remove the parts and deposit them on a conveyor belt.

• OLSA OF ITALY IS A MANUFACTURER OF AUTOMOTIVE AND INTERIOR LIGHTS.

DIARY

www.wittmann-group.com

www.olsa.it

New preform production press from Sacmi of Italy SACMI of Italy, the only world supplier to offer the alternative technologies for preform production, injection and compression moulding, introduced a new preform press using injection technology at the Plast show in Milan in May. The IPS (injection preform system) is a significantly new technology. Fully designed and developed by Sacmi, the IPS is available in a 48-cavity version, while a more powerful 300-ton model housing 72

cavities is already under development.

A key IPS feature is its simplified user interface: this makes for easy machine management and minimises worker training times. All the operator has to do is enter the preform geometry data.

Machine ergonomics and worker safety are also in evidence during the ejection phase: a robot – fully integrated on the machine – picks up the preforms with a 3-station gripper. The system also allows

Besides its energysaving and enhanced preform cooling technology, the new IPS system from Sacmi offers extremely short cycle times

for post-cooling prior to unloading. This solution ensures higher quality preforms and prevents the damage that can occur when preforms are handled before they’ve fully cooled.

Another key feature is the new linear motor that drives the gripper: this allows for recovery of braking energy during the deceleration phase, thus ensuring reduced energy consumption plus excellent precision, speed and repeatability of movement.

The picture is completed by extremely short cycle times. This has been achieved thanks to plant optimisation, digital servovalves fitted near the actuators and a machine design optimised to make press opening-clamping even more efficient.

The toggle system and mobile platen that make up the mould clamping unit are hydraulically controlled and have been designed using FEM structural analysis to optimise mechanical inertia while ensuring outstanding mechanical strength. This guarantees ultra-fast lock-to-lock, times, cutting the preform cycle time further. www.sacmi.com

108 JUNE / JULY 2012

GLOBAL PLASTICS TRADE & MARKETS: 11-12 June Istanbul, Turkey: www.cvent.com

Africa’s Big Seven & SAITEX

ARGENPLÁS: 18-22 June: Buenos Aires, Argentina: www.argenplas.com.ar BIO-BASED MATERIALS: 19-20 June Stuttgart, Germany: www.hanser-tagungen.de MASTERBATCH 2012: 19-21 June Renaissance Hotel, Vienna, Austria: www.amiplastics.com WORLD SYMPOSIUM ON PERFORMANCE FILMS: 20-21 June Düsseldorf, Germany: www.ihs.com/spf2012 INTERPLAS THAILAND 2012: 21-24 June BITEC, Bangkok: www.interplasthailand.com ECCM 15 (COMPOSITES): 24-28 June: Venice, Italy: www.eccm15.org MULTILAYER PACKAGING FILMS USA: 26-27 June DoubleTree Hotel, Chicago, USA: www.amiplastics-na.com/Events SAITEX (AFRICA’S BIG SEVEN): 15-17 July Gallagher Convention Centre, Midrand: www.exhibitionsafrica.com GERMAN RUBBER CONFERENCE: 2-5 July Nürnberg, Germany: www.dkt2012.de SUSTAINABILITY WEEK (INCL: GREEN BUILDING CONFERENCE): 24-29 July Sandton Convention Centre: www.greenbuilding.co.za VISION ZERO WASTE SEMINAR & EXHIB: 27 July Sandton Convention Centre: www.wasterevolution.co.za EUROMOLD BRASIL: 20-24 Aug: Joinville, Brazil: www.euromold.com INTERPLAST BRAZIL: 20-24 Aug: Joinville, Brazil: www.messebrasil.com.br GLOBAL POLYMER INNOVATION EXPO: 26-29 Aug Columbus, Ohio, USA: www.globalpolymerinnovationexpo.com

DIARY

PROPAK WEST AFRICA: 4-6 September Eko Hotel, Lagos, Nigeria: www.propakwestafrica.com SPE AUTOMOTIVE COMPOSITES CONF: 11-13 September Michigan, USA: www.4spe.org PLASTICS IN PHOTOVOLTAICS 2012: 19-20 September Arizona, USA: www.amiplastics.com TAIPEI PLAS 2012: 21-25 September Nangang Exhib Hall, Taipei: www.taipeiplas.com.tw MEDIPLAS: 25-26 September: Birmingham, UK: www.mediplasuk.com ARMO 2012 (ROTO MOULDING): 30 Sept-2 Oct Lyon, France: www.armo2012.com ITELEXPO KENYA 2012: 6-8 October: Nairobi, Kenya: www.expogr.com WASTECON 2012: 8-12 October: ELICC, East London: www.wastecon.co.za BRITYREX INTERNATIONAL 2012: 9-11 October Manchester, UK: eci-international.com@mimimail4.com AFRIMOLD 2012: 10-12 October Gallagher Convention Centre, Midrand: www.afrimold.co.za MULTILAYER PACKAGING FILMS 2012: 16-18 October Maritim Hotel, Cologne, Germany: www.amiplastics.com/Events PETNOLOGY EUROPE 2012: 12-13 November Nurermberg, Germany: www.petnology.com POLYOLEFIN ADDITIVES 2012: 23-25 October Maritim Hotel, Cologne, Germany: www.amiplastics.com DRINK TECHNOLOGY INDIA: 6-8 November Mumbai, India: www.drinktechnology-india.com PACKTECH INDIA: 6-8 November: Mumbai, India: www.packtech-india.com PETPOINT: 12-13 November Brau Beviale, Nürnberg, Germany: www.drinktec.com COMPAMED: 14-16 November: Düsseldorf, Germany: www.compamed.de WIND TURBINE BLADE MANUFACTURE: 27-29 November Maritim Hotel, Cologne, Germany: www.amiplastics.com EUROMOLD 2012: 27-30 November: Frankfurt, Germany: www.euromold.com 110 JUNE / JULY 2012

TWO of South Africa’s biggest trade expos - Africa’s Big Seven and SAITEX - get even bigger this year with the addition of three new components.

“This year, we have partnered with Trade Conferences International to host Gwarega Mangozhe, the inaugural Retail SoluMariette Broodryk, CEO of the Consumer project manager for tions Africa Conference in Goods Council events at Trade ConferSouth Africa,” said John ences International Thomson, MD of Exhibition Management Services (EMS), organisers of AB7 and SAITEX. “We are also hosting the On-line Retailing Conference for the third successive year.”

Africa’s Big Seven (AB7) is the biggest food and beverage trade exhibition on the African continent. This seven-shows-in-one event covers the entire gamut of the food and beverage business, from farm to shelf and everything in between - a veritable crop-to-shop experience. It happens at the same place and time as the other giant show, the Southern African International Trade Exhibition (SAITEX), a full spectrum trade show with product categories from A to Z. AB7 has been tempting trade visitor tastebuds for over a decade; SAITEX enticing entrepreneurs for almost 20 years. Both exhibitions take place at Gallagher Convention Centre in Midrand, Johannesburg, from 15-17 July.

The two retail conferences being hosted by SAITEX - ‘Retail Solutions Africa 2012’ and ‘On-line Retailing 2012’ - will focus on the latest trends and challenges regarding technology, innovation, systems and products in the retail industry.

Teaming up with AB7 and SAITEX for the first time is the Consumer Goods Council of South Africa (CGCSA).

As a unique and free service offered by the organisers, AB7 and SAITEX attendees have access to an easy-to-use, internet-based business matchmaking programme. It provides exhibitors and visitors with the ability to preprofile, pre-select and pre-schedule meetings for all three days of the shows. www.exhibitionsafrica.com

www.futureoftrade.com

New design option for loop and hook wire CONVERTERS and binders of spiral bound stationery can now customize their products using Bekaert combined colours wire. The new and unique polymer-coated wire can be printed with any colour to match. Bekaert attaches particular importance to co-development, taking a specific problem or more general business situation as its starting point. At the company’s main Technology Centre in Deerlijk, Belgium, and its R&D Centre in Jiangyin, China, teams of highly qualified scientists and engineers work closely with lead customers. It was a co-operative project that resulted in the Bekaert combined colours wire.

www.bekaert.com

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Masterbatch SA 61 MBT 65 MDS 27 Mercury Plastics 77 MGMW Trading 95 Miracle Mould 48, 49 MJH Machine Tools 104, 105 Mouldplas (Wittmann) 79 Mouldplas (GET) 71 Mouldplas (Battenfeld) 93 Performance Colour Systems 21 Perspex SA 36 Plasquip 81 Plastamid 107 PlastiChem IFC Plasticolors 13 PlasticsSA 43 Plastomark 85

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Polysaf 87 Protea Polymers IBC Rawmac 39 Reichmans 05 Relloy (Erema) OBC SAPY Colours 97 SES 01 Standex Engraving 41 Sun Ace 19 TaipeiPlas 109 Ultra Polymers 69 United Spectrometer 99 Univ of Pretoria 59 Univ of Pretoria 37 Victor Fortune 53 West African International 28

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SPORTS

The London 2012 Olympic Stadium marks the start of a new approach to design and engineering of stadia. This is an artist’s impression of the Stadium at night

Plastics are contender in

London 2012 Olympics Plastics companies contributing to sustainability effort across London 2012 Olympics sites THE British Plastics Federation has had temporary buildings. feedback from several of its member Innovation in plastics is further reincompanies which have secured contracts forced as a headline theme for the Lonto supply Olympic venues with items don 2012 Olympics as the 2008 BPF’s based on HDPE, PVC and masterbatch Horners’ Award winner, The Durakerb products among others.

Group, has confirmed that it will be supPhilip Law, BPF’s public and indusplying both the North and the South Park trial affairs director, said: “London 2012 with its recycled plastic kerbing system. lays down rigorous Durakerb is made requirements for mafrom recycled PP Plastics offer sustainable terials and the extenand HDPE and a solutions in construction sive use of plastics recent study has such as, durability, is an endorsement indicated a near 20% recyclability, energy that they can offer carbon reduction sustainable solutions using Durakerb comsavings and safety. in construction such pared to traditional as, durability, recyclability, energy savings precast concrete kerbs. and safety.”

The BPF said it also understands that BPF member company Polypipe TerPVC will be used in some iconic stadia at rain is supplying Terrain Fuze (HDPE), the Games such as a PVC wrap on the Terrain PVC soil and waste systems, two temporary seating wings in the Aquatand Rainstream rainwater harvesting ics Centre where up to 17 500m2 will be and underfloor heating to all the major needed.

Olympic Park venues, particularly the This follows the publication by the Athletes Village, the Olympic stadium and London 2012 organisers last May of a the Velodrome. strategy document covering the use of Another BPF member company PVC in the Games. This laid down varisupplying PVC products to the Olympic ous criteria such as the requirement for Games is Hunter Plastics which will be PVC to be manufactured in accordance supplying goods such as Multikwik WC with the ECVM Industry Charter for the Connectors and Multiwik traps for the Production of VCM and PVC. 112

The Olympic Velodrome stadium where the majority of the cycling events will take place

London 2012 could be the ‘compostable’ Olympics The NNFCC, the UK’s national centre for bio-renewable energy, fuels, and materials, has signed up to be an advisor to the Olympics Delivery Authority and London Organising Committee for the games on using renewable packaging throughout the event.

The body is helping to create a supply chain for bio-based packaging at London 2012 and will ensure that materials used comply with European Standard EN13432 – the certification requirement for packaging recovery through composting and biodegradation. The NNFCC said this certification would mean non-reusable, non-recyclable packaging would be suitable for ‘in-vessel’ composting or anerobic digestion.

JUNE / JULY 2012

• THE LONDON OLYMPICS RUN FROM 25 JULY – 12 AUGUST. WWW.LONDON2012.COM

â&#x20AC;&#x153;more than just a chemical supplierâ&#x20AC;?