SA Polymer Technology

S O U T H E R N A F R I C A N P O LY M E R T E C H N O L O G Y

POLYMER technology

www.sapt.co.za

VOL 19 NR 5 OCTOBER / NOVEMBER 2021

 VOL 19 NR 5

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OF FI

A SS O CI A S OU T

www.sapt.co.za

The Home of Size Reduction

LICATION PUB OF T C P A ( ) N & P TIO RN AF HE

ICS CONV A ST ER PL TE HE S INSTI STIC TU LA CA (PIS RI

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OCTOBER / NOVEMBER 2021

Greater involvement at International Coastal Clean-Up Day

Whole Earth Recycling grows from strength to strength Why SA leads the African circular plastics industry

No more lost time for Conver-Tek! Industry views on barriers and opportunities in SA

SA Plastics Pact Reuse Innovation Challenge 2021

34

First singlematerial pump for 100% recyclable packaging 42

SA entrepreneur saving the planet, one cup at a time 36

CLEARLY BETTER. TRITAN™ TER. TRITAN™ CLEARLY BETTER. TRITAN™

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BY THE WAY Publisher & Managing Editor: Martin Wells (martin@summitpub.co.za) Editor: Tessa O’Hara (tessa@summitpub.co.za) Publishers Assistant: Heather Peplow (heather@summitpub.co.za) Bookkeeper: Gloria van Heerden (gloriavanheerden@gmail.com) Designers: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za) Bronwen Moys Blinc Design (bronwen.clarke@gmail.com) Summit Publishing cc t: +27 (21) 712 1408 f: 086 519 6089 c: +27 (82) 822 8115 e: tessa@summitpub.co.za Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa Unit 8, Bergvliet Village Centre, Cnr Hiddingh & Children’s Way Roads, Bergvliet 7945

www.sapt.co.za GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew c: 082 904 9433 e: lynne@summitpub.co.za Printed by: Novus Print, Paarl Southern African Polymer Technology is published six times a year and focuses on these industries in South and Southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry.

The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either.

Copyright: All rights reserved.

ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902

Plastics Institute

Association of Rotational

Plastics Converters

of Southern Africa

Moulders of South Africa

Association

PET Plastic Recycling South Africa

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Institute of Materials

Power to the people – Bevan Davis of Conver-Tek of Carnival City is an altogether happier man these days. The reason: he no longer suffers from the stress of frequent damaging power interruptions.

Here we see Bevan with Jarred Gooman of Millennial Reign, the Johannesburg solar power and integrated power solutions contractor which supplied the solar panels, generators and control systems to power the Conver-Tek plant. We hear of the problem of continued power ‘outages’ too often, even from convertors whose monthly electricity bills are millions where the power goes out without warning. Although this is obviously a large capex project for Conver-Tek, switchover to solar or generator is within minutes and the company can now relax a bit and get on with their injection moulding and toolmaking business (See page 6). Meanwhile, Extrupet has commissioned their brand new 1.3MWp solar power plant, built in collaboration with Solarise Africa and NEC XON (see page 16)

Some questions over E Rand material heist IN THESE days of fake news, which is sometimes more real than the real, it’s difficult to know what to believe. News of a recent material heist on the East Rand was therefore not swallowed by all. Apparently, a gang of armed individuals held security personnel and night shift staff at gunpoint while not one, but three loads of material were loaded onto an ‘old white Freightliner truck’. An estimated 120 tons of PET were removed, or so the story goes, which at a rough estimate would be valued in the region of R4-million. Either way, it must have taken some time.

This sort of thing could only happen with the complete complicity of all personnel, and possibly also the management and maybe even the owners of the venture, so it’s difficult to imagine this is genuine. Incidentally, we know of such events before where firearms were not used but with the same effect on the material, disappeared and unaccounted for.

On the other hand, it does suggest again that plastic material is more valuable – a lot more valuable – than many consumers appear to believe.

Recycled product winner pulls out IT’S not often that a winner pulls out after an event has been completed, but that is what happened with the recent SAPRO 2021 Best Recycled Plastic Products Awards. Judging in the Plastics Recyclers Organisation competition in September took an entire day and in the end the judges opted for an ‘Eco Tile’ from a national roofing products manufacturer, a product which uses recycled material along with sand. If commercialised, considerable quantities of mixed recycled plastics could thus be used, which is what tipped the judges in its favour. A big factor in its favour was that the developer … IF YOU HAVE has a national sales network. The winners SOMETHING TO SAY are to be announced in October.

Look at the bright side: if you have some gem of wisdom to impart, please write to us at tessa@summitpub.co.za

2021/10/05 11:30

VOLUME 19 NR 5

OCTOBER / NOVEMBER 2021

CONTENTS Find out more at www.sapt.co.za

6 10 12 16 18 20

INDUSTRY NEWS

Conver-Tek commissions solar, back-up power plant

Linesco agreement with Pipestar International Extrupet switches to solar energy Industry views on barriers and opportunities in SA

26

Whole Earth Recycling grows from strength to strength

30

International Coastal Clean-Up Day

69

DESIGN

SA Plastics Pact Reuse Innovation Challenge 2021

60

COMPOSITES

SA entrepreneur saving the planet, one cup at a time

38

Hexcel revolutionizes the blade surface finishing process

40

Bentley reveal new carbon fibre rim

44 49

46

Polyco textends industry support

Plastics|SA training division upskills retrenched workers

36

40

Why SA leads the African circular plastics industry

22

34

22

SUSTAINABILITY

72

COPCO achieves significant milestones BASF introduces new additive solutions for mechanical recycling ON THE COVER: The Southern African Vinyls Association recently highlighted the critical role PVC plays in hospitals and the healthcare environments. The international webinar was well attended and attracted delegates from around the world, including Thailand, Argentina, India, the United Kingdom, Italy and Denmar. Read more on page 22

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COMMENT European recycler Plastic Energy is collaborating with ExxonMobil in an advanced recycling project in France that will convert post-consumer material into virgin quality polymers. Initial capacity of the plant in France is 25 000 tons of plastic ‘waste’ per year. It’s good to see one of the global material manufacturers participating in such a project, creating more value out of PCR material can create more value for virgin polymer too. See page 13

It’s a time when having good ties with material suppliers is vital Uncertainty makes manufacturing challenging

THIS ISSUE

A

4 OCT / NOV 2021

the suppliers also need to able to forecast well ahead and BOUT THE ONLY THING that can be said for expect the unexpected. It’s far easier to get it wrong than certain in these pandemic times is that hand right. The situation adds up to a very substantial financial sanitizer is very efficient for cleaning challenge for suppliers (and obviously for convertors spectacles (you’ll never get them too), so it’s a good time to maintain good relations cleaner), which is something with your suppliers.

Material I learned from a friend.

4.indd 4

suppliers have Besides that just about everything is Strike, you’re out uncertain, and the area where that has ONE person who doesn’t seem to believe the been tested to the most affected convertors is in material Covid pandemic has presented any problem for limit to supply sourcing. For the past 12 months at employers is Mr Irvin Jim of NUMSA, the trade convertors least it’s been a succession of plant union, who suggests manufacturers have been failures around the world and when that making big profits while neglecting their employers. hasn’t been a problem, shipping has. Freight In an interview in The Sunday Times, Jim even costs have escalated frighteningly and delivery suggested the union should be able to view companies’ times have been stretched for all imported materials, financial books. Our observation, based on numerous visits added significantly to moulded cost. It’s been a time when to companies, is that most businesses in the industry – by material suppliers in South Africa have been tested to the far – in South Africa are happy working environments where limit to supply convertors, putting added pressure on the there is respect and workers are fairly rewarded. local manufacturers, Safripol and Sasol too. That’s not to Achieving a healthy relationship with staff is one of the speak of the problems faced by equipment suppliers to land most difficult things for employers to do. It’s machinery and parts. If you don’t have a good relationship very necessary, going into the ‘strike season,’ with your material supplier(s), the situation could be very to have such a situation at your place of work. challenging.

Without that, things could be difficult.

Many think the process of material supply is simple, Martin Wells, Publisher maybe even have the feeling that ‘anyone can do it’. Not so, we notice. Besides the need to be very well connected and have reliable supply lines with material manufacturers,

2021/10/06 09:30

WE CAN’T BE SUSTAINABLE WITHOUT IT. Let’s plastic responsibly Plastic is an essential part of the products we interact with every day, from the containers that keep our food safe and hygienic, to the mattresses we sleep on, to medical equipment and medicine containers. Even the bins we need to use for recycling. Let’s all reduce, re-use, re-purpose and recycle.

safripol.com

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news

No more lost time

as Conver-Tek commissions solar, back-up power plant

BY BEVAN DAVIS

Solar power solutions supplier Millennial Reign reduces stress over power supply by a huge margin at Conver-Tek in Joburg I ASKED a highly respected, senior ex-Eskom engineer and power consultant to assess the risk of not converting my factory to a system totally independent of Eskom.

Any 24-hour plastics manufacturer, whether they are doing injection moulding, blow moulding or extrusion or other process, needs a continuous process and power.

Millennial Reign is a specialist in the technical integration of generators, solar and battery power. They monitored our power usage 24 hours a day for 10 full days. They also assessed our electricity usage bills for the past 12 months, and proposed we initially put

in a matched diesel generating plant to synchronise with the Eskom supply for our power consumed. This allows us to be able to manage our peak loads and to selectively run during peak demand times, as well as to install a hybrid solar system to take us off the grid from 8am to 4pm in summer. The integration from little to full solar power from 8am is done seamlessly and includes the switchover to diesel when no solar power is available.

Massive savings in first months We immediately saved R94 000 in July by using our diesel generator to switch on and off automatically just before and after peak times in the mornings and evenings, creating a seamless

6 OCT / NOV 2021

Jarred Gooman from Millennial Reign with Bevan Davis, MD of Conver-Tek, in front of a 525kW, fully-synchronised generator set

synchronisation and ‘handover’ with the Eskom supply.

We then saved +R130 000 on our bill in August by running a combination of diesel and solar, with four power outages included in August. The closer to capacity you run, the bigger the savings are.

After a power outage, we take at least four hours to get our 24 machines up and running effectively, and the problem is multiplied as we can never anticipate when outages will occur. You then face the issue of paying staff, by law, for four hours after a power outage.

The local council/Eskom can never Bevan Davis and Jarred Gooman with 120kW Grid-Tie Inverters with P.V. Combiners & SPDs

Thermoforming sector leaders in desperate search for rPET

confirm when power will be restored, so to arrange and pay for labour to stand around, or for the power to return, with labour and transport issues, leaves us with very costly downtime – and a frustratingly unpredictable situation.

Since hybrid system installed, no downtime To run or plan any 24-hour plastics production outside of peak demand periods is not financially viable.

For three months, since the hybrid system was installed, to date we have not had a single stoppage or downtime in production. After the power went down before, and without warning or confirmation, we never knew when it would be restored.

This happened at least five times during this period. With the predicted increases of 15% (last year) from Eskom, and the latest debacle of a generation unit exploding at Eskom, the likelihood of rolling or unpredictable blackouts is fairly certain.

The direct costs to the plastic industry, due to the nature of the materials cooling off, freezing, tool damage, resetting, restarting, electronic board failures, purging and getting back into quality approved products is financially crippling in our industry.

Any plant running at close to full capacity makes the use of hybrid solar an absolute no-brainer, in my opinion. I’m tired of hearing that, as a supplier, we must ‘make a plan’ to mitigate Eskom supply, and then we also have to deal with the effects of the local council’s incompetence, theft of cables, explosion of transformers and other issues.

We’ve taken the quantum leap and spent close to R6 million on our system. I would have preferred to buy a few state-of-the-art CNC and injection moulding machines for our toolroom, rather than this solar system. However, whether you have 10 or 100 machines, without reliable power, the plastics converting business will not be viable in future.

We are confident that the savings outlined above will repay our investment in four to five years.

The cost reduction of production is then phenomenal. The guarantee or confidence I now have to plan and deliver quality, uninterrupted production with less stress and irritation caused by Eskom, over which I have zero control, makes me very positive about my company’s survival and the success of the plastics industry. www.convertek.co.za

OCT / NOV 2021 7

THREE of SA’s leading PET thermoformers – Berry Astrapak, Mpact Versapak and Zibo Containers – have begun a cooperation programme aimed at increasing their usage of recycled PET. Combined, the output of thermoformed PET trays by the three companies is an estimated 85% of the approximate 26 000 tons p/a of PET converted in this sector in SA annually, which is estimated to be about 10% of the total volume of PET consumed in SA p/a, with the bulk going to the container sector. Thermoformers have been using only a small amount of rPET in the packaging products they produce.

By contrast, the PET bottle and container sector has been using a steadily increasing amount of rPET. Brand companies are now demanding that a percentage of rPET be included in their packaging. But with only one manufacturer of food-grade rPET in the country, Extrupet, quantities of the grade have been hard to come by. This has presented a problem for the thermoformers and the need to obtain sufficient food grade rPET supply is the factor that drove them into action.

Zibo, which operates plants in Cape Town and Olifantsfontein, earlier this year commissioned an Erema recycling system at its Blackheath site in the Western Cape.

There it has been processing mainly PET bottle flake purchased from Cape-based recyclers, or in some cases, even importing material. Using the Erema line, it has been producing quantities of food grade rPET for its own use.

Two of the three thermoformers mentioned are members of PETCO, the PET recycling company. The fact that the thermoformers’ products are not being recycled may be making it more difficult for them to procure rPET. Ironically, three businesses have now elected to throw their lot in with POLYCO, the polyolefins sector PRO. One of the main factors influencing the decision to tie up with POLYCO was that the thermoformers were more likely to be exposed to other collectors and recyclers and could potentially develop other means of obtaining supplies of collected PET container volumes to feed their own processes.

news

Why SA leads the

The informal sector waste pickers are crucial to the African recycling industry and must be incorporated and supported in any solutions in its development

African circular plastics industry

By Carolina Perujo Holland, analyst for plastic recycling at ICIS

8 OCT / NOV 2021

With more investment, recycling industry will be able to take advantage of the large volumes of plastics waste available SOUTH AFRICA is often viewed as the most developed country in the region for circular plastics. This is largely due to the close collaboration across the plastics industry, which often takes the lead in finding solutions. The ICIS Recycling Supply Tracker has identified just under 20 PET, PE and PP recycling plants in the country, the highest number in any African country, followed by Nigeria and Egypt. South Africa was also the first country to have a food grade PET recycler with EFSA positive opinion in 2015.

Due to the location of SA, focus has been on the domestic recycling market as trade to other regions has not been as attractive, unlike other markets such as Egypt and Morocco. Therefore, South Africa has tended to lead the region in working towards a circular economy.

Waste management is currently one of the main challenges faced by the African recycled polymer supply chain.

Population growth rates are over 2% per year and the consequent increase in consumption of plastics packaging makes this the largest fraction of waste after organic, which brings more urgency to the waste management challenges.

Most of Africa’s population has no access to kerbside collection or a formal waste collection system and

relies heavily on waste pickers in the informal sector for waste collection and sorting. According to industry estimates, 90% of waste still ends up in landfill or illegal dumping sites.

Extended Producer Responsibility (EPR) initiatives in Kenya, Ghana and Nigeria are encouraging, with the most recent EPR scheme being implemented in South Africa. Particular to the region, brands have often taken action and led these types of EPR schemes. Recycled content targets for plastics packaging set by legislation in other regions, coupled with consumer pressure, have pushed brands who operate in multiple regions to set sustainability pledges at a global level.

Now, these Fast Moving Consumer Goods brands are also looking for supplies of high-quality recycled plastics in Africa, particularly for PET, PE, and PP packaging.

The ICIS Mechanical Recycling Supply Tracker has identified just under 50 mechanical plastics recycling plants for PET, PE and PP in the African region with a total capacity of over 370 000 tons per year for post-consumer and post-industrial waste feedstocks. A total of 55% of the recycling capacity is allocated to recycling PET, and the majority of the polyolefin recycling capacity is allocated to PE. However, in 2020,

production of recycled PET, PE and PP represented only 3% of total virgin and recycled PET, PE and PP consumption in the region.

In Africa, 81% of PET, 49% of PE and 67% of PP capacity is from post-consumer feedstock. Food and beverage brands looking to meet their sustainability targets need the highest quality food grade recycled material, suitable for food contact applications.

There are three PET recyclers in Morocco, Egypt and South Africa with US FDA (Food and Drug Administration) Letter of No Objection (LNO) and EU EFSA (European Food Safety Authority) positive opinion, processing 21% of post-consumer PET feedstocks in the region.

Expansions in 2021 and 2022 will see food grade recycled PET (rPET) capacity increase by up to 40 000 tons per year, looking to meet the demand for high quality recyclates from both inside and outside the region.

Access to this plastic waste is an opportunity to develop the plastics recycling industry within the region rather than the current focus on trade outside the region. Investment in infrastructure will help to improve collection and sorting, increase recycling capacity and build end markets for recyclates in the domestic market.

www.icis.com/explore/services/recycling-supply-tracker/

CUSTOM SOLAR SOLUTIONS

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Innovating F Innovating Fo Innovating Fo Innova�vePvc PvcCompounds, Compounds, established established in in 2010, 2010, has Innova�ve has now now been servicing the industry for over 10 years with quality PVC been servicingPvc theCompounds, industry for established over 10 years PVC Innova�ve in 2010,quality has now compounds and great service.

The company, company, alsoquality known as been servicing the industry for The over 10 years with PVC compounds and great service. also known as IPC, started as a small family business, and has seen significant great service.

The company, also significant known as IPC,compounds started as aand small family business, and has seen growth over the past decade.

IPC, started as a small family business, and has seen significant growth over the past decade. growth over the past decade.

IPC specialise in the manufacturing of flexible, rigid, and semiIPC specialise in the manufacturing of flexible, rigid, and semirigidspecialise PVC compounds used in safety of shoes, gumboots, gaskets, IPC in the used manufacturing flexible, rigid, and semirigid PVC compounds in safety shoes, gumboots, gaskets, wire coa�ng, footwear, floor �les, electrical fi�ngs, pipe rigid PVC compounds used in safety shoes, gumboots, gaskets, wire coa�ng, footwear, floor �les, electrical fi�ngs, pipe fi�ngscoa�ng, and cling wrap etc.floor The company supply into bothpipe the wire footwear, �les, electrical fi�ngs, fi�ngs and cling wrap etc. The company supply into both the injec�on moulding and extrusion industries. fi�ngs and cling wrap etc. The company supply into both the

injec�on moulding and extrusion industries.

injec�on moulding and extrusion industries.

The Directors of the company speak of the company’s vision TheThe the speak of company’s vision toDirectors have a of world where PVC products made in an Directors of thecompany company speak of the theare company’s vision to to have a world where PVC products are made in an environmentally sustainable way products and to have have a world where PVC area quality made driven in an environmentally way and have aa quality qualityfor driven company that sustainable works towards crea�ng the environmentally sustainable way andto toand haveproviding driven company that works towards crea�ng providing for the the communi�es both around South Africa and company that works towards crea�ng and afar. providing for

communi�es both around communi�es both aroundSouth SouthAfrica Africaand and afar.

Classifieds Oct/Nov'2021.indd 74

As run business, company culture and and a pleasant workwork Asa afamily family run business, company culture a pleasant environment for the team is extremely important.

IPC works environment for the team is extremely important.

As a family run business, company culture and a pleasant IPC workworks towards synergy, emphasizing respect forIPC diversity environment for the team is extremely important. towardscrea�ng crea�ng synergy, emphasizing respect forworks diversity and encouraging empowerment and growth in the workplace. towards crea�ng synergy, emphasizing respect in forthe diversity and encouraging empowerment and growth workplace. and encouraging empowerment and growth in the workplace.

The is to its customers by by Thevision visionofofthethecompany company is engage to engage its customers encouraging operate isin to a closed loop system.

In the The vision ofthem the to company customers encouraging them to operate in engage a closeditsloop system.byIn the last two and a half years, for example, the team have worked encouraging them to operate in a closed loop system. In the last two and a half years, for example, the team have worked withtwo oneand of their to reprocess 80 metric tons of last a halfcustomers years, for example, the team have worked with one of their customers to reprocess 80 metric tons of their PVC, which was resupplied for their injec�on moulding with one of their customers to reprocess 80 metric tons of their PVC, which was resupplied for their injec�on moulding process. their PVC, which was resupplied for their injec�on moulding

process.

process.

Innova�ve Pvc Compounds strongly believe that to ensure Innova�ve PvcCompounds Compounds believe toIPC ensure customer sa�sfac�on, it needs tostrongly ensure staff sa�sfac�on.

Innova�ve Pvc strongly believe that that to ensure customer sa�sfac�on, it needs toand ensure sa�sfac�on. is fortunate to have extremely loyal dedicated staff. Many customer sa�sfac�on, it needs to ensure staffstaff sa�sfac�on.

IPC IPC is fortunate to have extremely loyal and dedicated staff. offortunate whom have beenextremely with the company incep�on, and aMany is to have loyal andsince dedicated staff. Many few have been with the CEO for up to twenty years or more. whom have been with company since incep�on, ofofwhom have been with thethe company since incep�on, and aand a

fewhave havebeen been with CEO uptwenty to twenty or more. few with thethe CEO for for up to yearsyears or more.

2021/09/23 09:59

ngFor ForAfrica Africa Africa Roto Compounds Africa Roto Compounds Innova�ve Pvc Compounds 10th anniversary fell in the midst Innova�ve Pvc Compounds 10th anniversary midst of the Covid 19 pandemic.

Fortunately, fell thein the company of the Covid 19 pandemic.

Fortunately, the company managed to overcome the challenges posed by the managed to overcome the challenges posed given by the pandemic and more importantly with the support by pandemic and more importantly with the support given by their valued customer base. It has been challenging �mes their valued customer base.

It has been challenging �mes indeed with the family losing a key member of the team, Mr. indeed with the Yunus Siddiqi, infamily Augustlosing 2020.a key member of the team, Mr. Yunus Siddiqi, in August 2020.

Looking forward, the team are excited for what the future Looking forward, the team of are IPC excited for whatAfrica the future holds. The shareholders launched Roto holds.

The shareholders of IPC launched Africa Compounds in early 2021. Both companies operate fromRoto the Compounds in early 2021.

Both companies operate from the same premises, albeit separate factory units. They service same premises, albeit separate factory units. service different segments of the plas�c industry while They applying the different segments of the plas�c industry while applying the same ethos of quality and service. same ethos of quality and service.

ARC (Africa Roto Compounds) manufacture Roto-Grade ARC (Africa Roto Compounds) Roto-Grade LLDPE compounds (in powder manufacture form). Through the networks LLDPE compounds (in powder form).

Through networks established over the past 26 years by the CEO the Mubeen established over the past 26forward years bytothe CEO Mubeen Siddiqi, the team is looking growing the ARC Siddiqi, the team is looking forward to growing the ARC footprint in Africa and abroad. footprint in Africa and abroad.

FAST FACTS: FAST FACTS: • IPC is an abbrevia�on for “Innova�ve Pvc • Compounds” IPC is an abbrevia�on for “Innova�ve Pvc which reflects the companies Compounds” which reflects the companies willingness to innovate, ensure the customers willingness innovate, ensure the customers sa�sfac�on to and manufacture quality compounds. sa�sfac�on and manufacture quality compounds.

• Vinyl Polyva�on is IPC’s 2021 slogan. The slogan • indicates Vinyl Polyva�on is IPC’s 2021 Theto slogan the company’s abilityslogan. and drive indicates with the company’s ability drive to innovate vinyl polymers toand create sustainable innovate with vinyl polymers to create sustainable and quality PVC compounds. and quality PVC compounds.

• • • •

Africa Roto Compounds (ARC) was established by Africa Roto Compounds was established by the Shareholders of IPC in(ARC) March 2021. the Shareholders of IPC in March 2021.

The Group aims to service various sectors of the The Group aims to service various sectors of the plas�cs industry. plas�cs industry.

All images are original and owned by Innovative Pvc Compounds & Africa Roto Compounds.

All images are original and owned by Innovative Pvc Compounds & Africa Roto Compounds.

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2021/09/23 09:59

news

The new standard of

HDPE seamless bends

BY BEVAN DAVIS

Unique process for manufacturing 3D seamless long radius HDPE bends LINESCO Pipeline Engineering Supplies, a leading supplier of steel backing flanges to the HDPE pipe market in Southern Africa, has increased its product offering to include HDPE pipe fittings.

Linesco is no stranger to HDPE pipe manufacturing, as they form part of the Rare Plastics group of companies who is a leader in HDPE pipe manufacturing in South Africa.

Linesco recently entered into a license agreement with Pipestar International based in Winnipeg, Canada, to locally produce Arc Bends* and Super Arc Bends*. Arc Bends and Super Arc Bends are HDPE 3D long radius seamless sweep bends, and will be manufactured by using the technology owned by Pipestar International.

In terms of the agreement, Linesco has been rebranded and will in future be

known as Pipestar Africa. The Arc Bends and Super Arc Bends will be produced in Pipestar Africa’s facility in Kliprivier, south of Johannesburg.

Pipestar International was formed when a group of associates with over 60 years’ combined experience in the distribution and manufacture of HDPE pipe and fittings, acquired a unique process for manufacturing 3D seamless long radius HDPE bends.

The group formed Pipestar International Inc in 2000, and set up a manufacturing facility in Canada.

Locally manufactured Arc Bends will be available in SDR11 and SDR17 in sizes up to 280mm Initially the product offering of seamless Arc Bends was limited to sizes up to 14” (350 mm). Over the past 21 years, Pipestar International Inc has

continued to improve and modernize its manufacturing processes. In 2013, Pipestar’s product offering increased to include 16” (400mm), 18” (450mm), and 20” (500mm) Super Arc Bends*.

Arc Bends and Super Arcs Bends in IPS sizing, from 1” to 20”, produced in every imaginable angle, have been sold worldwide and are now the preferred 3D long radius sweep bends in North America.

These ‘state-of-the-Arc’ bends have been used in a multitude of industries such as: mining, oil and gas extraction, power generation, infrastructure piping systems, to name but a few.

Given Pipestar International’s recent association with Pipestar Africa, Arc Bends manufactured in metric sizes are available for these same industries and applications all over the word.

Initially the locally manufactured

12 OCT / NOV 2021

Lightweight success on 2021 Jeep Grand Cherokee BASF, L&L Products and Stellantis have been recognized for lightweighting success on the composite tunnel for the 2021 Jeep® Grand Cherokee L. The vehicle, which launched in May, just won the prestigious Altair Enlighten Award for achievements in vehicle weight savings.

While researching opportunities to reduce mass and improve durability without compromising safety performance, the transmission mounting system (TMS) was one area of focus. The composite tunnel reinforcement (CTR) is located on the underside of the vehicle and is part of the overall TMS. This was also the first application for L&L Products using their CCS technology and BASF’s Elastocoat® 74850 polyurethane pultrusion system.

www.basf.com

Plastic Energy collaborates with Exxonmobil on advanced recycling project

Arc Bends will be available in both SDR11 and SDR17 in sizes up to 280mm. Pipestar Africa has already commenced manufacturing the equipment to expand the size range to 630mm.

Arc Bends suitable for butt fusion welding and electro fusion welding Arc Bends are non-reversion bends that will maintain their bending angle without the need to be restrained.

Due to their exceptional dimensional stability and roundness the Arc Bends are fully pressure rated and offer increased flow capacity. Arc Bends are manufactured to within two degrees’ angular tolerance as opposed to the market norm of five degrees’ tolerance, and they are suitable for both butt fusion welding as well as electro fusion welding.

“When we first saw the Arc Bends and Super Arc Bends manufactured

by Pipestar International Inc, we knew that we had to have them, it was love at first sight... Our dream was to offer our market locally manufactured Arc Bends that were of a similar quality to our pipes that we produce at our Rare Plastics facility in Meyerton, Gauteng,” says Renier Viljoen, director of Pipestar Africa “I believe that this will improve the integrity of HDPE pipe systems in our region as a whole. We are extremely proud that these world class Arc Bends will now be locally manufactured in South Africa and

we believe that it will be the new standard for sweep bends in our market,” he adds.

In addition to Arc Bends, Pipestar Africa has also commenced the manufacturing of stub ends up to 315mm in diameter in both long and short form at their local facility.

Full traceability back to the raw materials used “We will be the only manufacturer in our region that will offer full traceability back to the raw materials used in the manufacturing of our stub ends as a standard practice.

A pipeline is only as strong as its weakest component and if we are to improve the integrity of our industry we need to ensure that we focus on all the components that make up a pipeline and not just the pipes. Our market should be driven by quality if we are to build infrastructure to serve generations to come,” says Ashin Tasdhary, director of Pipestar Africa.

The stub ends will be branded as PSA. In addition to Arc Bends and stub ends, Pipestar Africa will continue to supply the full range of steel backing flanges as well as fasteners suitable for HDPE pipe sizes.

PLASTIC Energy, a global company based in the UK and Spain, is collaborating with ExxonMobil on an advanced recycling project in France that will convert postconsumer plastic waste into raw materials for the manufacturing of virgin-quality polymers. Based on current plans, the project is expected to be one of the largest advanced recycling plants in Europe, with an initial capacity of 25 000 tons of plastic waste per year, and plans to scale up to 33 000 tons in the near future.

Plastic Energy is a global leader in advanced recycling, specializing in recycling end-of-life plastics that would otherwise be destined for landfill, incineration or end up in the environment. The company’s patented, innovative technology transforms plastic waste into raw materials that can be used to create virgin-quality polymers.

Plastic Energy and ExxonMobil have been developing plans since 2018. A final investment decision is expected in mid2021 with startup anticipated in 2023.

Under terms of the agreements with affiliates of ExxonMobil, Plastic Energy will build, own and operate an advanced recycling plant adjacent to ExxonMobil’s Notre Dame de Gravenchon petrochemical complex in France. The plant will convert difficult-to-recycle mixed plastic waste into raw materials that can be transformed into certified circular polymers and other high-value products at ExxonMobil’s petrochemical complex.

The construction of this new advanced recycling plant will support the circular economy in Europe and will add to Plastic Energy’s growing portfolio of recycling units. www.plasticenergy.com

* Arc Bends and Super Arc Bends are registered trademarks of Pipestar International Inc. Email: info@pipestarafrica.com

www.pipestarafrica.com

OCT / NOV 2021 13

NEWS

Rotomoulding manufacturers keen to boost sustainability Companies diversifying their activities against Covid-19 shocks THE ROTATIONAL moulding global market is projected to clock CAGR of ~6% during 2020-2030, and surpass valuation of US$ 7.7 bn by the period-end. The versatility of plastic rotational moulding is a key trend that will drive the demand in several applications where plastics are used.

US market researcher, Transparency Market Research, says that against the backdrop of large outbreaks of Covid-19, especially in 2020, companies in the rotomoulding market have been consolidating their efforts in applications that need urgent attention. They are thus keen on offering rotomoulded products to customers to meet the applications of sewage treatment, medical sector, and traffic management. The shift has helped them maintain their business agility and bottom line. Further, they are focusing on selling cost-effective products to their B2B clients.

One of the key trends that has gathered steam

among manufacturers of rotomoulding is the focus on developing sustainable products. Thus, the rotomoulding market has witnessed the demand for products made with biodegradable resins and use of more bioderivative materials. Stakeholders are also investing sizably in plastic recycling infrastructure to this end.

However, there is a major challenge of the limited choice of raw materials. Since rotomoulding involves intensive thermal processes, mostly poly-based resins have been used. New technologies have thus come to the fore to meet these operational challenges for manufacturers. In an attempt to meet the customization need of the manufacturing process, mould pressurization processes have been extensively studied among researchers, for instance.

For more detail, visit www.transparencymarketresearch. com/pressrelease/rotomolding-market.htm

14 OCT / NOV 2021

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2021/09/22 09:50

NEWS The 1.3MWp solar plant has an annual generation capacity of 2GWh and will reduce Extrupet’s carbon emissions by 1 800 tons every year

Extrupet switches to solar energy New state-of-the-art 1.3MWp solar power plant to power green recycling for the African continent EXTRUPET has commissioned their brand new 1.3MWp solar power plant, built in collaboration with Solarise Africa and NEC XON. “Climate change is the greatest existential threat ever faced by humanity. It is the duty of every organisation to change the way it does business and adopt eco-friendly practices to help reduce climate change,” says Vijay Naidu, joint managing director at Extrupet. Extrupet recycles more than 4 million PET bottles every day at their Wadeville facility.

“Being one of the pioneering recycling companies in Africa, everything we do is dedicated towards building a greener tomorrow. We are always looking at new ways to reduce energy expenditure and decrease our impact on the environment, and a switch to solar energy was the next logical step towards a sustainable future,” he adds.

The 1.3MWp solar plant has an annual generation capacity of 2GWh and will reduce Extrupet’s carbon emissions by 1 800 tons every year, which is equal to the carbon sequestered by just under 31 000 tree seedlings grown for 10 years.

“We started the journey with Solarise Africa and NEC XON two years ago and are proud to be one of the first companies in the recycling industry to adopt solar power.

This is a significant investment, and we challenge other industries to do the same. We look forward to a very long and fruitful relationship with Solarise Africa and NEC XON,” Naidu comments.

Will bring down electricity costs an estimated 30% Solarise Africa provided the full-service commercial solution to finance the project.

“Not only is solar energy better for the environment, but it will also bring down electricity costs an estimated 30% from the first month and savings of around R130 million to R140 million over the course of the lifecycle of the solar plant,” says Sakkie van Wijk, chief commercial officer at Solarise Africa.

16 OCT / NOV 2021

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Vijay Naidu (joint MD at Extrupet), Herman Viljoen (head of alternative energy pre-sales at NEC XON), Sakkie van Wijk (COO at Solarise Africa) and Lungani Zwane, (recycling programme officer at PETCO)

The engineering, procurement and construction was managed by NEC XON, the combination of XON, a systems integrator providing custom ICT and security services and solutions in Southern Africa, and NEC Africa, the African business of global technology giant NEC Corporation.

“This project was particularly interesting because of the high voltage system and transformer integration. This 1.3 MWp solar installation will produce an average 2 GWh of energy every year, and not only will it provide energy at a reduced cost, but it will also ensure that Extrupet has a consistent and reliable power supply, even when the national grid is under severe strain,” explains Herman Viljoen, head of alternative energy pre-sale at NEC XON. www.extrupet.com

www.solariseafrica.com

2021/10/06 09:35

extrupet Serious about

sustainability

Practicing what we preach - Vijay Naidu, joint Managing Director at Extrupet

“

“

Being one of the pioneering recycling companies in Africa, everything we do is dedicated to building a greener tomorrow.

Photo courtesy of ESI-Africa.com

Contact: 011 865 8360 | Email: info@extrupet.com | Website: www.extrupet.com Extrupet is proudly associated with

NEWS

Polyco extends industry support to cover all plastics under new EPR regulations Polyco now a ‘one-stop shop’ to improve collection and recycling of all polymer types “We encourage you to THE Polyolefin Responsibility Organisation (Polyco) has been share the outcome of our the driving force behind 26 000 tons of polyolefin plastics vote within your supply recycled in South Africa and 64 000 tons collected. In response chain,” says Pillay. “By to recently introduced waste management regulations, Polyco joining an established has decided to broaden its focus to all plastic types under PRO like Polyco, extended producer responsibility (EPR) regulations. This responsible producers can decision has been made to increase its support to producers ensure compliance under to manage their products’ life cycle responsibly.

EPR regulations.”

Under the EPR regulations, legislated for implementation from 5 November 2021, producers, through their PROs or independent Patricia Pillay, new CEO at Polyco schemes, are legally mandated to manage their products at end of life to grow the downstream reuse and recycling of their materials to achieve the published legislated targets. Obligated producers have until 5 November 2021 to register with the DFFE and ensure that all identified products are covered by an EPR scheme. They can either join an existing PRO, form a new PRO or develop and submit an independent EPR scheme.

“A challenge with these new EPR regulations is that producers who manufacture more than one type of plastic are required to join more than one PRO to cover their full product range.

Considering this, Polyco has made the decision to now manage all plastic polymer types under our mandate. As a membership-based organisation, we followed a consultative process with our members and board to arrive at a 95% in favour vote to increase our mandate. We are very pleased with this result,” says Patricia Pillay, CEO at Polyco.

Polyco now constitutes a ‘one-stop shop’ to improve the www.polyco.co.za collection and recycling of all polymer types.

Plastics could see a second life as biodegradable surfactants SCIENTISTS at the Institute for Cooperative Upcycling of Plastics, an Energy Frontier Research Centre led

by Ames Laboratory, have discovered a chemical process that provides biodegradable, valuable chemicals, which are used as surfactants and detergents in a range of applications, from discarded plastics.

The researchers targeted their work on the deconstruction of polyolefins.

18 OCT / NOV 2021

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The new process uses what science already knows about key steps of polymerization – the assembling of long polymer strands – but in reverse, by breaking some of the carbon-carbon bonds in the chains. Once a few carboncarbon bonds are broken, the shortened polymer chains transfer to an aluminum end group to form reactive species.

The catalysts and reactions for this new process are related to those used

in alkene polymerization, leveraging well-understood catalytic chemistry.

Finally, the intermediates of this new transformation are easily converted into fatty alcohols or fatty acids, or used in other synthetic chemistry, to create chemicals or materials that are valuable in a whole host of ways: as detergents, emulsifiers, pharmaceuticals and cosmetics. Its end products are also biodegradable. www.chemeurope.com

2021/10/05 11:42

Mass production starts at Chimei’s new ABS production lines in Zhangzhou LOCAL raw material supplier, Rawmac, is delighted about recent news that one of its principal suppliers has begun mass production at its newly built ABS production line.

Zhangzhou Chimei Chemical’s new ABS production lines will have an annual production capacity of 450 000 tons, and are expected to be completely operational by December.

The addition of the new production capacity has bumped up Chimei Corporation’s total annual ABS production capacity to 2.6 million tons, as it continues to solidify its role as a leading supplier in the global ABS supply chain.

Going forward, the plant’s annual ABS production capacity will scale up to 600 000 tons, as annual PS production capacity of 350 000 tons and annual PC production capacity of 180 000 tons are set to be progressively added to the output, contributing to a combined annual output of more than 1 million tons in the future.

• Chimei is represented in South Africa by Rawmac Import & Distribution. www.chimeicorp.com

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NEWS

Industry views on and opportunities Plastics: From recycling to (post-consumer) recyclate FROM retailers to recyclers, informal waste collectors to plastic converters, what do the key players in the plastic packaging value chain see as the main barriers – and opportunities – to drive increased recycling and use of postconsumer recycled content?

The WWF South Africa, in collaboration with The SA Plastics Pact, SAPRO and Naturvårdsverket, have published a report to determine barriers and opportunities in the plastics industry.

This easy-to-navigate report captures opinions from direct and indirect stakeholders in the plastics value chain, as well as from food packaging experts. The research was an in-depth investigation of the inherent barriers

to increasing the recycling rates of plastic packaging in South Africa and to the development of end markets for post-consumer recyclate.

Some of the barriers overlap between sectors; some are unique to a specific sector. Packaging design and demand for post-consumer recyclate are identified as barriers that hinder the systemic shift towards a circular plastic packaging economy, along with the strong link of these barriers to protectionism, inertia arising from the current mindset and overall ignorance.

A practical infographic introduces the interdependence of each stakeholder in the plastics value chain, and the specific roles and interconnected actions needed to accelerate towards a vibrant recycling industry and a circular economy.

Some of the main findings include: 1. Food packaging is a challenge when designing for recycling and the inclusion of post-consumer recyclate.

Food-contact and safety standards are a significant barrier, as is the cost of recyclate compared to virgin plastic resins.

2. The sectors that have the most influence to shift the system are brand owners, followed by the government and retailers. This is pertinent with regard to the extended producer responsibility regulations for brand owners and retailers, who are categorised as ‘producers’.

3. There is general inertia in the value chain due to market protectionist strategies, mainly by the virgin polymer producers and converters. The lack of design

for recycling and poor demand for recycled content from brand owners and retailers add to this inertia.

4. There is very little collaboration between brand owners/retailers, converters and recyclers to develop, trial and implement products containing post-consumer recyclate.

5. With a lack of embedded organisational policy on circularity, packaging design for brand owners and retailers is governed by cost and marketing requirements (bright colours and a proliferation of formats and materials).

Very few, if any, brand owners and retailers have a packaging policy with criteria on design for recycling, the inclusion of post-consumer recyclate and procurement from suppliers who also support circular packaging.

6. There is a lack of understanding and implementation of design for recycling by brand owners and retailers, which are key to achieving good quality recyclate.

7. In the past, large capital expenditure investments have been made for non-circular packaging, leading to resistance by converters and brand owners to move forward with packaging redesign and investment in the corresponding equipment and processes.

8. Most surveyed stakeholders approve of extended producer responsibility regulations as they even out the playing field and make it less risky for players to suggest post-consumer recyclate to their customers. However, brand owners and retailers lack awareness of the changes extended

20 OCT / NOV 2021

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barriers in SA Packaging design and demand for postconsumer recyclate are identified as barriers that hinder the systemic shi towards a circular plastic packaging economy

producer responsibility will bring.

9. Consumers are not empowered and face structural barriers to support both recycling and the increased use of post-consumer recyclate in packaging.

The situation is worsened by brand owners and retailers not applying transparent and consistent labelling on packaging so that consumers are able to dispose of packaging correctly.

10. Waste sector stakeholders are incentivised to only collect high-value items. Informal reclaimers are not

The Kraaifontein material recovery facility in the Western Cape

economically included and face the brunt of any price fluctuations due to the failures of the current free-market system. Together with buy-back centres, formal waste operators and recyclers, they absorb most of the economic losses, which ultimately affects the supply of plastic recyclables.

11. Recyclers need to provide better quality feedstock but face many challenges – from limited access to insurance and loans to lack of demand for recyclate – which hamper their ability to invest in improving quality and providing stable volumes.

12. The government has until recently not provided a clear direction on policy or enforcement to improve waste collection systems and support the circular economy. Local government and the relevant by-laws

have inhibited access to material and there is a lack of financial and operational capacity.

13. Producer responsibility organisations have limited membership, which restricts their ability to fund plastic collection, recycling and end-use development projects. This also allows the boards of producer responsibility organisations to be dominated by individuals or organisations who drive agendas that are not always conducive to recycling. The producer responsibility organisations are seen to be operating in silos with very little collaboration between them.

•

To read the full report, download it at https://wwfafrica.awsassets.panda. org/downloads/barriers_to_plastics. pdf?34562/plastics-from-recycling-topost-consumer-recyclate

12 plastic products that are on their way out THE World Wildlife Fund SA has welcomed news that the Plastics Pact has published the first list of 12 problematic and unnecessary plastics for phasing out by the end of 2022.

In publishing this first list of problematic and unnecessary plastics, the SA Plastics Pact has become the fourth international Pact to do so, joining the UK Plastics Pact, Chilean Plastics Pact and Portuguese Plastics Pact.

The list of 12 plastic items which will be phased out is as follows:

1.

2.

3.

4.

Oxo-degradable plastics PVC bottles, pallet wrap and labels PVC and PET shrink sleeve labels Plastic stickers on fruit and vegetables 5. Thin barrier bags for fruit and vegetables 6. Thin barrier bags used at tills 7. Plastic straws 8. Plastic stirrers 9. Single-use plastic cutlery, plates and bowls 10. Cotton buds with plastic stems

11. Plastic lollipop sticks 12. Plastic microbeads in cosmetics Captured in a publication titled “Addressing problematic and unnecessary plastics”, this is an initial list of plastic items to be widely addressed in South Africa. Members of the SA Plastics Pact have pledged to stop producing, distributing, selling or using the items on this first list – by December 2022. The publication also lists items identified for inclusion in a second list, which is to be published in due course.

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news

Plastics|SA training division upskills retrenched workers

Enhancing retrenched workers’ employability and career prospects with learnerships and skills programmes THE Training Division of Plastics|SA is one of the Associations within the manufacturing, engineering and related services sector to be awarded a discretionary grant by merSETA to train and upskill retrenched workers from the plastics industry.

“Recent events this past year such as the Covid-19 pandemic, riots and the economic downturn had a devastating impact on companies around the country.

Unfortunately, the plastics manufacturing industry was not spared. Many factories were forced to close their doors or scale

down their operations, which left many staff members unemployed and without an income. Our focus with the Retrenchment Assistance Programme (RAP) is to make these workers more employable and attractive to future employers by enrolling them in learnerships and skills programmes,” says Kirtida Bhana, training executive at Plastics|SA. According to a Memorandum of Agreement signed between Plastics SA and merSETA, 156 learners will be funded to enrol for learnerships and 84 learners to enrol for skills programmes that will be

offered at Plastics|SA’s regional training offices in Midrand (Gauteng), Maitland (Western Cape) and Pinetown (KwaZuluNatal). Learners will be equipped with in-demand technical manufacturing skills while they earn stipends for the duration of their training.

“We have already enrolled our first group of learners and the feedback received from them has been fantastic.

Most of them have years of workplace experience, but were lacking the academic qualification and certification they needed to advance their careers,”

22 OCT / NOV 2021

Setting the record straight!

PLASTICS|SA has responded to recent anti-plastics articles that appeared in the media, specifically the Daily Maverick.

Executive director of Plastics|SA, Anton Hanekom’s writes: “There comes a time when we find it necessary to stand up to defend the truth, set the record straight and refute claims that are defamatory, biased and damaging to an industry that strives to make a valuable contribution to the economy, the country and the environment.”

Hanekom says that as South Africa recently recorded the highest unemployment rate in the world (34.4%) with 7.8 million citizens jobless, one would expect that any effort to create a publicprivate partnership that is focussed on sustaining and creating jobs would be

welcomed.

“It therefore defies belief that the publication would support the view that Government should close down an industry that provides employment to roughly 60 000 people and contributed R68 billion (2.3%) directly to GDP and 20% to the manufacturing GDP in 2020.

During the same year, R2.1 billion was injected into the informal sector through the purchasing of recyclable plastic waste,” he adds.

Hanekom also defends South Africa’s mechanical recycling rates, which currently are at around 22%.

“Although it is true that there is ample amount of plastic waste available within our own borders, it is not necessarily the right type, quality or volume that can be

used by recyclers to produce a consistent supply of the type or grade that is required.

These recyclers need to keep their businesses going, workers employed and the industry operational,” says Hanekom.

These recyclers have to import waste from neighbouring SADC countries if local supply runs short.

“We are confident that plastic waste imports will eventually be completely phased out as South Africa’s EPR schemes are being developed. The PROs will implement improved collection and recycling mechanisms, focus on design for recyclability, reduce unnecessary packaging through light weighting, promote the use of recycled content in new products and develop new end-markets for recycled plastics,” says Hanekom.

Clas

RAP learners currently enrolled for skills programmes at the Plastics SA’s regional office in the Western Cape

to ensure the high quality of training is maintained, although the in-class instruction period has been slightly condensed to allow the learners to re-enter the job market as soon as possible.

Enrolment will be on-going over the next three years. Companies interested in registering their retrenched workers, or who are willing to make their workplace available as a training space for learners to gain workplace experience, are encouraged to get in touch with Plastics|SA’s Training Division as soon as possible. says Kirtida. “Apart from enjoying being back in circulation and part of the industry again, they are hugely appreciative of the opportunity to gain exposure to new

techniques and skills that enhance their resumés and employment prospects.

All regular learning and assessment processes and procedures are followed

For more information, please contact Kirtida Bhana on (082) 322 0117 or via email at Kirtida.

Bhana@plasticssa.co.za.

OCT / NOV 2021 23

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2020/06/15 11:11

news

SAVA highlights critical role of PVC in healthcare environments

24 OCT / NOV 2021

Twenty empty IV bags and 17 seconds to manufacture one pair of school shoes THE Southern African Vinyls Association (SAVA) recently highlighted the critical role PVC plays in hospitals and the healthcare environments. This international webinar was well attended and attracted delegates from around the world, including Thailand, Argentina, India, the United Kingdom, Italy and Denmark.

“PVC is the third most widelyproduced polymer globally and the most frequently used thermoplastic in the medical device industry,” says Monique Holtzhausen, CEO of SAVA. It can easily and effectively be cleaned and sterilised (at temperatures ranging from -40°C to 121°C), and be extruded to make IV tubing, thermoformed to make blister packaging or blow moulded to make hollow rigid containers.

PVC can also easily be welded to itself or with other plastics by heated tool welding and vibration welding. For this reason, PVC is used as wall and floor coverings, mattress covers, oxygen marks, catheters and tubing, surgical gloves and gowns and blood-, IV- and dialysis bags.

Ole Grøndahl Hansen, Project Manager at the PVCMed Alliance (Denmark), explained that since the 1960s, PVC has played a huge role in allowing the broader population access to affordable, quality healthcare.

“Thanks to its versatility and cost efficiency, PVC enables the massproduction of medical devices and reduces cross-contamination between patients. It has been extensively tested and researched for patient safety, and has a track record of billions of safe patient days,” he said. “PVC can be relied upon for its strength and durability under changing temperatures and conditions, can be formulated with www.savinyls.co.za

excellent transparency to allow for continual monitoring of fluid flow and can be created in virtually any colour if colour-coded applications are required”.

“Phthalate Plasticisers (DEHP) is a well-defined and tested plasticiser that facilitates the separation and storage of blood components. It increases blood safety and the efficiency of blood banking thanks to improved morphology, deformability and osmotic fragility. The increased durability and flexibility of PVC blood bags prevent container breakage and bacterial contamination, allowing blood to be stored for up to 49 days with an increased chance of survival and cell recovery,” Debbie Munford, Marketing Manager at Isegen SA reported.

Tandy Coleman, CEO of Polyflor SA, educated the delegates about the important role vinyl floors play in hospitals, clinics, old age homes, rehabilitation and frail care facilities.

Design and functionality go handin-hand with vinyl floors, as they are not only beautiful to look at, but offer exceptional versatility, practicality and comfort. Vinyl floors are soft underfoot, shock and noise absorbent (thereby helping to reduce noise and stress thanks to their fantastic acoustic properties) and significantly reduce slips, trips and falls when special slip resistant products are used.

Delanie Bezuidenhout, general manager of My Walk Made with Soul, reported on their successes achieved with the collection and recycling of nonhazardous and uncontaminated PVC IV bags, PVC oxygen masks and PVC oxygen tubing from various participating Netcare hospitals.

“My Walk is a partnership between www.pvcmed.org

Adcock Ingram Critical Care and Netcare that manages the cradleto-cradle process of collecting and recycling these products into new, durable and shiny school shoes made from 100% recycled material!” she explained.

It takes twenty empty IV bags and approximately 17 seconds to manufacture one pair of school shoes.

With more than twenty hospitals around the country already participating in the project, the My Walk Made with Soul Project has already collected and diverted more than 41 913kg of hospital waste from landfill.

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news

Whole Earth Recycling

grows from strength to strength Currently recycles over 120 tons of recyclable material every month

26 OCT / NOV 2021

a simple, reliable, and hassle-free way to WHAT began as a small recycling effort in recycle from home, the office, or school.

March 2007 has grown into Whole Earth The recyclable material that Whole Recycling, a sizeable recycling business Earth Recycling collects is sorted by a that currently recycles over 120 tons of community-based project, the Hawk Flight recyclable material every month – team, currently a group of 24 sorters who 13 789kg of that plastics during August, generate an income for themselves by most of it clear PET. sorting and selling the material to local Whole Earth Recycling was buy-back centres. founded in March 2007 on a The recyclables are collected farm in Randburg outside from the Whole Earth Johannesburg. At that Whole Earth Recycling warehouse by the stage sorting was done Recycling provides buy-back-centres so that by just four sorters until a simple, reliable, the sorters don’t have to 2009 when Whole Earth and hassle-free pull their recyclables in bulk Recycling moved to Décor way to recycle from bags along busy roads to Park, and finally to Strijdom home, office, or buy-back-centres to sell the Park where it launched its school. recyclables. community-based project The Whole Earth Recycling in 2011. warehouse provides shelter for the sorters Carmen Jordaan took over Whole Earth against the elements and ensures that Recycling at the end of 2014 and has the recyclables do not end up in the helped the business grow from strength to environment. Traditionally reclaimers have strength. Whole Earth Recycling provides

Carmen Jordaan took over Whole Earth Recycling at the end of 2014 and has helped the business grow from strength to strength

had to sort recyclables in the open veld and some of the recyclables are blown into the veld and washed into nearby rivers. The sorters also have access to toilets, showers and a tea area in the Whole Earth Recycling warehouse.

“This is the only source of income for the sorters and without it they would be rummaging through municipal refuse bins to gather recyclables to sell,” says Jordaan. “By recycling with Whole Earth Recycling, people are contributing towards job creation (a total of around 40 people) – the Whole Earth Recycling drivers, truck assistants (loaders), and admin team and through the sorters that make up the community-based project – while reducing the impact that we are having on our environment. Every little bit helps.”

By recycling with Whole Earth Recycling, people are contributing towards job creation (a total of around 40 people) – the Whole Earth Recycling drivers, truck assistants (loaders), and admin team and through the sorters that make up the community-based project

Upskilling where possible “We try to upskill as many people as possible. Over the years we have employed some of the sorters as truck assistants/loaders and we have helped some of the truck assistants/ loaders to get their drivers licenses.

We have also done other training for employees – forklift driver certification, first aid training, and basic Excel training. We also helped one of our previous employees to start his own business – Bophelo’s Birdseed Bells.

How the Whole Earth Recycling collection service works For a nominal monthly fee, Whole Earth Recycling provide blue recycling refuse bags and all dry recyclables (paper, cardboard, plastic, glass, cans, cartons such as Tetra Pak and electronic waste) can be placed into the same blue bag (or blue bin). The Hawk Flight team takes care of the sorting.

Recyclables are placed outside in blue bags (or a blue bin) on the

Whole Earth Recycling was featured on TV on Pasella earlier this year – view it here at www.youtu.be/72XGHbk3Lhs.

kerb for collection every week, and the Whole Earth Recycling team collects it. The recyclables are then taken to the Whole Earth Recycling warehouse where they are sorted by the Hawk Flight sorting team.

Some of the sorted recyclables are collected by buy-back-centres, while other sorted recyclables such as cardboard, are baled until there are enough bales to send directly to a paper mill for recycling.

www.wholeearth.co.za OCT / NOV 2021 27

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PEOPLE

On the move New face at DH Polymers CARLO Wilmans will join Deon Holtzhausen at DH Polymers on 1 January 2022 as a partner and sales director responsible for the day-to-day servicing of clients and to grow the business.

After completing his mechanical engineering studies, Carlo joined PM Manufacturing based in Chamdor Krugersdorp, where he gained experience in injection moulding, blow moulding, product development and client management.

Following a successful career at PM Manufacturing, Carlo left the plastics industry for a 13-year stint in the short-term insurance industry fulfilling various roles in risk management and corporate client service.

Carlo Wilmans (left) will join Deon Holtzhausen at DH Polymers

Carlo is excited to return to the plastics industry where he started his engineering career and believes he can add value with his client focused approach.

SU’s Dr Katherine de Villiers awarded for outstanding chemical research FOR the third time in her academic career as a chemist, Dr Katherine de Villiers has been honoured by the South African Chemical Institute (SACI) for her outstanding contribution to research in this field.

Dr De Villiers, a senior lecturer in bioinorganic chemistry in the Department of Chemistry and Polymer Science at Stellenbosch University, is the recipient of the 2021 Raikes’ Medal of the SA Chemical Institute. The award is made annually to a member of the institute, under the age of 40, whose original chemical research shows outstanding promise.

Two new faces at Continental Compounders in Durban are Jason Agnew (product manager) and Keegan Govender (commercial director). Jason was with Cathay Industries before and Keegan at Chemiplast, and before that at Clariant.

Clinton Farndell has been appointed as managing director at Krones Southern Africa. Clinton was previously group executive of Nampak Rigid Plastics in Sandton, Johannesburg. He spent four years at Nampak Rigid Plastics where he worked his way up from divisional commercial director, business development director and divisional managing director. Before Clinton joined Nampak, he was managing director at Amcor Flexibles Europe, Middle East & Africa in Durban for four years. Prior to Amcor he spent 12 years with Nampak in the flexibles division.

28

PEOPLE-.indd 28

Gareth Akerman has been appointed general manager at Van Ryn Rubber Holdings in Maxmead, KZN. Prior to this appointment, Gareth was factory manager for four years at Davro Compounding in Pinetown, a division of Anchor Chemicals and part of the International Hobart Group, from February 2017. He was also the founder and COO at Envande in Pietermaritzburg for seven years – a rubber crumb and reclaim business which was razed by fire in March 2014. In March 2015 Gareth re-started Envande in a difficult climate. Gareth and his team grew Envande to reach pre-fire turnover and full capacity within six months of re-start.

OCT / NOV 2021

2021/10/05 11:31

Mera Clas

OBITUARIES

NEWS NEWS

KZN’s Vishnu Colan gone so suddenly

- ( #)& -&("!% &% )* ') * - ( #)& -&("!% &% )* ') * * -!## #!$!* * -!## #!$!* % && * ) '# %) * ) '# %) , $ '(&,!)!&% &( % , $ '(&,!)!&% &( % % && in technical sales he worked for qualifi ed electrician by trade and started* !$'&(*!% & '# )*! - )* *& '(&* * Brian Norman Murray * career !$'&(*!% & '# )*! - )* *& '(&* * 1 $ )* ( '# % !) #)& !% , #&' *!, - )* $ % $ %* )/)* $ * *!, - )* $ % $ %* )/)* $ * * * 1 $ )* ( '# % !) #)& !% , #&' various machine agencies, including his career in the plastics industry as passed away in & !( $"! & !( $"! !& & $ * ! ! '%&$* !& & $ * ! ! '%&$* &( * &( * '# )*! ) !% +)*(/ % - '# )*! ) !% +)*(/ % - &' &' ")% "$ & % # $ & "! " & "! ! ")% "$ & % # $ & "! " & "! !

Halogen Distributors, Adron, and Plastic a maintenance manager for Gallo July 2021 at the ! $") & ! $") & ! "$ " ) %& , ! "$ " ) %& , * * * * !#) -!## ( # ) !% * * !#) -!## ( # ) !% *

'(& ))!% & ( / # # $ * (! #) (&$ '(& ))!% & ( / # # $ * (! #) (&$ * * * Chemical Trading and eventually Records that produced vinyl records. He age of 82 years.

! "

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% ( +*+( * * -!## ))!)* !% (&-!% * -!## ))!)* !% (&-!% * ) * ) &+) &+) &# ) &# ) !) -!## & #&% - / !) -!## & #&% - / % ( +*+( * retired from Maritime Marketing. He then went into technical sales, selling He worked in the will be sorely missed by his wife, two machinery and providing technical plastics industry

daughters, son and extended family. support to numerous manufacturers for more than 40 in the plastics industry. During his years. He was a OCT / NOV 2021

Trade.

Trade.

Create.

Create.

Elevate.

Elevate.

23

23

& % &"$ , % ! " + "$ "( $ + "$ "( $ *& ( + * & !*!0 %) * & !*!0 %) * * & ) * & ) & % &"$ , % ! "

*& ( + * )* ') * " % *& # $' &-% &% !## # %&* %&* , )) *& - )* $ % $ %* , )) *& - )* $ % $ %* )* ') * " % *& # $' &-% &% !## #

!$'&(*) % +% ( !%,&! '(& + *) ( " !* %"$&% ! "'& $ , ! " " !* %"$&% ! "'& $ , ! " * - ) ( , # +(!% * * - ) ( , # +(!% *

*

* * * KZN material and masterbatch ace was popular far and wide !$'&(*) % +% ( !%,&! '(& + *) ( #)& - # &$ % -) ) - #)& - # &$ % -) ) - , % , %

% - 2)$ (* !*/3 !) * "!% ) % - 2)$ (* !*/3 !) * "!% ) ' !% ' !% becoming regional-&("!% #&) #/ -!* sales manager for * Southern Africa. Then IT IS with that we report!% about -&("!% #&) #/ -!* !% ( %* * !% ( %* %) (! %) (! ! sadness -!## &$'# * -!* ! -!## &$'# * -!* !% the sudden passing of he started his own$&%* company, KZN Polymers, which Colan of Durban, who was just 50. $&%* ) *& , #&' $ )* ( '# % * ) *& , #&' $ )* ( '# % * * he * ran

* % .* * Vishnu % .* '(& )) !) !% '(& )) !) !% from 2007-2015. The company represented Manuchar group Born in Chatsworth 1970, Victor Denver Colan briefly studied % % & $")& %'%& ! &* ! & $")& %'%& ! &* !

# / * # / * %, )*$ %* % % ( )*(+ *+( %, )*$ %* % % ( )*(+ *+( from 2012 to 2015. marketing and then started working in 1990 or 91 at Hoechst, ' ! & $ ! "!" ' ! & $ ! "!" * ") $ ! * ") $ ! & ( * # ( ( $ (" * &( )$ ## & ( * # ( ( $ (" * &( )$ ## - ! & $ % ! * "! % & ! & $ % ! * "! % & He then joined * (! ) % !%*(& + !% !% %*!, ) &( #& # Samchem in 2015, where he remained. which was the ‘school of hard knocks’ for '% ! %% % "( $! many in the industry !& # !% &" * (! ) % !%*(& + !% !% %*!, ) &( #& # '% ! %% % "( $! !& # !% &" '(&,!% ! # &, (%$ %*) & +* % % '(&,!% ! # &, (%$ %*) & +* % % During this time he !' &'$ $% , also !' &'$ $% , ran the aptly names VC Agencies, in that era (including many of the most knowledgeable and )! % * #& ##/ '(& + '(& + *) )! % * #& ##/ '(& + '(& + *) "$& %& )"$ ! &" & $ ) & & "$& %& )"$ ! &" & $ ) & & through which he supplied some recycled polymer. experienced individuals still active). He was mentored

by John %& % % ! (" & ! "$ %& % % ! (" & ! "$ * * $+)* '(& +( (&$ ) * * $+)* '(& +( (&$ ) & % " " !! % '$ % ) ! ! & % " " !! % '$ % ) ! !

“Vishnu was a very giving man who #"$&% went above and beyond Kaizer who encouraged him to get more involved in the industry. && $ "!&$" "( $ #"$&% %'$ % &" %'$ % &" $ % !& !!"'! & & #$" &% $ % !& !!"'! & & #$" &% && $ "!&$" "( $ ! % &("!% -!* ! % &("!% -!* , #&'$ %* , #&'$ %* for all.

He was known for being a semi-professional drinker, Besides a short stint in converting (as a consultant) at )*!$+# * #& # '(& +( $ %* % % *!&% # )*!$+# * #& # '(& +( $ %* % % *!&% # % !%, )*$ %* , #+ & !##!&% % !%, )*$ %* , #+ & !##!&% - ! ! !%& &'& "!% & "( $!

- ! ! !%& &'& "!% & "( $! !& % *% !& % *% -!* -!* always taking clients out for a beer and a bunny chow, and an wife’s business, from that point was involved in !%!*! *!, *& +/ #& ##/ '(& + '(& + *) !%!*! *!, *& +/ #& ##/ '(& + '(& + *) , #( / % &$'# * %

, #( / % &$'# * %

!* ) ( * % !%%&, *!, '(& )) * !* his ) ( * % !%%&, *!, '(& )) * * on * Vish excellent salesman,” said Samchem CEO Hadley Lasarow. polymer or masterbatch supply in KZN,#$" &% )"$& '%& "( $ "! $ as #$" &% )"$& '%& "( $ "! $ a result of which % '(& + *) -!* % '(& + *) -!* ( / # &%* %* ( / # &%* %* ) '! & ' % ) $ &$ &* ) '! & ' % ) $ &$ &* “Everything about him was extraordinary.

He was an he was widely known in the industry in the province.

1 - * (! & ) % ) *& 1 - * (! & ) % ) *& !% !$'# $ %* *!&% ' !% !$'# $ %* *!&% ' ) * ) * * -!## ) * -!## ) ) & $ & ! $ %&$' &'$ ! $" % ) & $ & ! $ %&$' &'$ ! $" % unusually kind, funny and dynamic man.”

He worked with Clariant, a masterbatch supplier, from , #&' *& * ** ( &%*(&# &, ( * , #&' *& * ** ( &%*(&# &, ( *

% -#/ +!#* *&(! ) * * $ %+ *+( * $ %+ *+( 1 #* 1 #* &+ &+ #!**# !% &($ *!&% !) , !# # #!**# !% &($ *!&% !) , !# # % -#/ +!#* *&(! ) * RIP Vish.

1994 for roughly 15 years, climbing the%corporate ladder and #$" ' &% " #$" ' &% " ! !&" "'& $ ! ! !&" "'& $ ! $&# "! % $% #") $ % &*$ % % $&# "! % $% #") $ % &*$ % "$ #' "!%' "$ #' "!%' #& "! ) $ "# ! & & #& "! ) $ "# ! & &

29

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2021/05/24 2021/02/01 11:06 2021/10/05 11:49 11:32

NEWS

International

Plastics SA’s 25th year of coordinating South Africa’s participation PLASTICS SA’s 25th year of coordinating South Africa’s participation in the International Coastal Clean-Up Day was once again a huge success. This year’s event and the World Clean-Up Day took place on Saturday, 18 September.

John Kieser, sustainability manager at Plastics|SA, reported that more than 15 000 volunteers took part in clean-ups in the coastal areas, as well as at rivers, streams, and inland water sources.

Bottle tops were the most collected macro item in urban and non-urban clean-ups, followed by plastics earbud or lollipop sticks. Although volunteers collected some PPE items such as masks and gloves during their clean-ups, it was encouraging to note that it was not at the same magnitude as being reported in the northern hemisphere.

A detailed report of the amount and type of litter that was collected will be released later this year after Plastics SA has compiled and assessed the audit forms.

30 OCT / NOV 2021

CLEAN UP-.indd 30

2021/10/05 11:37

Coastal Clean-Up Day www.cleanupandrecycle.co.za

www.plasticsinfo.co.za

OCT / NOV 2021

CLEAN UP-.indd 31

31

2021/10/05 11:37

NEWS

Purpose partners convert waste to good ‘One Desk, One Child’ campaign excellent example of purpose coupled with circular economy WHAT started as a small, but impactful recycling initiative among 13 schools during lockdown, has boomed to 100 schools. The ‘One Desk, One Child’ campaign upcycles yoghurt tubs into school desks for Early Childhood Development (ECD) schools. In February, Danone donated 230 school desks made from recycled yoghurt cups to seven ECD schools in the Ekurhuleni district, home of Danone.

Rewind Polystyrene SA reported that in 2020, over 3 000 tons of the plastic type used to manufacture yoghurt tubs was recycled. Pick n Pay, Mpact Plastic Containers and Interwaste have joined the programme to be this force for good. Pick n Pay’s School Club (an educational platform which reaches two million learners each year) provided the school activation infrastructure to collect more yoghurt tubs.

Mpact Plastic Containers donated 87 collection bins to the participating schools. These unique Wheelie Bins are 100% recyclable and are also made from upcycled plastic.

Interwaste manages collection logistics, transporting the collected plastic from the schools, and delivering it to the desk manufacturer partners monthly.

Students from Kidz Paddle Preschool in Boksburg enjoying their new desks made from recycled yoghurt tubs

www.corporate.danone.co.za/one-planet-one-health/healthy-planet/OneDeskOneChild.html

SA’s gumboot manufacturers step up to support Clean-Up Day

32 OCT / NOV 2021

THE Southern African Vinyls Association (SAVA) supported by SA’s leading gumboot manufacturers, stepped up to support the many volunteers and teams who cleaned the country’s rivers on River Clean-Up Day

on 15 September.

The gumboot manufacturers’ donations formed part of a ‘Water Warrior’ kit issued to volunteers and clean-up teams. Wayne Plastics, Neptun Boot and Silver Lining

Gumboots donated much-needed gumboots to be used by river cleanup teams primarily in Gauteng and KwaZulu-Natal. Clean-up groups worked in the Gauteng region, such as Jukskei Clean-Up and Hennops Revival, and equipped various new community-led initiatives that are underway within catchment areas, such as Tembisa, Alexandra and Diepsloot. An example of this is the collaboration with Triple P and the training of 33 participants in water awareness, monitoring and testing, where the boots were issued to these ‘water warriors’ as part of their PPE. Douw Steyn, sustainabililty director of Plastics SA with Jonathan Robb, managing director of Neptun Boot

CLEAN UP-.indd 32

2021/10/05 11:38

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DESIGN

SA Plastics Pact Reuse

Contest for innovative reusable packaging solutions THE South African Plastics Pact in partnership with the MAVA Foundation recently held a contest for innovative reusable packaging solutions. Congratulations to the winners, in first place, Waterpod by I-Drop; in second place, Sonke Retail; and in third place, Green Tap. “The I-Drop Waterpod team are absolutely thrilled to win the inaugural SA Plastics Pact Reuse Innovation Challenge.

This is particularly special given the amazing solutions presented by all the competitors, all of whom are a proud showcase of South African innovation in sustainability and new approaches to a more circular plastics economy,” says Kate Thiers, CEO of Waterpod by I-Drop.

Waterpod plans to build and grow the company’s reach to shop-owners looking for a convenient and simple way of selling purified water refills for a sustainable alternative to bottled water in single-use plastics.

The first runner up in the challenge was Sonke Retail.

‘Sonke’ is a Zulu word meaning ‘All of Us’. Sonke is an The I-Drop Waterpod team are absolutely thrilled to win the inaugural SA Plastics Pact Reuse Innovation Challenge

34 OCT / NOV 2021

DESIGN-.indd 34

African start-up which was founded to give all people economic incentive to make environmentally friendly choices. Sonke designs, manufactures and manages automated refill stations for fast-moving consumer goods (dishwashing liquid, fabric softener, etc).

“Sonke designs, manufactures and manages automated refill stations that encourage shoppers to bring their own packaging – for a discount. Sonke refill machines are fully automated, ‘smart’, compact and can dispense up to three liquids,” explains Eben De Jongh, founder of Sonke Retail.

Reacting to the announcement, the second runner up, Green Tap’s founder Carmen Francke said: “We are very grateful for the opportunity and generosity we have received which will definitely assist our brand growth going forward.

We are excited and would like to take some time to put a plan in place as to how we will be spending our winnings but we can say that we will be looking at a community initiative, a marketing campaign, and a new product line.”

Second place went to Sonke Retail that designs, manufactures and manages automated refill stations that encourage shoppers to bring their own packaging – for a discount

www.iom3.org

2021/10/05 11:38

Innovation Challenge 2021 From over 45 entries, the following top six innovators pitched online to a panel of expert judges, hosted by SA Plastics Pact: 1. Waterpod by I-Drop 2. Sonke Retail 3. Green Tap 4. Bag Pack 5. Instore Refill Station 6. Earthly

“For supporting a transition towards a circular economy of plastics, it’s crucial to have concerted and collaborative action across actors (businesses, government/local authorities, NGOs) and the value chain – like the South African Plastics Pact (SAPP) – to transform words into concrete actions.” said Nathalie Cadot, Impact & Sustainability Manager, MAVA Foundation.

“We are thrilled by our collaboration with SAPP aiming to support the pact members’ effort to find reuse of packaging.

We hope this first edition of the Reuse Challenge is just a start, many more editions will follow to promote South African reuse innovations and collaborations between startups and larger corporates,” she added.

The prize money of R500 000 will be shared among the three winners, with the potential for product development or implementation assistance through partner companies from the SA Plastics Pact membership.

The judging panel was made up of local retailers and brand owners representing Unilever, Tiger Brands, Woolworths, Spur, Spar, Food Lovers Market and international experts in circular plastics, WRAP. The entries had to propose a reusable packaging solution that could be viably implemented by brand owners and retailers in South Africa. The solution had to be geared towards reducing the amount of single-use packaging in South Africa, ideally addressing currently non-recyclable plastics, or plastics that are often littered. www.purewaterpod.com

www.sonke.org

www.thegreentap.co.za

In third place, Green Tap hand-pick sells eco-friendly cleaning and degreasing solutions, oxygen-detergents and hydrosols, wraps and cloths, loofahs and bamboo straws, spritzers, sprays and surface-cleaners

Adidas also sells a pair of 100% recyclable running shoes which must be returned to the manufacturer once they reach the end of their life

OCT / NOV 2021

DESIGN-.indd 35

35

2021/10/05 11:39

COMPOSITES

SA entrepreneur uses 3D printing

to help save the planet, one cup at a time

Using 3D printing technology, Red Cup Village started by creating biodegradable drinking cups using polylactide (PLA) filament – a biodegradable polyester derived from sugarcane and corn starch.

Biodegradable drinking cups using PLA filament AS AN entrepreneur, hobbyist, 3D printing enthusiast, and inventor, Luvuyo Ndiki (30) is the man behind Red Cup Village, a lifestyle brand dedicated to producing high quality and innovative products that help its users make a difference in society.

Ndiki established Red Cup Village in 2014 with a vision to become a leading disruptive 3D printing and 3D scanning company through innovative concepts and premium products. And this vision is steadily coming to fruition thanks to the hard work and dedication of the talented Ndiki and his creative and forwardthinking team.

Using 3D printing technology, Red Cup Village started by creating biodegradable drinking cups using polylactide (PLA) filament – a biodegradable polyester derived from sugarcane and corn starch. Born in Butterworth and raised in Bathhurst, Ndiki says the idea to start the business struck him while studying Design Foundation at the Cape Peninsula University of Technology (CPUT) in 2010.

where we are today – specialists in “The Design Foundation gave me manufacturing on-demand consumer a wide view of the design disciplines, products and medical devices from architecture, interior design, using 3D printing and scanning graphic design, product design, technology in combination surface design and fashion Using with material science. Our design. I majored in 3D printing, platform allows users to product design, known construct personalised as 3D dimensional Red Cup created functional parts and design, in 2011, but biodegradable drinking products in a matter could not complete cups using polylactide of hours, faster than the course due to (PLA) filament – traditional manufacturing financial constraints. derived from processes, using However, I was sugarcane & corn biodegradable raw material determined to graduate, starch derived from corn-starch, so I enrolled in Public sugarcane and recycled Relation Management, which I plastics,” he explains. completed in 2014,” says Ndiki.

The Red Cup Village 3D printing While studying public relations, Ndiki farm currently holds over 117 highcontinued to self-teach himself 3D performance industrial and commercial dimensional design and 3D printing 3D printers with the capacity for technology. mass volume customisation and “I fell in love with 3D printing and personalisation. established Red Cup Village with the idea to make world-class 3D printing Inspired by Africa and scanning accessible to individuals, Ndiki recalls how Red Cup Village was organisations and start-ups across inspired by his grandmother’s story various sectors. about an immensely enlightened African “It has been a long journey to

Hexcel showcases carbon fibre prepreg capability for UAV applications THE successful maiden flight of a lightweight camera drone, developed using Hexcel HexPly® carbon fibre prepregs, has highlighted the capability of carbon fibre prepregs for Unmanned Aerial Vehicles (UAV) applications. The composite drone was developed by a team of students from 36 OCT / NOV 2021

the University of Applied Sciences Upper Austria in Wels with composite materials supplied by Hexcel Neumarkt in Austria.

A team of six students in the university’s lightweight construction and composite materials course was responsible for the complete design, engineering, and

manufacture of the camera drone over a period of 18 months. Hexcel materials and optimization of the composite engineering enabled the team to reduce the composite structural mass by an impressive 42% compared to similar drones.

Hexcel Neumarkt was one of eight

Ndiki established Red Cup Village with the idea to make world-class 3D printing and scanning accessible to individuals, organisations and start-ups across various sectors

The bio-composite outer cladding and steel substructure of the Ermerweg underpass engineered by Solico, and the newly refurbished Valsteeg viaduct with composite handrail.

woman in the 13th Century.

“She united two rival kings by inviting them to a social gathering, where she made them drink from the same wooden cup. The two rival kings ended up not only sharing the cup but, belief systems and cultural backgrounds, which created social cohesion and united them and their villages.”

As such, the Red Cup Village name is a combination of his grandmother’s story and the disposable red cups popular in the hip-hop community. Even the brand’s logo, an upside-down R & V, makes reference to the ancient wooden cup shared by the rival kings, with the V-shaped vessel allowing users to pour their drinks from both sides.

Ndiki shares that his brand story has always been about bringing people from different cultures together. “It’s not just a cup, but a lifestyle. We are building a global lifestyle brand through the best quality products using raw and locallygrown materials and ethical sourcing

industrial partners supporting the university team throughout the project, providing all carbon fibre prepreg materials used for the drone’s landing gear as well as the fuselage.

The ultra-lightweight 32g landing gear was laid up and cured in the press, whereas the fuselage was autoclave cured by the student team using Hexcel HexPly M901 and HexPly M78.1 prepreg

practices.”

“As a company, we look towards creating sustainable products for the environment and stimulate green economic growth in the country by producing local products from recycled plastics pallets. We also aim to empower young people to a lifestyle of unity, friendship and discovery,” he says.

“We want Red Cup Village to be a hub for innovative people from diverse cultures. We want South Africans to come together and drink from the same cup as one, united nation,” Ndiki adds. www.redcupvillage.com

www.hexcel.com resin systems with a combination of woven and unidirectional carbon fibre reinforcements.

Composite elements for viaduct

DUTCH composite engineering specialist Solico has partnered with composites systems integrator Advantage Composite BV to engineer the composite elements of the 3 Phase N34 reconstruction project in the Netherlands.

The project includes the extensive reconstruction of multiple viaducts and underpasses along the N34, a provincial dual carriageway road linking the Dutch provinces of Drenthe and Overijssel.

Advantage Composite BV manufactured composite elements engineered by Solico for the project.

Solico’s scope of work covered the detailed engineering of various infrastructure elements including steel support structures, composite claddings, railings, and handrails used throughout the project. In addition, Solico’s in-house test laboratory supported Advantage Composite BV with an extensive material testing and characterisation programme, enabling the finite element analysis of components using a novel bio-based material with a wood finish aesthetic.

One such example is the bio-based material used on the Valsteeg viaduct cladding in Phase 1, which combines the striking visual aesthetic of weathered steel with the durability and weight reduction of a composite material. www.solico.nl OCT / NOV 2021 37

COMPOSITES

Hexcel’s surface technology revolutionises the blade surface finishing process Eliminates need for a traditional in-mould gel coating process HEXCEL has launched its latest HexPly® XF surface technology that significantly reduces shell manufacturing time within the wind blade surface finishing process.

HexPly XF increases overall blade manufacturing efficiency by reducing time in the mould by up to two hours and by banishing surface defects that require rework before painting.

As the surge in wind energy continues, wind turbine manufacturers are under increasing pressure to reduce costs, increase quality, and optimize productivity. Hexcel’s HexPly XF surface technology has been formulated to address the limitations of current blade shell surfacing techniques whereby pinholes and other surface defects have to be repaired by hand to achieve the perfectly smooth surface required for painting.

HexPly XF surface technology satisfies the most challenging surface

quality requirements by introducing a new material format as the surface finishing layer, eliminating the need for a traditional in-mould gel coating process.

HexPly XF for infused rotor blades, is a lightweight non-woven semi-preg construction, comprising an epoxy resin matrix, that co-cures with standard epoxy infusion systems. The product has a successful track record in prepreg blades and has now been adapted for infusion processes.

Easy to handle and supplied in a ready to use roll form, HexPly XF can be quickly applied by hand or with semiautomated layup equipment. It features one self-adhesive, surface finishing side - indicated by a removable protective foil.

This side of the prepreg is placed against a release agent treated mould surface.

Once the material has been positioned, the lay-up of the blade shell structure can start immediately, and the laminate

can be infused. After curing, the blade is de-moulded with the manufacturer benefitting from a pinhole-free surface that needs minimal preparation before painting.

HexPly XF material is less than half the weight of a typical gel coat per square metre, reducing the overall weight of the blade. Additionally, the consistent areal weight and thickness of the prepreg film provide a completely uniform surface coating, ensuring blade weight distribution and balance are maintained, which is critical as rotor diameters continue to increase. With no need to handle or mix liquid chemicals as in the gel coat process, HexPly XF also improves the health and safety working conditions on the shop floor.

The material has a shelf life of six weeks at ambient temperature, which also minimizes cold storage requirements and helps to reduce scrap.

SPECIALTY chemicals company Lanxess (Cologne, Germany) and Korean auto parts specialist INFAC (Seoul), which specializes in automotive control cables, actuators, antennas, and battery packs, have together developed a battery module housing for electric vehicles (EVs).

The battery housing uses Durethan BKV30FN04 from Lanxess to satisfy stringent mechanical and chemical property requirements for latest EV components. The halogen-free, flame-retardant and glass fibrereinforced polyamide 6 (PA6) is characterised by its optimized flame-retardant and electrical properties. Lanxess notes that the material is highly processable and enables the integration of complex functions required for housing

components, resulting in a smaller number of parts and a simplified assembly process as well as lighter weight.

The new battery housing part has also been adopted by series production of EV models launched by a Korean OEM this year.

According to Lanxess, Durethan BKV30FN04 is not only mechanically robust, but also boasts high-voltage insulation, is resistant to up to 800 volts and effectively blocking high-voltage current, characteristics that are critical to protect the battery from external shock. In addition to maintaining high strength and stiffness when in contact with electrolyte or cooling media, and enabling chemical resistance to suppress chemicallyinduced damage, the material’s flame-retardant

properties help prevent or delay flames from spreading in case of a fire. Lanxess claims glass fibre-reinforced Durethan BKV30FN04’s durability to mechanical loads is also superior to unfilled PA6.

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Lanxess, INFAC develop composite battery module housing

www.lanxess.com

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COMPOSITES

Bentley reveal new carbon fibre rim A weight saving of 6kg per wheel COMING from the ‘Carbon Valley’ of the Emilia Romagna region, the innovative full carbon car wheel that the prestigious British car manufacturer Bentley recently revealed for its Bentayga SUV is developed by Bucci Composites.

The 22” carbon wheel, the largest ever made in carbon, guarantees an innovative design and excellent performance, as well as a weight saving of 6kg per wheel.

All the benefits of using the ultralight carbon fibre wheel are directly linked to the reduced weight of the wheel: a lighter component design means less rotational inertia, which translates into greater

acceleration, shorter braking distance and better vehicle handling.

Furthermore, less un-sprung mass means improved grip between the tyre and road thus ensuring excellent road holding characteristics.

A further key benefit of the Bucci Composites wheel is the hub-wheel coupling system which allows the wheel to be fixed to the hub in the traditional way, eliminating the risk of wheel bolt torque loss. This assembly system provides all the advantages of a conventional wheel fixing system but with the significant added weight reduction.

The carbon fibre rim has undergone

rigorous testing as part of this process and Bucci Composites is the only manufacturer globally to have passed the new TUV standard (German testing body for the certification of automotive components) for non-metallic rims, a standard that was not in existence when the project started.

Bucci Composites has also invested in new innovative production technology (High Pressure RTM – HP-RTM), which will enable them to continue developing new carbon fibre wheel models for the automotive sector. www.bucci-composites.com

Lambo goes retro with hybridised, carbon fibre-intensive LPI 800-4 supercar ASK any automotive designer about classic vehicle designs and you’re likely to hear ‘Lamborghini Countach’, a vehicle that rolled out of Sant’Agata Bolognese,

Italy in 1974 and had iterations until 1990.

As the Italian builder of supersport cars transitions to an electric future, it is paying tribute to the Countach with the LPI 800-4, which has a hybridised 6.5-litre V12 with a system output of 802 horsepower.

And to make the four-wheel-drive car light for high performance, the engineers went carbon fibre intensive.

The LPI 800-4 features a carbon fibre monocoque with aluminium front and rear 40 OCT / NOV 2021

frames. All of the exterior body panels – hood, doors, quarter panels, etc – are carbon fibre, with the exception of the roof, which is a photochromatic material that changes from solid to transparent with a pushbutton.

The front splitter, wind surrounds, side mirror caps, engine cover air intakes, rocker panels and rear splitter are also carbon fibre. Even the brakes are carbon fibre ceramic discs with aluminum calipers.

www.ycom.it

YCOM composite all-electric race scooter Initial prototype to a production-ready design within less than four months YCOM (Stradella, Lombardy, Italy), a company that specialises in motorsports engineering and lightweight composite design, has completed the official delivery and testing of its high-performance composite S1-X eSkootr for the eSkootr Championship (eSC), a new racing series that highlights e-mobility and frontier innovation. Supplied to all eSC competitors, the S1-X Skootr is YCOM’s first full-electric vehicle and can reach speeds of up to 100 kilometres per hour.

With expertise in designing and manufacturing technology for motorsport – including Formula 1 and FIA World Endurance Championship winners – as well as experience in the launch of

multiple new race series, YCOM says it was well-positioned to develop, build and supply eSkootrs to the eSC. YCOM’s agile approach also enabled it to accelerate the S1-X’s development, taking the initial prototype to a productionready design within less than four months.

Not only that, but 10 race-ready eSkootrs have been delivered, YCOM notes, just five months after the partnership with eSC began.

In a collective test with 16 different riders, the S1-X was initially limited to 40% power, increasing to 70% by the end of testing. Even at this output, YCOM says, many riders were fatigued by the physical demands of such speeds and lean angles

of up to 55°. With improved physical conditioning and additional practice in October testing, it is hoped that the riders will be able to use 100% power as well as the additional 20% temporary boost function in the first race.

Formed in 2020, the eSC is the world’s first micromobility racing series. Following exhibition events in 2021, its opening season in 2022 will see fierce racing between 30 competitors on specially designed circuits from 400 to 800 metres long. Intended to raise awareness of e-mobility and promote the rapid advancement of sustainable transportation solutions, the eSC marks a new chapter in motorsport history.

TEIJIN Aramid has helped engineer a new protective motor racing suit that will be worn for the first time at the Berlin Formula E ‘E-Prix’. The ultra-light suit harnesses the superior protective qualities of Teijinconex neo for professional motor racing.

Based on Teijinconex neo fibres, the professional racing suit is the latest product to emerge from Teijin Aramid’s longstanding collaboration with OMP Racing, a market-leading producer of premium motorsport safety equipment.

The new suit has been custom-made for Envision Virgin Racing, one of 12 teams competing in the Formula E World Championship, the world’s premier electric racing competition.

The suit contains innovative features designed to maximize both the safety and comfort of drivers during competition.

The outer layer of the garment consists of an ultra-light fabric made with Teijinconex®, resists temperatures of up to 400°C and does not burn or melt when exposed to extreme heat. Because of these superior protective qualities, the suit contains just two layers, one less than most standard racing suits. This allows the wearer greater flexibility and a more tailored, comfortable fit. The suit is also

www.teijinaramid.com

up to 10% lighter than the previous racing wear worn by the Envision Virgin Racing Formula E Team, further enabling the movement and performance of drivers.

OCT / NOV 2021 41

Raising the bar for protective performance with ultra-light Formula E racing suit

v N o i n AtioN INNOVATION

First chemically recycled plastic milk bottle HDPE plastic waste converted into its original molecule and transformed into new high-quality polymers FRENCH company Lactel, the flagship brand of the Lactalis group, world leader in dairy products, and its partner, the chemical producer Ineos, have started producing UHT milk bottles made of recycled high-density polyethylene (rPEhd). A world first!

Lactel is the leading brand of drinking milk in France. For more than 50 years, the company has made many advances in its sector, particularly in terms of packaging. After launching the opaque plastic (HDPE) one-litre UHT bottle with a 100% recyclable resealable cap in the early 1990s, it became a forerunner in the organic market and in lactose-free products.

It is now experimenting, in collaboration with Ineos, with the industrialisation of the first bottles produced by chemical recycling. Thanks to this advanced recycling technology, used HDPE plastic waste is converted into its original molecule and then transformed into new high-quality polymers, suitable for contact with foodstuffs and therefore suitable for the production of new circular HDPE plastic bottles. These new recycled HDPE bottles are an alternative to traditional virgin HDPE bottles.

For the time being, 140 000 certified bottles will be produced at the Lactel plant in Montauban, France. www.ineos.com

Single-material pump for 100% recycling

Made use of principles of eco-design for a product that is easy to recycle

BY 2030, all plastic packaging in the EU must be recyclable or re-usable. This is a major challenge and a race to develop sustainable packaging has started among all relevant manufacturers.

The US-based Aptar company, a global leader in pharmaceutical and consumer goods packaging, appears to have taken the lead after unveiling a cosmetic pump for the beauty and personal care sectors made from a single material, polyethylene.

The innovative and sustainable pump, christened ‘Future’, is the result of two years of design, engineering and testing within the R&D teams at Aptar. To achieve this, they made use of the principles of eco-design to design a product that is easy to recycle, unlike traditional pumps whose delivery system is based on a complex technology composed of various materials, including metal, which are not suitable for recycling streams.

And it’s no coincidence that they chose PE 42 OCT / NOV 2021

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as their sole material: it is currently the most commonly-used plastic for bottles and flasks, and the most and best recycled. Thus, the pump and its companion bottle can be easily recycled with the other PET and PE bottles and flasks, without prior handling and sorting, or any risk of disruption.

Aptar has stated that, due to its composition, Future could also be made from post-consumer resin (PCR), PE waste from the oceans, as well as from chemicallyrecycled PE. Although eco-designed, Future is nevertheless a technologically-innovative and functional packaging, characterised by its advanced locking system and 360-degree rotating container. Partly intended for e-commerce, it was designed from the outset to be suited for and withstand sometimes difficult transport and distribution conditions. www.aptar.com

2021/10/05 11:39

Boat’s hull covered in rubber flipflops found on beaches FOR Flipflopi’s 2021 campaign, a new 10-metre 100% recycled boat has set sail on an expedition around Lake Victoria, the largest freshwater ecosystem in Africa, but also the most polluted in the world.

The Flipflopi’s hull is entirely covered with 30 000 used multicoloured flipflops collected from the plastic waste littering the beaches of Kenya’s east coast. The first expedition took place in 2018 with a very specific aim: to raise awareness of good waste management practices and promote recycling initiatives.

The new boat, which is made from 10 tons of plastic waste, made 21 stops in the three countries that border the lake – Kenya, Uganda and Tanzania – and travelled 995km.

The crew met with local people, schoolchildren, business leaders and local authorities to advocate for alternative and innovative solutions to reduce plastic waste and promote the circular economy in Africa through education programmes, innovation centres for plastic recycling and waste management. www.theflipflopi.com

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SUSTAINABILITY

5 golden rules for using

Brings the plastics industry a big step closer to a closed-loop economy THERE’S a steadily growing demand for more environmentally friendly products. Politicians are also calling for much higher quotas for the use of recycled material. So plastics processors are already facing fierce competition for sufficient quantities of high-quality recycled materials. It’s not just procurement that’s a challenge for manufacturers; processing the recycled material also calls for in-depth expertise.

For the application to be successful, plastics processors should observe the following five golden rules.

who specializes in the procurement of prime and recycled material. Plastics distributors like Meraxis have access to a worldwide logistics and distribution network. Unlike pure recyclate manufacturers, who can only supply what they currently produce, Meraxis has a close network of audited supplier partners for high-quality regranulates and recompounds.

“With us, customers are sure to receive recyclates in the quantities they need and at the best quality,” says Marc Stachura, Director of Product Management at Meraxis. “At the same time, we also offer primeware. So there is an optimal material for every application in our portfolio. In addition, we can quickly offer suitable alternatives in the though event of supply bottlenecks.”

Rule 1: Secure the best sources In the European Union, almost 23% of plastic packaging must be recyclable, according to Even the EU’s Circular Economy Action Plan. the use of recycled Rule 2: Pay attention to material By 2030, the quota will be raised to 55% material has to be properties – more than twice as high. Thus plastic When you’re processing secondary producers must now step up their game well thought out and you need to make sure that the and use more recyclates. requires comprehensive material, recyclates have a similar quality to the The problem: There’s often not enough process engineering prime material that was used previously. For high-quality recycled material available industrial mass production, it’s also important due to decentralized market structures. know-how, it’s that the quality remains the same. However, This causes shortages of raw materials and worth it because recyclates naturally differ from one price fluctuations. Processors should be very another depending on their origin, different batches familiar with the recyclate market so that they are homogenized. This means: They’re mixed so that can still find the right supply partner. In fact, they would large quantities of consistent quality are produced. have to carefully examine potential suppliers or even conduct “Precise testing and initial sampling are essential because extensive audits to ensure that the raw materials are actually recyclates from different origins are not comparable in terms of processed in the desired quality and quantity. This approach is their properties,” Stachura knows. especially costly for small and medium-sized enterprises. The This initial testing is a technical process for material research isn’t just time-consuming – it also requires technical characterization that precisely tests whether recyclates are knowledge about the production of recycled materials. suitable for the intended use.

That’s why it’s advisable to work with a distribution partner

COPCO achieves significant JUST 18 months after its launch, SA’s Compostable Plastics Council (COPCO), has achieved some significant milestones.

COPCO is in the process of appointing an independent auditing firm to verify compliance with international certification for compostable plastics. Companies that receive this endorsement will be

able to use the COPCO logo on their products. The Council is also lobbying with Government for an exemption on collection and recycling targets in terms of the proposed EPR legislation, to give the industry time to catch up with its plastic equivalents.

COPCO was formed in March 2020 with the mandate to provide representation to the compostable plastics industry in South Africa, to promote the recognition of compostable plastics and to grow the market for compostable plastics

in South Africa. COPCO is now is registered as a non-profit organisation.

“A few people have been working hard this year to promote the interests of the compostable plastics industry and to make the industry recognised as the new player on the block,” says COPCO’s chair, John Fox. To date COPCO has also achieved the following: • working with the Organics Recycling Association of South Africa (ORASA) to on establish standardised and integrated waste management

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recycled materials Rule 3: Develop the right formulation Every material development starts with the most detailed definition possible of the desired technical properties. The proportions of recyclates, primeware and other ingredients must be matched to each other in line with the application. This needs to be done because the requirements for the product differ depending on the application. Additives can be added as needed to improve the properties. Meraxis develops these kinds of formulations in its own materials research department.

“Our development team ensures that the materials match our customers’ exact requirements,” explains Elmar Schröter, Executive Director Recycling & New Business Development at Meraxis. “For example, we can even recreate colours with nuances.”

Rule 4: Select the appropriate production processes and machines.

It’s also important to match process technologies, tools and the right materials. The parameters on the machines – such as material throughputs, cycle times or processing temperatures – must be set individually for each material to prevent faulty production.

This is especially true when recycled materials are used: Processors should use the most homogeneous raw material mass possible in production, so that it stays constant throughout the production process. Ideally, this means that only one basic adjustment needs to be made to the machine.

To ensure an optimal product, Meraxis offers its customers comprehensive technical services as well as on-site support from its in-house application technology.

“Our technical experts help with selecting the most efficient production processes and tools, and finally with setting

individual parameters correctly to get the best possible result,” says Schröter. “If necessary, our technical team is on hand to offer advice if new machines and tools need to be purchased specifically for processing recycled materials.”

Rule 5: Demonstrate sustainability The interest in products that are as environmentally friendly as possible is enormous, especially among consumers.

“The use of recycled materials has long been an additional sales and marketing argument,” says Stachura. “That’s why it may be advisable to indicate on the end product that recyclates were used. Recognized certificates such as EuCertPlast are suitable for this purpose.”

EuCertPlast is an EU-wide certification program that focuses on the traceability of plastic materials throughout the recycling process and supply chain.

“Even though the use of recycled material has to be well thought out and requires comprehensive process engineering know-how, it’s worth it,” sums up Philipp Endres, Deputy CEO of Meraxis.

“After all, this brings the plastics industry a big step closer to a closed-loop economy. That’s why we’re consistently working on enhancing conventional materials with recycling innovations.”

milestones •

•

SUSTAINABILITY-.indd 45

•

has contributed to the drafting of the SANS standards for home compostable plastics.

COPCO is now inviting importers, manufacturers, traders and users of compostable plastics to become members, and inviting interested parties to support its work in establishing a PRO and section 18 EPR scheme for the compostable plastics industry.

• For more info, contact John at email john@enviromall.co.za,

We have been working hard this year to promote the interests of the compostable plastics industry and to make the industry recognised as the new player on the block Jaco du Plessis at Jaco du Plessisjaco@oryxpolymers.co.za, or Emma Algotsson at emma@kompost-It.co.za

OCT / NOV 2021 45

•

systems for compostable plastics.

COPCO represents the compostable plastics industry in the Biodegradable and Compostable Packaging working groups as part of the Alliance to End Plastic Pollution in the Environment and the South African Plastics Pact. has successfully lobbied for the OnPack Recycling Label (OPRL) logo for home compostable plastics. has presented at seminars organised

by PETCO, the Plastic Pact, DTI, DEFF, the Consumer Goods Council of South Africa and TIPS.

www.meraxis-group.com/en

2021/10/05 11:34

SUSTAINABILITY

AECI & Clariter join forces Collaboration to transform plastic waste into sustainable petrochemicals The process comprises three steps: AECI have invested €2,5 million in Clariter to reduce the 1. Thermal cracking to convert plastic waste into a wide negative global effects of plastic pollution by producing range of liquid hydrocarbons. sustainable high-value industrial products made from 2. Hydro-refining to remove impurities and to form 100% plastic waste. naphthenic and paraffinic hydrocarbons.

As part of the partnership, both companies will explore 3. Distillation and separation to distil fractions into stable the development and construction of Clariter’s full-scale products which can be blended into diverse product plants across parts of AECI’s existing geographic footprint, families. specifically South Africa, Germany and the USA. “We’re well-positioned for this partnership In addition, both companies will work given AECI’s extensive chemical application together for the Research & Development of Clariter uses expertise, industrial experience, market new specialty chemical applications and a continuous, access in key geographies and product blends of advanced high-value industrial proprietary and proven development capabilities,” says AECI products. This includes blending chemical upcycling chief executive, Mark Dytor. products to create new products with process that overcomes “Besides the opportunity to positively a “green” premium as well as AECI’s the challenges faced by impact South Africa as well as other off-take agreement and distribution of international markets, the partnership also Clariter’s oils, solvents and waxes. traditional mechanical fits well with the Group’s internationalisation Clariter uses a continuous, proprietary plastics recycling strategy and ambitions for growth in terms and proven chemical upcycling process of hard currency earnings. The opportunity that overcomes the challenges faced by also allows AECI to be an early mover in the waste traditional mechanical plastics recycling – plastics-to-products industry and position the company being highly sensitive to the types of plastics suitable as a formidable sustainable industrial player.” for their processes and limitations on the number of Clariter’s President and CEO, Ran Sharon, added: “Since times plastics can be mechanically recycled before their our upcycling technology uses plastic waste as a feedstock properties begin to degrade. for green petrochemicals, we address a key global issue.

Clariter’s process treats the majority of all types of plastic Processes and products that are green and more circular waste (including polyethylene, polypropylene and some have a meaningful role to play in the global trend towards polystyrene) in mixed quantities and converts plastics back to sustainability and ultimately a net-zero carbon future. We believe their constituent forms to deliver pure products that are dropthat AECI joining our strategy is a win-win for both companies.” in ready replacements for existing product manufacturers. www.clariter.com

www.aeciworld.com

World’s first bread packaging based on recycled post-consumer plastic ALLIED Bakeries, a major UK based supplier of bakery products, has introduced bread bags made by St Johns Packaging, using SABIC’s certified circular polyethylene (PE) in the packaging of their Kingsmill No Crusts 50/50.

Following the kick-off of the joint project in November 2020, the trial phase was completed in May 2021 at the St Johns Packaging production site in China and Kingsmill introduced the bags made from PE film with certified circular polymers content to UK stores in September 2021.

The bags are made using a PE resin grade from SABIC. The bags incorporate a 30% recycled feedstock from post-consumer waste. Using advanced recycling, the used and mixed plastic is converted into pyrolysis oil which is then used in the production of new polymers with the same purity and quality as traditional virgin plastics.

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www.sabic.com

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SUSTAINABILITY

Avery Dennison’s latest CleanFlake label materials Companies no longer have to choose between true recyclability and outstanding performance when it comes to labels WHAT began as a breakthrough solution for PET plastic bottles can now make PET packages in a range of markets more recyclable: Avery Dennison has launched the latest iteration of its award-winning CleanFlake™ filmic label materials, which are now suitable for PET packaging in food, home and personal care and other segments in addition to beverages.

“More than ever, CleanFlake helps brands keep the promise of PET,” said Avery Dennison product manager Mariya Nedelcheva. “Companies that use PET packaging no longer have to choose between true recyclability and outstanding performance when it comes to their labels.

We are closing the gap between CleanFlake materials and conventional, general purpose label materials. For companies that care about recyclability, the question now is not why they would use CleanFlake, but why they wouldn’t.”

First introduced in 2013, CleanFlake technology solves a critical problem in PET plastic recycling by helping to ensure

that a label’s adhesive stays with the label and not on the package, so that all label material fully detaches during the recycling process. The resulting washed PET flakes can then be recycled into new PET packaging. Flakes that are otherwise contaminated by conventional label materials must be downcycled or sent to landfills or incinerators.

With a new proprietary adhesive, SR3011N, CleanFlake materials look and perform like any other self-adhesive label material. An upgrade to a best-in-class topcoat provides outstanding printability, and CleanFlake materials are designed to deliver fast, flawless application on high-speed labeling machines. CleanFlake facestocks offer the same attractive, ‘no-label’ look as comparable Avery Dennison materials. www.label.averydennison.com/cleanflake

First chemically recycled PP coffee cups

48 OCT / NOV 2021

Chemically recycled PP used is manufactured with Borealis Borcycle™ C portfolio of transformational chemical recycling solutions SWISS dairy company Emmi is partnering with Borealis and Greiner Packaging to produce Emmi Caffè Latte drinking cups using chemically recycled polypropylene.

Emmi Caffè Latte, one of the leading ready to drink iced coffee brands in Europe, has started to incorporate chemically recycled polypropylene into its packaging.

The cups are produced by Greiner Packaging and the chemically recycled material comes from Borealis, based in Vienna, Austria.

Emmi has the stated goal to make all of its packaging 100% recyclable and is committed to various measures to promote circularity such as

packaging that contains at least 30% recyclate by 2027.

From September 2021, Emmi Caffè Latte, will use at least 100 tons of plastic based on the recycled material each year. Chemical recycling renews plastic back to plastic creating recycled materials with a level of purity equivalent to fossil-fuel based PP and hence, fit for protective, food-safe and other demanding applications.

The new technology to recover the polypropylene is currently still in its infancy, where Greiner Packaging and Borealis are leading the way.

Only limited quantities of chemically recycled polypropylene are currently available, and Emmi is one of only www.borealisgroup.com

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a few food manufacturers to have secured a share of the chemically recycled polypropylene plastic through its early commitment and long-standing collaboration with the development companies.

The chemically recycled polypropylene used in this new Emmi Caffè Latte cup is manufactured with Borealis Borcycle™ C portfolio of transformational chemical recycling solutions, giving polyolefin-based, post-consumer waste another life.

www.group.emmi.com

www.greiner-gpi.com

2021/10/05 11:35

The new IrgaCycle™ solutions address specific quality issues associated with recycled resins to improve processability, long-term thermal stability and outdoor weathering protection

BASF’s new

additive solutions for mechanical recycling of plastics Novel plastic additive combinations for recyclers, compounders, converters BASF has launched IrgaCycle™, a new range of additive solutions to address the imminent needs in plastics recycling.

The plastics industry is seeking ways to incorporate higher content of recycled polymeric material in all major applications to meet sustainability goals, while facing growing consumer concerns and stricter regulatory requirements to reduce plastic waste.

A major challenge is to mitigate quality deficiencies of polymers arising from thermal and mechanical stress during the recycling process. ‟The production of plastics from mechanical recycling is expected

to almost triple by 2030, driven by improved technologies and regulation.

This corresponds to a growth of around 10% per year,” says Dr. Thomas Kloster, President of BASF’s Performance Chemicals division. ‟With IrgaCycle we are expanding our existing portfolio step by step by specific solutions for recycling to support the circular economy goals for plastics.”

The new IrgaCycle range includes additive solutions that can help increase the percentage of recycled content in several end-use applications such as packaging, automotive & mobility, and building and construction.

These solutions address specific quality issues associated with recycled resins, such as limited processability, poor long-term thermal stability and insufficient protection from outdoor weathering. At launch, the product line includes a range of different additive formulations, with more to follow in the future.

A specific advantage of these blends lies in their ready-to-use product forms, which are easy to apply in the recycling steps. The granulated nondusting product form ensures safe and easy dosage during converting or compounding of reclaimed material. www.plasticadditives.basf.com

INEOS Styrolution introduces first post-consumer recycled specialty ABS solutions New solutions target applications in the automotive and household industries

OCT / NOV 2021 49

INEOS Styrolution, the global leader in styrenics, has introduced the first Novodur® ECO specialty ABS and Novodur® ECO High Heat grades being the result of mechanically recycled post-consumer waste.

The new Novodur ECO solutions will contain up to 70% recycled material, while the new Novodur ECO HH solutions will contain up to 40% recycled material. The new materials offer identical mechanical properties as their virgin equivalents making them drop-in solutions for application developers.

The new Novodur ECO HH solutions offer a balanced property profile, making them sustainable options for automotive applications including centre consoles, radiator grills or mirror housings. These novel Novodur grades will be available in standard colours e.g. pure white, cream or traffic blue as well as customer specific colours. An option for selfcolouring will also be offered. www.ineos-styrolution.com

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RE-INVENTING

A strategy for

innovation

Five lessons that will become the defining principles of our future story

BY KIRTIDA BHANA

SUCCESSFUL economies are not jungles – they’re gardens, says Nick Hanauer. They need to be tended and looked after and not left to grow wild. According to John Sanei and Iraj Abedian as written in their book Future Next, building a more sustainable, prosperous society fit for our era, driven by our collective consciousness, and engineered by our combined inputs, wisdom and aspirations starts with five lessons that will become the defining principles of our future story.

1. Collaboration: We are increasingly aware of the fact that ‘no man is an island’ and that coordinating our efforts to solve systemic and existential problems that have been created by pervasive social norms and biased regulations is no longer a choice but a necessity.

Lesson: Collaboration inspires self-analysis and challenges people to think and articulate with clarity.

2. Inclusion: Inclusivity is not a luxury once the elite have had their fill, but essential for economic growth.

No country can flourish if economic citizenship is not held by the majority. We all suffer the consequences of an unequal society whether rich or poor as moral fibre devolves to a frail single thread and human values deteriorate.

Lesson: Inclusion inspires creativity and unleashes loyalty.

3. Serve society, not shareholders: Authentic leadership is easily recognisable by those who use the more intelligent criteria rather than the ‘faulty’ yard stick that is in dire need of re-calibration. Leadership is not about whom you rub shoulders with or how popular you are but rather about designing a public value proposition that is both actionable and value creating. The following elements of the scorecard are to be considered: • Clientele perspective – quality of the services delivered • Internal process perspective – employee satisfaction • Learning and growth perspective – empowerment initiatives

•

Financial perspective – accountable leadership; good governance and financial health Lesson: The ultimate task of a visionary leader is to honour and dignify the lives of the people he/she leads by allowing them to manifest their highest potential through the work that they do

4. Goodbye Greed: “Being rapacious does not make you a capitalist, it makes you a sociopath,” says Nick Hanauer.

In his book Big Pharma: Dirty lies, busy bees and Eco Activists, David Bristow has a short story titled “Food for Thought – Sugar and Spice and all things nice, Fatty and Salty and Many Things Nasty”. He also aptly has a warning at the beginning of the chapter which reads: “Warning: This chapter contains colourants, additives, starches, extracts, enzymes, added sugar and salt and might be contaminated with nuts and other ingredients that could be harmful to your health.”

Lesson: By acting in the interest of others, we give purpose and meaning to our lives, satisfying a deep need for fulfilment that goes well beyond material things, ultimately, we are acting in our own interest.

5. Choose a new system: If we truly want a more equitable, prosperous, sustainable economy we must have a new economics. The questions we need to be asking are: How do we make the shift towards a new world? What can we do to leave the world a better place then we found it? Where should we start to create a new world order? The answer to when should we start is of course, RIGHT NOW. Lesson: The Covid pandemic has taught us to learn fast, adopt with speed and become used to doing things differently. Let’s use this momentum to transform for the better.

•

To devise a strategy for Innovation in your organisation contact Kirtida Bhana on Kirtida.bhana@plasticssa.co.za

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WORLD NEWS

Highlighting innovation in colour SABIC debuts latest LNP VisualFX portfolio

SABIC has launched its latest LNP™ VISUALFX™ resin portfolio featuring unique colours and special effects from the company’s new Expression 2021/2022 colour palette, developed through research on emerging aesthetic trends.

Designers and engineers in the colour, material and finish (CMF) field can find inspiration within this portfolio from the consumer preferences revealed through this research, for new 5G-enabled mobile devices and Internet of Things (IoT) applications. In addition to the new LNP VISUALFX materials, SABIC’s complete colour offering includes global ColourXpress™ custom colour and colour matching services.

Major trends including urbanisation and sustainability, together with current consumer sentiments such as nostalgia

and an innate desire to be in nature, significantly influenced the development of SABIC’s new Expression palette for LNP VISUALFX resins.

SABIC’s LNP VISUALFX resins are formulated with the rich colour and effect inherent in the pellet, enabling customers to create colourful and distinctive parts while avoiding the environmental impact, time and costs of secondary painting.

Communicating the themes from the company’s Expression 2021/2022 programme, the new LNP VISUALFX portfolio captures the look and feel of today’s hottest design trends, from retro to futuristic, and from edgy to gentle. www.sabic.com

52 OCT / NOV 2021

Engel back on growth course AUSTRIAN machinery maker Engel Austria GmbH has ‘skyrocketed’ out of a downturn caused by problems in the automotive sector and the Engel CEO, Covid-19 pandemic, Dr Stefan Engleder and is operating at full capacity, with its order books “as full as they last were in 2018”.

Shortly before the start of its recent live e-symposium 2021, Engel officials gave an optimistic outlook for the current fiscal year. “Our order books are as full as they last were in 2018,” said Engel CEO, Dr Stefan Engleder.

But at the same time, he cautioned,

new challenges await the injection moulding machine manufacturer and system solution provider, above all, the current supply bottlenecks in raw materials and components.

The company’s 2020/2021 fiscal year came to what it calls “a conciliatory end”, generating €1.1 billion in sales revenues.

Although sales revenues again fell compared to the previous year with a minus of 15%, Engel is expecting growth again for the current fiscal year.

“If the upward trend consolidates, growth in the order of up to 20% is realistic,” said CSO Dr Christoph Steger.

The regional distribution of sales at the end of the 2020/2021 fiscal year reflects the impact of the crisis, Engel said.

Europe contributed 45% of group sales revenues, well below the previous year’s www.engelglobal.com

share of 54%.

The Americas accounted for 30% – compared to 25% the year before – and Asia for 23%, compared to 20% the year before.

There were also shifts in the distribution of sales by business line, with Engel’s technical moulding division – which includes the domestic products, sports, games, and leisure segments – seeing significant growth. There was also further growth in the medical business.

On the down side, Engel said, Covid-19 lockdowns in individual countries and travel restrictions with quarantine rules are still making daily business difficult. Although Engel can still ensure global delivery capability, the cost gap is continuing to widen.

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WORLD NEWS

Covestro to cut up to 10% of jobs worldwide

GERMAN chemicals maker Covestro plans to cut up to 1 700 of its 16 500 jobs worldwide, the Rheinische Post newspaper reported.

In Germany, the maker of foam chemicals and hard plastics could cut up to 950 jobs out of 7 600, the paper said in its report, citing trade union circles.

Covestro confirmed the figures as a first preliminary estimate. A further update would come in the coming months, the company’s spokeswoman told Reuters on Wednesday, saying the move was part of the company’s restructuring plan implemented on July 1.

“We are now looking into all our activities and processes and see if they fit with the strategy and how they contribute to it.

This also means personnel adjustments,” the spokeswoman said.

She said the adjustments, which Covestro would make in cooperation with employee representatives, would take place until the end of 2023.

54 OCT / NOV 2021

Successful start for motan-colortronic in Mexico

MOTAN-COLORTRONIC employees have been busy serving the Mexican market since 1 May this year. motan holding gmbh recently founded a new subsidiary in Santiago de Querétaro, Mexico. The motan group’s decision to reinforce its activities in the area was based on the positive order situation, combined with a loyal customer base and projects in the pipeline.

The team currently consists of five people: two area sales managers, one admin assistant, one applications and service manager and a service technician.

The location will allow motan-colortronic to provide flexible services and offer swifter, targeted responses to customer requirements from all over Mexico. motan-colortronic will offer a comprehensive range of services in Mexico and will also be able to provide customer training as required. otan is represented by Greentech •M Machinery in SA www.motan-colortronic.com www.greentechmachinery.co.za

Sales training at the new motan-colortronic offices in Querétaro

Berry sets its sights on e-health innovations

www.berryglobal.com

THE latest pharmaceutical packaging and devices are supporting the growing trend towards eHealth, according to leading global supplier Berry Healthcare.

Berry Healthcare says that eHealth can encourage the shift towards personalised and precision medicine, which allows targeted, individualised care to be tailored to individual patients, based on their specific genetic profile and medical history. eHealth is also an important part of the move towards telemedicine and remote diagnostics, a trend that has been accelerated by the Covid-19 crisis. According to the US Centre for Disease control, doctors meeting patients via videoconferencing and real-time chat technologies increased by 154% in the early stages of the pandemic.

As well as greatly improving the patient experience and quality of life, eHealth can also bring major cost benefits through helping to reduce the amount of medicine wasted unnecessarily. For example, a recent study on patient medication adherence found that adherence to asthma and COP treatments was as low as 32%, meaning two out of three people were incorrectly taking their medicine.

Berry Healthcare has recently launched its RS01X™ single dose Dry Powder Inhaler (DPI) with built-in sensors and digital capabilities that tracks inhaler use and connects to the companion Respiro™ app from Amiko Digital Health, which provides personalised guidance to improve adherence and inhaler technique.

The app acts as companion to the inhaler, reminding patients when it is time inhale a dose and providing personalised insights and tips to help them selfmanage more effectively. In previous clinical studies, the Respiro platform delivered improvements in controller medication adherence by up to 37% and in optimal inhaler technique by up to 42%.

EcoBlue tackling plastic waste problem in Thailand EcoBlue Ltd., Thailand’s first bottle-to-bottle recycler, has invested US$25 million to set up a new recycling facility for PET and polyolefins. A new Starlinger PET bottle-to-bottle recycling line is going to be part of the expansion.

“Our aim is to turn post-consumer and post-industrial waste materials into a sustainable substitute of virgin resin”, explains Pranay Jain, founder and MD of EcoBlue Ltd. “In anticipation of the increased commitment of organisations towards sustainability, EcoBlue has invested in setting up a new world-class recycling facility with the very best technologies for PET and polyolefins recycling.

By having Starlinger as a technology partner, we will ensure that we are able to provide consistent and high-quality bottle-grade rPET to our customers.”

Starlinger’s recoSTAR PET 215 iV+ bottle-to-bottle recycling system will be delivered to EcoBlue’s production site in Rayong Province, Thailand, in July 2021 and within the following weeks be assembled by the local Starlinger technician with remote support from Starlinger’s headquarters in Austria. The line reaches an output of 2,500 kg per hour, equalling a total production capacity of about 20,000 tons of bottle-grade rPET per year.

A unique feature of the Starlinger PET recycling line is its special extruder size: with the 215mm screw the line reaches an output of 2 500kg per hour.

www.starlinger.com

Same result.

With recyclate.

Recycled material is naturally subject to greater batch fluctuations than virgin material. Our intelligent assistance systems and technologies ensure a constant melt volume and thus consistently high product quality despite fluctuating raw material quality.

Learn more about the Topic Circular Economy. www.greentechmachinery.co.za

WORLD NEWS

Car interior parts with seamless, intelligent surfaces Cooperation between Covestro, Votteler, Reichle and Merck HOW can intelligent surfaces provide more design freedom and functionality in car interiors and still be produced cost-effectively? Covestro investigated this important question together with a team of three industry partners: Votteler Lackfabrik GmbH & Co. KG, laser texture specialist Reichle Technology Center and Merck KGaA as a manufacturer of pearl effect pigments.

The result is an effective concept for the production of interior parts with seamless, intelligent surfaces using Covestro’s DirectCoating technology.

The coated component is produced in two steps using a polyurethane reaction injection moulding (PU-RIM) process.

Car manufacturers and their suppliers face the challenge of integrating smart functions such as display and ambient lighting and touch control, in addition to a wide range of visual and haptic surface properties. Above all, the aim is to manufacture durable products as cost-effectively as possible to achieve broad acceptance in the industry. The goal is an environment can be created in the car that combines comfort and

infotainment with a feeling of safety.

PURIFLOW® paint systems from Votteler Lackfabrik GmbH & Co. KG enable outstanding surface properties such as good scratch resistance and a self-healing effect, but also a feel that ranges from soft leather to hard metal.

These benefits, and the ability to create completely seamless surfaces, are thanks in part to polyurethane coating raw materials from Covestro.

Votteler drew on the manufacturing expertise of Reichle Technologiezentrum GmbH, which

Lanxess launches hollow-profile hybrid technology

56 OCT / NOV 2021

LANXESS is in the process of launching its hollow-profile hybrid technology on the market. With this new lightweight design technology, metallic hollow profiles can be functionalised on conventional injection moulding machines with plastic compounds.

The result is plastic-metal composite components that boast far greater torsional stiffness and strength than could previously be achieved with other technologies for functionalizing hollow profiles.

“Hollow-profile hybrid technology has now progressed to such an advanced level that we have embarked on a variety of development projects with customers and have already reached the prototype stage with some of them,” says Dr. Matthias Theunissen, an expert in lightweight design at Lanxess.

The potential applications in the automotive industry include cross car beams, coupling rods, stabilisers and seat elements. In addition, the new lightweight www.lightweight.lanxess.com

technology could be used to produce skiing and hiking poles and components for furniture and the construction industry, for example.

The general strength of the new technology is that processors can manufacture with short cycle times, as is typical for injection moulding in high-volume production. As a result, the manufacturing process is efficient and economical. There is no need for auxiliary units or tooling technology, which keeps investment costs low.

The fact that reasonably priced hollow profiles with relatively large dimensional variations can be used helps to make the process cost-effective, too.

With its simulation tools, Lanxess is able to accurately predict the maximum stresses hollowprofile hybrids – such as automotive cross car beams (left-hand screen) – will withstand and at what point they will fail.

Canada adds plastic products to list of ‘toxic’ substances

With the help of Covestro’s DirectCoating technology, automotive interior parts with seamless, smart surfaces can be produced quickly and effectively.

operates Europe’s largest laser texturing site. The company provided laser-textured PU-RIM moulds for the project. Covestro supplied process technology know-how, coating raw materials from the Desmodur and Desmophen ranges without solvent additives, and Makrolon and Bayblend polycarbonate plastics, which proved to be a key to the project’s success.

Effect pigments from Merck KGaA can be used to achieve various colour and transparency effects.

In the DirectCoating process, the

plastic substrate is first produced in an initial cavity by injection moulding.

The resulting part is then transferred to a second, minimally larger mould.

The cavity between the substrate and the laser-engraved RIM mould corresponds exactly to the desired volume of the coating that is injected there. This creates a coated precision part in just two steps. It requires little rework and is highly resistant to chemicals and daylight. www.covestro.com

SABIC launches polyol for cast polyurethanes, SABIC has introduced Noryl™ AP2001G polyol for cast polyurethane (PU) applications. By partially replacing polypropylene glycol (PPG) or polytetramethylene ether glycol (PTMG), this oligomer of polyphenylene ether (PPE) improves the performance of cast PU systems by increasing both hardness and elasticity – properties that have been difficult to improve simultaneously until now.

In addition, Noryl AP2001G polyol provides resistance to oils, moisture, abrasion, tearing and heat, helping cast PU parts withstand extreme conditions and potentially lengthen their useful life. Potential applications include mining drill bits, screens and protective pipe liners for slurry transport; components for hydraulic, robotic and conveying equipment; and wheels, casters and rollers.

The cast PU system is one of the most popular thermoset processes and the market is showing strong growth. According to Emergen Research, the increasing use of cast elastomers in the mining industry is the key driver of a CAGR estimated at 4.3% from 2019-2027. Other industries that use cast PUs are agriculture, oil & gas, material handling, and sports and recreation.

www.sabic.com

Clariant divests its pigments business

CLARIANT has reached definitive agreements for the divestment of its pigments business to a consortium of Heubach Group and SK Capital Partners. The combined business will be a global pigments player with approximately 3 000 employees generating more than €900 million in annual sales and strong service and production capabilities across the globe.

The transaction is subject to customary closing conditions and regulatory approvals and is expected to close in the first half of 2022.

OCT / NOV 2021 57

SABIC has introduced Noryl AP2001G polyol for cast PU applications, such as coated pipes for mining and coated industrial rollers used in conveyors or printing processes.

HE Canadian government has officially added ‘plastic manufactured items’ to its list of toxic substances on Schedule 1 of the Canadian Environmental Protection Act (CEPA).

While drawing praise from some environmental groups, industry associations, including the Ottawa-based Chemistry Industry Association of Canada (CIAC), expressed disappointment with the announcement.

“We remain concerned that today’s decision sends the wrong message to global chemistry investors, namely that Canada is ambivalent about the enormous investment prospects for the circular economy for plastics,” CIAC said.

“We’re disappointed that safe inert plastic materials that play such important roles in Canadians lives are being labelled as toxic substances.”

In the US, the American Chemistry Council (ACC) said in a statement that a CEPA listing is misleading and counterproductive.

“Banning efficient plastic products will likely lead to forced substitutions with alternatives that increase greenhouse gas emissions and prevent the transition to a low-carbon future.”

And the Washington, DC-based Plastics Industry Association weighed in with its own criticism. “Our two countries are powerful plastics economies,” said president and CEO Tony Radoszewski. “This development is a symbolic gesture to activists and threatens tens of billions of dollars of commerce. The idea that plastic is toxic is the true danger. Such a label could have ramifications far beyond some single-use items. It could fast-track more bans on other consumer products that are fully recyclable. Our main concern should be improving recycling.”

PIPE MATTERS

Bar has been raised for locally produced swept bends

BY MIKE SMART, PR. ENG., B.SC. (HONS) CIV. ENG., MSAICE

IN South Africa, the production of HDPE swept bends often individual experience, or information gleaned from another producer. The process is somewhat arbitrary and intended for use in the mining industry, is a ‘cottage the reproducibility and thereby quality consequently also. industry’ in which each manufacturer develops their own All these factors notwithstanding, many South African process parameters on a trial and error basis that they manufacturers, usually SAPPMA members, produce jealously guard as their intellectual property that gives acceptable “fit for purpose” SWEPT BENDS – while them their strategic advantage. others do not.

The custodians of these process parameters are often the operators, supervisors and production managers New era has dawned directly involved in the manufacturing process. Therefore, However, a new era has dawned in the local production the consistency of this data both in location and value is not of swept bends that is poised to revolutionise this good, which does not assist repeatability of the process most important, but oft neglected, component in and thereby consistency of product quality. numerous pipelines throughout South African The applicable South African National mining and industry. Pipestar Africa, formally “There is Standard SANS 4427-3 Part 3: Linesco Pipeline Engineering Supplies, Fittings, Clause B.4 swept bends, is a nothing wrong has concluded a license agreement with performance specification that specifies in change if it is in Pipestar International Inc, Winnipeg, what the finished product shall conform Manitoba, Canada, to manufacture the right direction. To too dimensionally, mechanically and Arc Bends™ and Super Arc Bends™ improve is to change, in configuration. Furthermore, the 3D swept bends in SDR 11 and 17 so to be perfect is conformance to these requirements configurations up to 630mm OD locally to have changed justifies the omission of a derating at their plant in Kliprivier, Gauteng. In, factor to the pressure rating of the fitting. o en.” and of, itself there is nothing remarkable or However, all of the processes by which interesting in this development except when the swept bend is produced together with the considering the following. magnitude of all the parameters are omitted from the Pipestar International Inc has devoted the past 20 years standard – therein lies the rub. to perfecting their manufacturing process that not only The first essential requirement to produce a conforming eliminates the problems inherent in the current processes swept bend is that the pipe from which it is produced that include, inter alia, dimensional stability, configuration must be conforming. Furthermore, because of the stability, accuracy and waste, but also produces a product manufacturing process it is expedient to arrange with the that conforms completely to the requirements of SANS pipe supplier to manufacturer the pipe on the maximum 4427-3 Part 3: Fittings believed to be unique. conforming wall thickness because the material on the The bar has been raised for locally produced swept outside of the swept bend is redistributed over a longer bends, which may inspire other producers to aspire to a length relative to that on the inside, and will inevitably new level of conformance in order to secure business from tend to be thinner. Documented proof, COC or COA, of the discerning specifier and customer. The less discerning the pipe’s conformance is an essential prerequisite that is and knowledgeable will continue to accept nonconforming often neglected. products as the ‘only products available’.

The myriad parameters, including inter alia, heating Incidentally, Pipestar Africa has also commenced temperature, heating time, bending rate, cooling time and manufacturing stubs up to 315mm OD, from 100% PE100 strapping configuration that is expressly forbidden by the material conforming to SANS 4427-1 Part 1, that are applicable American Standard are all determined by the reputed to be completely vacuole free throughout their structure – machine one out and see if it is true. individual producer. The basis of this determination is 58

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OCT / NOV 2021

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www.inkuluplastics.co.za Inkulu Advert- 02'21.indd 78

sales@inkuluplastics.co.za 2021/02/12 09:08

MIDDLE EAST

Increased competition for natural gas A necessary step on the transition away from fossil fuels

BY NIALL MARSHALL

THE headlines of British newspapers have been dominated by reports of long queues at petrol stations, and empty shelves in supermarkets caused, not by shortages of fuel or toilet paper, but by a shortage of heavy-duty truck drivers.

Also in the news, although not getting the same headlines, is a shortage of carbon dioxide.

CO2 is used in food packaging (to replace air and slow down the deterioration of fresh fruits, vegetables, and meat); it is important in medicine (where it is used during invasive surgery) and it’s used to carbonate water and soft drinks. In the UK it is also used in their advanced gascooled nuclear reactors. And possibly most worrying for the British government, it is used as a propellant for draft beer – shortages of petrol is one thing but imagine if pubs are forced to close!

The carbon dioxide shortage has been caused by the temporary shutdown of two large fertilizer plants (which produce 60% of the commercial CO2 in the UK) due to the high cost of their raw material.

If empty shelves and carbon dioxide shortages in the UK seem unrelated to the Middle East petrochemicals industry, there is an unexpected connection – gas.

Petrochemical and polymer plants competing for gas as a feedstock Natural gas (liquified natural gas or liquified petroleum gas) is becoming an important source of energy, particularly as a lower-carbon alternative to other fossil fuels like coal or diesel. The main source of this gas has historically been from the North Sea, but over the last few years a combination of lower yields from the British North Sea platforms and increased demand has meant that 50% of the UK’s gas is now imported – mainly from Norway but also from the USA and Qatar.

Increasingly over the last few years, liquified gas has been shipped globally on specially designed tankers. And so, when demand increases in one part of the world it

impacts on global prices, and this is what is happening. In the UK the wholesale price of gas has increased by 250% since January and a massive 70% since August.

There are several reasons for the high gas prices: high and growing demand, a lack of storage capacity in various regions and low oil prices mean that inventories haven’t been built up through the summer.

In China there is another reason for the increased demand for LNG and LPG. As part of its climate goals the Chinese government has implemented a “dual control policy” which focusses on reducing CO2 emissions and air pollution from coal power stations and on reducing energy intensity (in other words, moving away from high energy low value industries).

Electricity prices have been increased, partly to encourage the reduction in energy intensity but also due to high thermal coal prices and a decrease in wind and hydroelectric power generation in parts of the country. This has now come to a head as increased demand has meant that manufacturers and electricity producers have already used up this year’s emission quotas due to higher than expected demand as the global economy rebounds from the coronavirus.

Provincial governments are now imposing rationing and in many regions, factories are only able to run for two or three days a week. This is causing further delays in already congested supply chains, resulting in massive price increases. In the short-term electricity rationing in China will reduce demand for polymer from the Middle East. Globally, any slowing of the Chinese economy will have a knock-on effect on other economies. It will also increase competition for natural gas which is a necessary step on the transition away from fossil fuels and reduced emissions.

Competing for the gas as a feedstock (rather than a fuel) are petrochemical and polymer plants as well as British beer drinkers. In this hyper-connected world everything somehow influences everything else, and pubs in London will be competing with factories in Guangdong and polymer plants in the Middle East for LNG and LPG produced in Qatar.

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diary

Keyplast RESIST high voltage car charger

Millad NX 8000 ECO sustainable clarifying agent for polypropylene

FAKUMA 2021

KeyPlast colorants for PET are used to create distinctive shades in both transparent and opaque applications

Milliken colorant, additive and sustainability solutions MILLIKEN & Company showcased its portfolio of clarifiers colorants, additives and modifiers.

Milliken’s Millad NX 8000 ECO clarifier is the latest addition to its market-leading Millad NX 8000 product range, which is used to produce the durable, fully transparent, highly recyclable material known as NX UltraClear™ PP. Millad NX 8000 ECO offers the added benefit of even faster production rates, contributing to average energy savings of 10% for the production of clarified polypropylene parts.

The KeyPlast colorants for plastics are versatile products that can be used by liquid and solid masterbatch producers, resin producers and compounders, and are suitable for use with a wide range of polymer and resins systems. The

Africa Strategy Execution Conference

FDA-compliant KeyPlast colorant range for PET can be used to create distinctive shades in both transparent and opaque applications. Ideal for food-contact applications, this specially developed range is well suited for beverage bottles, pharmacopeia containers, and for products that require differentiated design.

Additionally, Milliken has fine-tuned its KeyPlast RESIST colorants to perform well in extreme temperatures in various engineering polymers, including polyamides, polysulfones, PEEK and other high-heat polymers and alloys.

Several grades in Milliken’s energysaving Hyperform HPN range of performance additives for PP will also be on display at Fakuma. These additives are easy to use and reliable while also

THE most insightful conference for African business leaders, The Africa Strategy Execution Conference, takes place on 21- 22 October as a virtual event.

Three of the world’s most influential keynote speakers will share their knowledge and tools on innovation and strategy execution: Renée Mauborgne, Alex Osterwalder and Robert Kaplan. The most successful CEOs on the continent will give you their insights on how to drive innovation and strategic results in time of uncertainty and disruption: Standard Bank, Discovery, Dimension Data, Nestlé, TymeBank, etc. www./africastrategy.co.za/register/

62 OCT / NOV 2021

improving the performance of recycled polypropylene (rPP). They enable thermoformers and injection moulders to produce stronger, lighter parts. In addition to increasing stiffness significantly when compared to conventionally nucleated resin, they also aid processing productivity and offer balanced, tuneable properties.

Milliken’s DeltaMax Performance Modifiers for polypropylene help contribute to a circular economy by enhancing the impact strength and meltflow properties of rPP resins, blends and PP impact copolymers. DeltaMax can raise melt flow by as much as five times while maintaining impact and stiffness properties. www.milliken.com

3rd Libya Food Expo

THE third Libya Food Expo will be held from 25-28 October.

The exhibition is organized with the partnership of the Libyan General Union of Chambers of Commerce (GUCC); Industry and Agriculture. Libya is heavily dependent on foreign markets to import goods to rebuild the food, packaging, processing and agriculture markets. Libya’s large market size and annual growth rate make Libya more attractive for foreign and national investors.

5th Morocco SIEMA & Food Expo

MOROCCO is one of the most important trade hubs of Africa.

Morocco is strongly dependent on foreign food markets such as grain, sugar, coffee, tea, spice, packaging and many other products. This expo takes place from 7-9 December.

FAKUMA 2021

Engel thin-wall injection compression moulding for stack mould technology high component quality in many applications can only be achieved by means of injection compression moulding. Other advantages of injection compression moulding technology include the lower clamping forces and injection pressures required in comparison with conventional compact injection moulding, plus the fact that even high-viscosity materials can be processed in a repeatable manner.

Despite this, injection compression moulding tends to be seen as ruling out the use of a stack mould; this is because for many injection moulding machines, the speed of the platen movements is insufficient for a stack mould.

For the Engel e-speed injection moulding machine – designed to handle the long-term, highperformance output required by the packaging industry – things are different. The electrically driven clamping unit and the toggle lever design facilitate very fast, short compression strokes – 4mm in the case of the margarine tubs.

The parallel movements can be controlled very exactly – the prerequisite for coordinating the compression stroke and injection profile to the necessary degree of precision. www.engelglobal.com

Africa Strategy Execution Conference 21-22 October: Virtual event info@siyenza.za.com Middle East Foam & Polyurethane Expo 26-28 October: Dubai, United Arab Emirates www.mefpu.com ArabPlast 2021: 15-18 November Dubai, United Arab Emirates www.arabplast.info IATF Automotive Show: 15-21 November Durban ICC, Durban www.intrafricantradefair.com UTECH Europe: 16-18 November MECC in Maastricht, the Netherlands www.utecheurope.eu

EVENTS

ENGEL’s stand at Fakuma 2021 from 12-16 October in Friedrichshafen, Germany, will put the spotlight on sustainability.

The production of decorated monomaterial food packaging and the processing of regrind from labelling waste is supporting circular economy by creating a process chain. At the same time, the company is celebrating the world première of the 4 200 kN version of the Engel e-speed injection moulding machine. The sophisticated packaging application combines extreme thin-wall injection compression moulding with stack mould technology.

At Fakuma, an e-speed 420/90 injection moulding machine with integrated in-mould labelling (IML) will be used to produce ready-to-use margarine tubs from PP in a fully automated injection compression process.

The containers, which have a wall thickness of 0.4 mm (including the label), will be removed from the 4+4-cavity stack mould via highspeed, side-entry automation and stacked on a discharge conveyor following camera-based quality control.

The continuing trend for reducing wall thickness is leading to ever more extreme flow path/wall thickness ratios that are often in the range of 1:400. From a ratio of 1:300 and above, consistently

AMI’s Plastics Recycling Technology 20-21 October Vienna, Austria: www.ami.international/events

Manufacturing Indaba: 22-26 November Virtual event: www.manufacturingindaba.co.za Putech Eurasia: 25-27 November Istanbul Expo Centre, Turkey www.putecheurasia.com WireShow 2021: 25-27 November Shanghai, China: www.wireshow.com Int’l Morocco Food & Siema Expo 7-9 December: Casablanca, Morocco www.siemamaroc.com

2022 interplastica 2022: 25-28 January Moscow, Russia: www.interplastica.de KZN Industrial Technology Exhibition 16-18 February: Durban Exhibition Centre, Durban www.kznindustrial.co.za 3rd Libya Food Expo 22-24 February: Tripoli, Libya www.icffair.com Injection Molding & Design Expo 16-17 March: Detroit, Michigan, USA www.ami.ltd/Injection-Molding-Expo Chinaplas 2022: 25-28 April Shanghai, China: www.chinaplasonline.com Saudi Plastics & Petrochemical Exhib 6-9 June: Riyadh, Kingdom of Saudi Arabia www.saudi-pppp.com

K 2022 19-26 October Düsseldorf, Germany www.messe-duesseldorf.de

OCT / NOV 2021 63

Trenchless Asia 2022: 27-28 July Kuala Lumpur, Malaysia www.trenchlessasia.com

diary

BASF opens up possibilities with sustainable plastics solutions Innovations keep pace with trends, contribute to net zero emissions TOGETHER with customers and partners, BASF has set itself the goal to contribute to a circular economy in which raw materials are conserved, plastic waste is reduced and materials can develop their full potential during use. This requires innovations,and BASF will be showcasing a large number of them from 12-16 October at the 27th Fakuma in Friedrichshafen, Germany.

Alternative drives, electromobility and CO2 emission reductions are the defining topics in the automotive industry. Many solutions demonstrate the potential of BASF’s versatile engineering plastics and polyurethanes. From high-voltage connectors and bus bar holders to electromagnetically shielded housings,

a wide range of innovative eMobility applications will be shown. In addition, engine and transmission mounts will be presented that lead to savings in production, but also contribute to optimized acoustic experiences. A tunnel reinforcement, which is a joint project with Stellantis and L&L Products, recently won the Altair Enlighten Award for its weight savings. BASF will also present a new flame-retardant Ultramid grade (PA66) that expands the portfolio of colour-stable, tailor-made engineering plastics for use in electric cars. The newly developed material combines colour stability (available in orange RAL 2003) and mechanical strength and is able to meet the technical requirements the market

Automotive Forum at IATF2021

THE IATF Automotive Show from 15-21 November in Durban, KwaZulu-Natal, will present a platform for car manufacturers, assemblers, original equipment manufacturers (OEMs) and component suppliers to exhibit their products and also interact with potential buyers and suppliers.

The IATF2021 Automotive Show has three components: a dedicated exhibition, a workshop and a conference.

Automotive companies including Original Equipment Manufacturers (OEMs) and component suppliers will have an opportunity to showcase their products and also interact with potential buyers, suppliers and government. Pavilions can also be set up to enable them to customise their exhibition to fit their unique requirements.

The automotive workshop will form part of the IATF2021 conference programme. The conference will feature leading African and international speakers and a variety of sessions dealing with the Automotive industry in Africa. It will also feature a high-level panel with selected Heads of State to discuss policy issues affecting the automotive industry with a view towards providing practical solutions for developing the African auto-sector. www.intrafricantradefair.com/en 64 OCT / NOV 2021

demands. With the innovative portfolio of Ultradur FC grades (PBT) for coffee capsules, BASF now offers customized, sustainable materials tailored to customer needs. Together with the basic material Ultradur B1520FC R01, further productspecific features and services are offered, which can be used individually or combined by the customer as desired.

The PBT portfolio also includes Ultradur B6560 M2 FC TF, the world’s first PBT for the extrusion of films and thermoforming of food packaging. The mono-material exhibits excellent barrier properties, enables mechanical recycling and thus a closed material loop. www.fakuma.basf.com

Putech Eurasia & Eurasian Composites Show

PUTECH Eurasia, the world’s second largest polyurethane industry exhibition, and Eurasian Composites Show, the important professional meeting point of the composite industry in Eurasia, are preparing to host its exhibitors and visitors under the organisation of Artkim at the Istanbul Expo Center from 25-27 November.

In 2019, Putech Eurasia and Eurasian Composites Show hosted 203 exhibitors from 21 countries and nearly 6 000 visitors from 69 different countries visited the exhibitions. www.putecheurasia.com www.eurasiancomposites.com

Trenchless Asia 2022 WESTRADE Group is delighted to announce a new date for the Trenchless Asia taking place from 27-28 July 2022 and be held at the Kuala Lumpur Convention Centre, Malaysia.

FAKUMA 2021

Wittmann presents new Sonic 108 for use on small injection moulding machines

which substantially simplifies the enclosure, especially in the area behind the fixed clamping plate of the machine.

The Sonic 108 has been optimised for high-speed parts removal in packaging and pick-and-place applications. It is designed for cycle times below 4 seconds, with IN/OUT times kept below 0.9 seconds.

The Sonic 108 is able to handle payloads up to 2kg.

Wittmann Group represented in South Africa by Ipex Machinery

OCT / NOV 2021 65

IN 2019, the Wittmann group launched the Sonic robot series to replace the high-speed robots from the UHS series. Sonic robots come with a new design and are equipped with the ultra-modern R9 robot control system. The new Sonic 108 for use on small injection moulding machines with clamping forces from 50t upwards, now joins the appliances already on the market for clamping forces from 150 to 500t.

In contrast to the larger Sonic models, the Sonic 108 has been fitted with a fixed demoulding axis – extremely advantageous for small injection moulding machines. Short overhangs and a compact control cabinet simplify the CE-compliant housing of the automation cell. During the active demoulding stroke movement above the mould space, no axis elements are pushed towards the injection unit,

www.wittmann-group.com

Win your share of R25 000 in prize money

ENTER OUR PHOTOGRAPHY COMPETITION WHAT TO ENTER:

We are looking for striking digital images to celebrate the important role plastic pipes play in South Africa. Show us how you view plastic pipes and their use in infrastructure (e.g. supplying clean drinking water), “behind the scenes” images that show the manufacturing process, the often unappreciated hard work and team effort involved in a pipeline installation, the skill required when welding a plastic pipes, or a striking, artistic photograph of a plastic pipe, etc.

SCAN THE QR CODE FOR RULES AND CONDITIONS

HOW TO ENTER:

• A maximum of 2 photos per entrant must be submitted in digital format to SAPPMA via email to Admin@sappma.co.za or delivered on a USB stick or CD/DVD by close of business on Friday, 5 November 2021.

• We will require details, including name, phone number, email address and other information about your photo submission.

ENTER TODAY!

We are calling on all photographers to submit your creative interpretation of our theme:

THE VALUE AND ROLE OF PLASTIC PIPES IN SA

www.sappma.co.za

diary

Sikora reveals Purity Scanner Advanced IN the area of online inspection and sorting of plastic pellets Sikora will present the Purity Scanner Advanced. The system combines in a unique way an X-ray with up to three optical cameras. Thus, even the smallest metal inclusions in the raw material from a size down to 50µm can be detected. In addition, the optical cameras detect black specks and burns on the pellet surface. Defective pellets are separated immediately after detection by means of compressed air.

The Purity Concept V system is

Interplastica 2022

typically used for offline laboratory testing and random sample inspection.

The automated light table automatically inspects the test material placed on a sample tray within a few seconds by using a colour camera and evaluates the image recordings. The system detects black specks and colour deviations down to a size of 50µm and highlights contamination in colour on the monitor image and in parallel via a projector on the sample carrier. A clear assignment of the contamination and a follow-up control are

THE organiser of interplastica and upakovka exhibitions, Messe Düsseldorf Moscow, have projects in Russia and CIS, which will be held offline within the framework of the largest industrial events under a special joint name – Interplastica Meeting Point.

The next Interplastica event will be from 25-28 January 2022.

Interplastica Meeting Point means exhibition projects where exhibitors can demonstrate their products to professionals, international clients and industrial specialists. These projects enjoy a vast geographic footprint, allowing the participating companies to enter new markets with their products, equipment and technologies.

In the course of four days the visitors will have a unique opportunity to find out more about a wide range of innovative products, offers and services, as well as new trends and

66 OCT / NOV 2021

Sikora’s CENTERWAVE 6000 for quality control during pipe extrusion

thus possible at any time.

For a 100% quality control during pipe extrusion the Centerwave 6000, based on millimetre wave technology, precisely measures the diameter, ovality, wall thickness, inner profile as well as sagging of the pipe. The measuring method does not require any coupling media or calibration and is free from influences such as temperature or the plastic material. www.sikora.net

opportunities in the industry of plastics, rubbers, packaging and packing technologies. www.interplastica.de/

Saudi Plastics & Petrochem

THE 18th edition of the Saudi Plastics and Petrochemicals trade exhibition is set to take off. This is the largest event of the year in the Kingdom of Saudi Arabia, aspiring to be an extravagant paradigm of innovation and sustainability.

In 2022, the event aims to bring all esteemed businessmen, organizers, industry professionals, decision-makers, and sellers alongside each other to showcase their innovative solutions on an exclusive platform. The distinguished event will be held from 6-9 June 2022 at the Riyadh International Convention & Exhibition Center.

IntElect including an LSR package showcases state-of-the-art elastomer injection moulding

FAKUMA 2021

One stop shopping, machine & process from a single source Focus on sustainability, unveils solutions for modern networking SUMITOMO (SHI) Demag Plastics Machinery GmbH will present numerous new products showcasing itself as a competent machine partner and innovative and sustainable innovation driver.

Highlights on show at Fakuma, were three all-electric injection moulding

New and even more energyefficient: The dry-air dryer EKO-N. Here: EKO-N 200F with two drying containers of 150 and 60 litres.

machines from the IntElect series. An IntElect 130/520-450, including an LSR package, will showcase state-of-the-art elastomer injection moulding integrated with the Servomix Z200 metering system from partner Nexus Elastomer Systems.

An IntElect 220/660-1100, equipped with a special plasticising unit for processing crystal-clear multilayer PC, will demonstrate all of the IMD advantages in a single, seamless process. Automating the production of emblems for automotive exterior applications, the IMD decoration process involves back-injecting

a second surface using a single image followed by contactless cleaning in a laminar flow box.

Another highlight is the inaugural launch of a series of permanent machine status condition monitoring systems. Reducing maintenance costs while maintaining reliability, they can be used to determine the actual degree of wear and tear, enabling early detection and optimal maintenance planning towards the end of the service life of the injection moulding machine.

Sumitomo (SHI) Demag represented in South Africa by DemaPlasTech Machinery (Pty) Ltd

www.sumitomo-shi-demag.eu OCT / NOV 2021 67

Koch-Technik showcase mixing, dosing, conveying and drying solutions GERMAN company Koch-Technik will showcase the broad portfolio of its product range in the areas of mixing, dosing, conveying and drying, as well as a variety of sustainable solutions for applications in the automotive, consumer goods, health care and several others industries.

The new EKO-N dry air dryer, celebrates its debut at this year’s Fakuma. The dryer has been developed further with respect to energy efficiency. Together with the patented KochÖKO energy system control, the new dryers can save up to 50% energy.

Another highlight is the KKT mobile granulate dryers, which was presented with a new touch control. The new colour displays are larger than before and grant further advantages such as the simple, intuitive operation of the control unit, the integrated central conveying system.

Another innovation is the MCGT control unit for the gravimetric mixers, Graviko. Together with the control units of the volumetric pre-mixers and the mobile KKT dryers, the new control units of Koch-Technik present themselves in a uniform and modern appearance. www.koch-technik.com

• Official Distributor in Southern Africa for BASF

on TPU Elastollan® Thermoplastic Polyurethane

• Official Distributor in Southern Africa for Elastron on TPE, TPV Elastron® SEBS and EPDM/PP

• Official Distributor in Southern Africa for CGFSE on FSE® Fluoroelastomers and Perfluoroelastomers

• Distributor for Weifang on Weipren CPE • Suppliers of EPS, Various Grades • Engineering Polymers • Polyolefins • Reworked and Repaletised Materials • Official distributor for Politem on PA6, PA66 ®

unfilled and filled compounds

diary

Arburg at Interplas 2021: production cell combining numerous innovative technologies

Smart Allrounder injection moulding machines with Gestica controllers “learn” the parts that they should produce on account of the “aXw Control FillAssist” function

Smart: assistance systems for filling simulation and regulated injection THE focus of the Arburg trade fair stand at Interplas from 28-30 September in Birmingham, UK, was a digitally networked, electric Allrounder with a ground-breaking Gestica-control system. The smart turnkey system manufactures plastic cups fully automatically, which can be sorted by type by means of a digital product passport. The application sets new plastics processing standards in terms of digitalisation, automation and the circular economy. The Arburg host computer system ALS and the arburgXworld customer portal will also

be on show at the exhibition.

This energy-efficient production cell will also bundle together numerous innovative technologies, all of which make injection moulding more efficient and convenient.

The heart of the turnkey system is an electric Allrounder 370A with a clamping force of 600kN, a single hot runner mould by Haidlmair and the new vertical robotic system Multilift V 20 with a 20kg load in a transverse design. The machine is also equipped with an IIoT gateway as standard. In addition the system is connected to

the Arburg Turnkey Control Module (ATCM) Scada system, which amalgamates all the relevant process and quality data for each specific part.

A cup is manufactured from PP, then printed with a QR code according to the injection moulding process. This enable separation by type after use.

Arburg represented in South Africa

by Hestico (Pty) Ltd

www.arburg.com

68 OCT / NOV 2021

Arburg at Moldplas 2021: turnkey solution for digitalised moulded part production FROM 3-6 November, Arburg will be in Batalha at Moldplas 2021, Portugal’s largest trade fair. At its stand the company will present innovative injection moulding technology, efficient automation, and a wide range of digital products and services. A fully automated and digitally networked Allrounder will produce ready-to-use mask boxes.

Taking the fully automated production of mask boxes as an example, Arburg will be demonstrating a high-end

solution for efficient injection moulding: digitally networked, fully automated, 100% traceable and safely managed via its pioneering Gestica control system.

As an exhibit for the fair, Arburg Spain has designed a turnkey system around an electric Allrounder 470 A with 1 000 kN clamping force and Gestica control system. Its numerous assistance functions offer a very high degree of convenience and extensive support during set-up and operation. Multilift and six-axis robotic systems can be fully integrated into the system, retaining the

Gestica look and feel during operation.

This increases the speed, efficiency, and reliability of the cycles.

The exhibit uses a 1+1-cavity family mould from Portuguese partner Gura to produce a PP box and clip for storing face masks in a cycle time of around 30 seconds.

An integrated Multilift Select robotic system performs the handling tasks. It first removes the two moulded parts and feeds them to a station for plasma pre-treatment. The mask box is then pad-printed with the partner logos, the clip is mounted and then closed in the gripper, and the finished part is placed on a conveyor belt.

At Moldplast 2021, an electric Allrounder 470 A with 1,000 kN clamping force and Gestica control system will produce a box and clip for storing face masks

www.arburg.com

Accraply Revolve shrink sleeve seamer line to launch at Label Congress ACCRAPLY, a global leader in the design and manufacture of shrink sleeve converting equipment, introduced the Accraply Revolve™ line of seamers at Label Congress 2021, from 29-30 September in Chicago. This new line of modular shrink sleeve seamers includes three machine configurations that were engineered to make shrink sleeve seaming simpler and more efficient.

The Accraply Revolve machines leverage next-generation controls and an intuitive human-machine interface

(HMI) to simplify operations. Through the HMI, operators can access step-bystep help guides, diagnostic reporting, preventive maintenance alerts, on-board parts ordering and several additional resources. Also, advanced machine design features eliminate operator error.

The Accraply Revolve line operates smoothly and easily. The technology and servo motors work together to create a crash-proof forming table that restricts operators from inputs that drive the machine out of spec, which limits

operator dependency and dramatically reduces the risk of downtime.

There are three machine configurations: the standard Accraply Revolve, the Accraply Revolve RT2 and the Accraply Revolve Fully Continuous.

Each of these configurations has distinct, flexible options, with the intent to make it easier for customers to select the shrink sleeve seaming machine that is right for their business. www.accraply.com

Endless possibilities combining design, performance & sustainability for footwear Innovative coating technologies for highly flexible substrates dedicated themselves to during a recent design competition. The basis for the students’ various creative interpretations is the designers’ “RE2.0” sole design.

(RE implies Restart, Rethink, Recreate, Reconquer the world). The students’ unique shoe creations, combinations of design, performance, and sustainability, were presented at the BASF booth.

At Simac 2021, BASF 3D Printing Solutions GmbH with its brand Forward AM also presented 3D printed moulds and lasts through which development cycles can be shortened tremendously.

Visitors were able to see completely 3D

printed high heels and barefoot shoes as well as midsoles manufactured with latticed designs which enable new ways of cushioning, shock absorption and comfort and which can be tuned to the customer’s specific needs.

Infinergy, is an expanded thermoplastic polyurethane (E-TPU). The closedcell, elastic particle foam combines the properties of TPU with the advantages of foams, making it as elastic as rubber but lighter. It provides exceptional cushioning.

Infinergy offers a natural cushioning effect at the heel and middle part of the foot in the sole.

Design in the sign of sustainability – Footwear Design Contest 2020; School for design Calzaturiero Politecnico, Padua, Italy.

Students’ unique shoe creations, combinations of design, performance, and sustainability, were presented at the BASF booth at Simac 3D printed moulds and tools to completely 3D print shoes were presented at Simac

OCT / NOV 2021 69

SUSTAINABLE PU systems, TPU and E-TPU, 3D printed moulds, functional coatings, and the comfort of a sneaker for dress shoes – all these solutions for the footwear industry were presented

by BASF at Simac in Milan from 22-24 September.

To achieve the ultimate goal of a circular economy, we need to rethink the production and use of footwear in general. This is the task that Italian designer Linda Lipari, together with designer Pierpaolo Righetto and students from Calzaturiero Politecnico (the School of Footwear Design and Technology)

www.footwear.basf.com

BOOKS

Composites additive manufacturing: 10-fold market growth within 10 years ADDITIVE manufacturing of composites is approaching an inflection point. There is an increasing number of printer manufacturers, market launches, more funding, notable partnerships, and importantly demonstratable value-add with a wide range of success stories.

In their new report “3D Printing Composites 2021-2031: Technology and Market Analysis”, IDTechEx forecast the market to reach $2bn by 2031. This represents significant growth from the current market size; a greater than a ninefold increase from the calculated 2021 revenue for the

most mature extrusion/placement technology is expected.

Over the next 10 years, the global additive market is projected to grow 10 times and advanced composite printers and materials will play a key role as manufacturers look for new ways to overcome their supply chain challenges.

• For more information on this report, visit www.IDTechEx.com/3DComp, or for the full portfolio of 3D Printing research available from IDTechEx please visit www.IDTechEx.com/Research/3D.

Sustainability drive creates new growth opportunities for cast PP films in Europe

A NEW report from AMI Consulting presents a comprehensive analysis of the state of play and future outlook for the recycling of flexible polyolefin films in Europe. It analyses the industry’s operating environment, and the particular challenges involved in the collection, sorting and recycling of flexible films.

In preparing the report, AMI’s comprehensive and detailed in-house data on virgin polymer demand, polymer end use applications, and recycling capacities was combined with an extensive research programme including conversations with a wide range of industry participants.

The quantitative analysis includes a focus on volumes of post-use flexible polyolefin films generated as waste by end use sector and, considering collection rates, levels of contamination and international trade in post-use plastics, an assessment of the volumes of post-use films available to EU+3 recyclers as inputs into the recycling extrusion process. The latter data point is of particular importance given it marks the new calculation point for the EU’s recycling targets. Data is provided for the years 2019, 2020 and 2021, with forecasts for 2025 and 2030.

THE European Market 2021, is a brand new report from leading plastics market intelligence providers, AMI. The report provides critical insight and analysis of the production, capacity and demand of Cast Polypropylene (CPP) film in Europe, together with trends in key consumer and industrial applications.

Demand for Cast PP films continues to grow. The heat resistant properties of the film are invaluable to food packaging converters as well as those catering to the medical and healthcare market, sectors which have proven themselves to be Covid-19 resilient industries.

The study explores the variety of different properties that Cast PP films can offer the end-user, and the trends which differ by application. Each of these properties and more, is explored by end-use sector, whether in food packaging, non-food packaging or other technical applications.

www.ami.international

www.ami.international

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sport

Peak braking force experienced by the athlete during running is reduced by 15%

Adidas 4DFWD launches in new colourway Takes 3D printed performance running technology to the next level ADIDAS Running has introduced a new colourway for adidas 4DFWD, the data-driven running shoe that takes 3D printed performance running technology to the next level. The bold new solar red and white colorway is the latest update to the silhouette following its limited release in May. The adidas 4DFWD combines years of athlete data with Carbon’s Digital Light

SynthesisTM technology to produce precision tuned 3D printed midsoles.

Identified from one of five million possible lattice structures and made of 39% bio-based material, the bowtieshaped FWD CELL has been specifically coded to compress forward upon vertical impact. When compared to previous generations of 4D midsole, adidas 4DFWD generates three times as much

forward motion under vertical loading in mechanical testing conditions.

As a result, peak braking force experienced by the athlete during running is reduced by 15%, redirecting these vertical impact forces into horizontal forward motion, to create an all-new running experience. www.adidas.co.za

72 OCT / NOV 2021

Nike enlists Newlight’s Aircarbon to explore carbon-neutral products NIKE has partnered with biotechnology company Newlight Technologies to reduce its carbon footprint. Specifically, Nike plans to explore the use of AirCarbon, which is Newlight’s carbonnegative biomaterial produced by ocean microorganisms.

The creation of the material also utilises the conversation of greenhouse gasses.

Newlight’s goal is to aid in the fight against plastic pollution and climate change by producing this plastic substitute. Currently, the material has been used as a plastic leather substitute for eyewear, bags and wallets. Nike’s

goal is to explore the capabilities of AirCarbon with several applications to create more environmentally equitable products.

“AirCarbon offers an opportunity to further reduce our impact on the planet,” said Noel Kinder, chief sustainability officer at Nike. “Materials account for 70% of Nike’s total carbon footprint, and we’re accelerating our efforts and exploring new opportunities in this space because, in the race against climate change, we can’t wait for solutions, we have to work together to create them.”

To create AirCarbon, Newlight

www.newlight.com

uses ocean microorganisms that eat greenhouse gasses and air and then convert it inside of the material’s cells.

As such, AirCarbon is an energy storage material composed of 40% oxygen from the air and 60% carbon from greenhouse gasses.

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