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polymer VOL 20 NR 3 JUNE / JULY 2022

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 VOL 20 NR 3 JUNE / JULY 2022

ARMSA gets Rotation show on the road again Extrupet, EPR legislation a benefit not a burden

Changes about titanium dioxide important, says Sun Ace

Mpact Plastic Containers’ annual conference impresses

Rubber Products & Mouldings unveils major expansion plans Pioneer wins Product of year award

2022/04/06 07:23

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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 The Stoep, 3 Tiverton Road, Plumstead, 7800

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GAUTENG Lowrie Sharp t: (011) 793 4691 f: (011) 791 0544 c: 082 344 7870 e: lowrieplasticsmedia@absamail.co.za KZN Lynne Askew 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

Institute of Materials

Smart move Safripol – Safripol has been sponsoring wheelie bins for outdoor sports and social events which have had the effect of reducing litter considerably. Here a participant in the Joburg-to-Sea event in April deposits a plastic container into one of the several bins available at the finish, as was the case on all of the nine days of the event. All packaging container types, including cans and paper and board products, and other products and materials were dropped in … making it far easier to keep the place clean and prevent products from being blown into the nearby Indian Ocean.

Solution to keep your plant and surrounding area clean PLASTICS|SA sustainability staff have been crisscrossing the continent to be at UN and Global Plastics Alliance-funded meetings in Kenya and Senegal and elsewhere at which plastics environmental matters are discussed – but for most of us keeping the area in and around our plants is also very important. So it was that the writer recently visited an exceptionally clean and tidy plant, where there was respect for all. Here the boss had worked out a way to incentivize staff to collect litter, with ‘zero tolerance’: the solution being to subtract from their collective bonusses if the situation deteriorates at all. Now they don’t even think about it, they just do it!

Mob returns, with new demands THERE they were again, the mob at the gate, but this time they weren’t demanding protection money and access to your procurement processes (and other accusations), now they wanted you to hand over ‘foreigners you are employing’. This was a potentially dangerous situation. The manager brave enough to deal with the group advised that the foreign workers were all legally in the country and had been employed by the East Rand business for some years already. There the ‘negotiations’ ended, email address details exchanged. As far as we know, employing foreign individuals is common in most countries, especially industrialised nations, and the main reason why these people are employed is because they add value in terms of skills and culture, if it is the intention of the owners and management to develop a talented, diverse, capable and effective work force. So, it’s no surprise that the company referred to here resisted. The matter was addressed in emails with the said group, which in the circumstances is a safer way to deal with the matter, and fortunately resolved. But why should any members of the public believe they have a right to confront and threaten businesses and their personnel ad hoc? We don’t mention this to be sensationalist, but these things happen and it’s probably better that you know in advance of the possibility of such a thing occurring at your plant.

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

Volume 20 No 3

JUNE – JULY 2022

Contents

Find out more at www.sapt.co.za

INDUSTRY NEWS 6

Sun Ace, changes promulgated by eCHA regarding titanium dioxide in europe important

WAG, phenolic resin continues long-standing importance in blending materials

23 33

10 12

RPM unveils major expansion plans

ARMSA gets Rotation show on the road again

Mpact Plastic Containers’ annual conference impresses

Minister Creecy applauds tubs2Classrooms project

Recycled HDPe with excellent carbon footprint

Revotech by Bandera, a response to Circular economy needs

Mattel first toy company to use SABIC’s certified renewable polymers

32 34 36

New EPR legislation is a benefit, not a burden – Pet recycler explains

SUSTAINABILITY

CoMPoSITES

PCT is new agent for Mold-Masters

79 70

Hyco expands assembly work

Stellenbosch University polymer scientists develop novel method to break down lignin

JEC World reaffirms dynamism of the composites industry

Moulding thermoplastic composite aircraft sidewall panels using recycled carbon fibre

DESIGN 46

Innovators across the globe showcase sustainable packaging

ON THE COVER:

The Recycling Oil Container (ROC), a roto moulded product from Pioneer Plastics of Rosslyn, won the ARMSA Product of the Year award in May. Manufactured for Neutral Fuels, the container is designed for the safe collection and transport of used cooking oil for reprocessing into bio-diesel. See pages 22, 23

commeNt SAVA registers as packaging PRO – The Southern African Vinyls Association (SAVA) has registered as a Producer Responsibility Organisation (PRO) to represent the interests of the PVC packaging producers in South Africa. According to SAVA chief executive officer, Monique Holtzhausen, about 12 000 tons of vinyl packaging is produced in SA each year, and most waste management companies and material recovery facilities do not have the manpower or capabilities to remove this potentially valuable material from the waste stream. Large volumes of vinyl packaging are also imported into SA each year. www.savinyls.co.za

Now may be the time to look

at import substitution

THIS ISSUE

… if you’ve survived so far

4 JUNE / JULY 2022

S YOU probably know, the South African plastics industry ran a ‘trade deficit’ estimated at over R15-billion for 2020, the most recent period for which Plastics|SA has stats. This is the value by which imports of raw materials, manufactured goods and machinery exceeded exports by. If anything, the situation could have been worse. Large volumes of raw materials and manufactured goods enter the country, and it is especially the latter that is worrisome, even though there are numerous world-class converting and fabrication businesses active in the sectors which we cover, the plastics, composites and rubber sectors, respectively. Of the 1.73 million tons converted in 2020, 296 480 tons was recycled material which was ‘reconverted’ into finished goods (a total of 1 443 000 tons of virgin material was used). Local virgin consumption was down 4.1%. Usage of recycled material also declined in 2020, from 337 745 tons for 2019 to the 296 000 tons for 2020, which was the year of the major Covid lockdowns where turnover in most sectors besides PPE (personal protective equipment) declined. The one other sector where the graph lifted was in packaging, which has increased its share of the overall market during the Covid. Now we hear China’s export juggernaut has slowed due to the extreme Covid regulations and lockdowns in that country and, although I wouldn’t expected

Chinese manufacturers to remain on the back foot for long, this could create opportunities in South Africa, not for exports, but for import substitution. These are indeed challenging times with rapidly increasing costs for just about everything and probably the biggest problem for most manufacturers is just getting enough material to run the plant. Shipping costs have also gone ballistic and delivery times are stretched, but this appears to be improving. With most South African manufacturers having already proved their ability to survive extreme challenges, and worse, now may be the time to look at opportunities to substitute imported goods with local solutions? You don’t need to worry about whether we run a trade deficit, it’s more about getting the most out of your business.

It’s more about getting the most out of your business

This issue Here we look at a wide variety of topics again, with sustainability being among the most relevant. Worrying about sustainability is difficult to justify when you’re battling for existence, but we need to be smart now. Martin Wells, Publisher

WELL-PROVEN

HIGHLY SECURE

SEAL OF QUALITY

GESTICA

ALL-PURPOSE

BEST OF THE BEST CONTROL CENTRE

GLOBAL STANDARD

SUSTAINABLE

www.hestico.co.za

Only the best is good enough. This should be the motto that guides you. Because this is also the principle behind our new controller generation: the GESTICA. Our control centre, which was developed and produced entirely inhouse, is second to none. On all fronts: reliability, performance, durability, compatibility, security, intuitive operation as well as the look and feel. Just try it. www.arburg.com

GESTICA_SA_Polymer_Technology_275x210_Juni_en_GB.indd 1

24.03.2022 13:12:12

NEWS

Changes promulgated by ECHA regarding titanium dioxide in Europe important, says Sun Ace Regulations regarding the use of TiO2 in Europe need to be adhered to for exporters to EU, suggests Snyman ECHA, the European Chemical Association, has recently promulgated regulations that TiO2 addition levels in powder mixtures above 1% carry specified warning labels, which regulation has since been included in the REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) protocols in Europe. The European Commission classified TiO2 as a suspected carcinogen (cat 2.) by inhalation, limited to certain powder forms. Sun Ace South Africa with their global presence stays close to changes in legislation and has been monitoring the changes in the regulations adopted in Europe for addition levels of titanium dioxide. This is because the inhalation of powder dust from titanium dioxide (TiO2) during manufacturing processes is deemed to be carcinogenic. The TDMA (Titanium Dioxide Manufacturers Association) is lobbying for ECHA to overturn the legislation. Renier Snyman, technical manager at Sun Ace in Jet Park in Johannesburg, addressed a SAPPMA (Southern African Plastic Pipe Manufacturers Association) webinar on the topic in May during which he noted that manufacturers outside of Europe need to comply with these regulations if exporting into Europe, and goods need to be clearly labelled that they are compliant. Failure to comply could result in shipments being rejected at entry ports in Europe. Rejection of container loads of goods can be perilous for manufacturers, so Sun Ace’s initiative to inform the market 2 of the recent change is valuable for SA manufacturers. TiO2 is a widely used whitening colouring agent and UV protector for plastic products, toothpaste, paints, cosmetics and foods. It occurs naturally in beach sand or is made from mineral ilmenite. Uses of TiO2 are many and varied: the substance has a high refractive index and can reflect and scatter light as well as absorb ultraviolet rays, but it is in PVC extruded and moulded goods where its use is particularly prevalent. The main activity of TiO2 is to reflect harmful UV rays away from moulded plastic items such as PVC pipes, gutters or other goods which are exposed to sunlight. Essentially what happens is that UV light degrades the surface layer of the item, causing a loss of brightness and chalking, which is evident as a powdering deposit. Use of coated TiO2 slows, or reduces, this process.

Renier Snyman, technical manager at Sun Ace

Surfaces of aged PVC products often appear dull and brittle, detracting from consumer appeal. By contrast, the use of properly formulated PVC material with the required addition levels of good quality coated TiO2 tend to perform better and retain their surface gloss for longer. Use of TiO2 is thus important. According to Renier, South Africa does not need to be worried at this stage, unless exporting to Europe. “These changes are only for Europe at this stage, but now is a good time to discuss the regulations and formulate a stance. “SAVA (vinyls association) is the right vehicle to host these discussions, it is already involved in similar activities for other PVC products,” added Renier. • For more information, visit the TDMA website at www. tdma.info/what-you-should-know-about-eu-titaniumdioxide-regulations/ • And the ECHA Guide on the classiﬁcation and labelling of titanioum dioxide at www.echa.europa. eu/documents/10162/17240/guide_cnl_titanium_ dioxide_en.pdf/d00695e4-e341-0a33-b0acbee35cb13867?t=1630666801979

The main activity of TiO is to reflect harmful UV rays away from moulded plastic items

JUN / JUL 2022

NEWS SUN ACE-.indd 6

2022/06/09 17:03

A GLOBAL LEADER IN THE DEVELOPMENT AND PRODUCTION OF PVC STABILISERS AND METALLIC SOAPS

From pack to product creating the perfect PVC pipe and cabling

WE ALSO SUPPLY QUALITY MINING CHEMICALS XANTHATES | FROTHERS | COLLECTORS FLOTATION REAGENTS | NASH Suppliers of xanthates, frothers and collectors to the mining industry, including copper, gold, zinc, lead and other sulphide metallic ores. www.sunace.co.za/mining-chemicals

SUN ACE South Africa (Pty) Ltd | +27(11) 552 6200 | www.sunace.co.za

Sun Ace SA Plastics 2021.indd 1

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15/02/2021 20:24

2021/02/16 09:05

NEWS

Binder of materials

Phenolic resin continues long-standing importance in Few are aware of the important role of these materials IF YOU don’t know much about phenolics, you are not alone. The topic drew interest recently following West African Group’s acquisition of the distribution rights for phenolic resins in Southern Africa. This came about as a result of SI Group’s termination of production and supply of these materials in South Africa. SI Group, a global business headquartered in USA, shut its production plant in Durban last year. The transition from SI to West African Group (WAG) was straightforward as Demitri Loukidis, then the SI manager responsible for sales, had been using WAG as its distributor. WAG has since been appointed as the official distributor. WAG has developed a reputation for identifying key raw materials and handling sales, logistics and distribution in a seamless manner and supporting customers with a reliable service. Since the transition of the SI Group portfolio to West African Group, ASK Chemicals Group completed the acquisition of the industrial resins business from SI Group in November 2021. With this transaction, ASK Chemicals Group, headquartered in Hilden near Düsseldorf (Germany), has strengthened its position as a global supplier of high-performance industrial resins relating to market segments such as friction, abrasives, insulating material and refractory products. Loukidis has also transitioned to WAG, which has overnight become the leading supplier of phenolic resins into the rubber, adhesive and industrial resins sectors (previously Loukidis handled only the ‘bigger’ client users). Phenolic resins are mostly used in the formulation of other materials and end products, chiefly as a binder, which is why few people out of the cycle would know much about them. But closer examination, however, reveals that the phenolic group of materials are one of the longest known building blocks used in the manufacture of synthetic goods, from as far back as the mid-1800s, when phenol formaldehyde (better known by the Bakelite tradename) was first used in the production of many widely-used household items such as telephones, combs and brushes, crockery … and in fact at that time a huge array of domestic items.

Since then, other materials have been used to manufacture such items, with these materials gaining ascendancy due to cost and faster production cycle aspects. Now HD, PP and a variety of engineering materials are used for these applications. Our curiosity as to what applications phenolic compounds are used in today was perked up. Possibly the biggest use is as a binder to join materials which would otherwise not have coalesced, to form stronger end products. One of the most obvious examples of this is the production of grinder wheels and brake pads where the material is used to bond whatever grit/friction particles are required for the various applications within each segment. Possibly the biggest use of phenolic resin is as a binder to join materials which would otherwise not have coalesced to form stronger end products. One example of this is the production of brake pads

Phenol formaldehyde (better known by the Bakelite tradename) was first used in the 1800s to produce a wide range of domestic items

NEWS WAG-.indd 8

JUN / JUL 2022

2022/06/10 12:12

blending materials, now with West African Group Phenolic resins are chemically defined as compounds containing hydroxylated aromatic rings, the hydroxy group being attached directly to the phenyl, substituted phenyl or another aryl group. Many phenol compounds which make up round 60 to 80% of phenolic resins, were discovered and used long before chemists were able to determine their structures. The materials can be defined as plant substances, are widely distributed in the plant kingdom and are the most abundant secondary metabolites of plants. They are found ubiquitously in Algerian plant species, which comes as a surprise. From a human physiological standpoint, phenol compounds are vital in defence responses, such as anti-aging, antiinflammatory, antioxidant, and anti-proliferative activities.

But it is in industry where phenolics come into their own, and where they have continued for over more than a century-and-a-half to hold their own. They are a vital building block in rubber compounding to produce tyres and technical rubber products, and they are used very extensively in adhesives, coatings and brake pads, so you probably come into contact with items which are formulated with phenolics (whose production is made possible by their inclusion) on a daily basis. Often the volumes supplied are relatively small – since the percentage ratios at which the compounds are used are often miniscule – but the values are high, presently selling at between R50 – R90+ per kilogram, underlining the vital role phenolics play. JUN / JUL 2022

West African Group is now the leading local supplier of solid phenolic compounds The main duty of phenolic materials is to bind materials to form stronger and more durable end products. Applications include: Rubber products, including tyres, belting/reinforced conveyors, technical rubber mouldings Surface coatings Grinders and related friction products Insulation materials Call us on: +27 31 202 9000 or email: demitri@westafricangroup.co.za Or visit our website at

NEWS WAG-.indd 9

www.westafricangroup.co.za

Brake pads Adhesives

2022/06/10 12:12

NEWS

Rubber Products & Mouldings unveils major expansion plans

Rolling on … Wayne Tozer and Sue Supasar with one of the rollers being prepared at the Rubber Products & Mouldings’ plant in Maitland, Cape Town. Surviving Covid appears to have given them a new lease of life and several new projects are underway

10 JUNE / JULY 2022

Increase in demand for rollers gives it momentum NO RISK, no gain. It’s really as simple as that in South Africa at present, there is just no rescue net for entrepreneurs who venture forth and as a result for most of these people failure is just not an option. That is certainly the case over at Rubber Products & Mouldings in Maitland in Cape Town, which was bought by Wayne Tozer and Sue Supasar in 2019. Three years later, this dynamic duo has been picking up market share, partly by offering to manufacture previously imported products and, more recently, in the rollers sector. Supasar and Tozer ventured out on their own when they purchased RPM from Barry Hollis in 2019. Established in ’54, RPM had to a large extent become moribund and had exited several of the markets where it was formerly a leader. RPM had stopped production of rollers and instead outsourced orders. But much of the equipment to produce

the rollers was on hand, so the new partners decided to make a go of it and established RPM Rollers in early 2020 … just in time for the Covid lockdown ‘apocalypse’! From that point on there was no looking back. “We were halfway there before we started,” says Supasar. Some new equipment was purchased, including a larger lathe to manufacture 2m-plus rollers. Possibly the biggest benefit, however, lay in the quality of materials used. RPM had in 2019 also concluded a sole distributor agreement with Hexpol of Britain, a leading international manufacturer of high-spec rubber compounds. RPM now uses the Hexpol materials exclusively in its roll covering processes and also supplies the materials to other users across the southern Africa region. The Hexpol materials are available in a range of pre-coloured compounds and allow for Wayne and Sue explain the roller recovering process to Martin Wells, publisher of SA Polymer Technology. Roller users across the country and in Africa are now freighting rollers to the Maitland plant for recovering

www.rpm.co.za

the production of high standard rollers, which has helped increase demand for the RPM rollers and recovering service. Roller users across the country and in Africa are now freighting rollers to the Maitland plant for recovering. But that’s not all that’s happening at RPM now. Due to start PU production of mouldings and rollers – The partners have also recently concluded the purchase of a polyurethane business, which will give it a whole new set of options. RPM will now offer the market polyurethane moulded products and Polyurethane Roll Covers will now be produced onsite. A full range of high spec’ed Polyurethanes will be on offer. RPM staff are presently undergoing training in PU technology, which is new to them. New rubber injection moulding machine – RPM will shortly also be installing a world-class rubber injection moulding machine. The new machine, from France, will far transcend the technical abilities of the machinery it currently has on site. The new machine offers more flexibility than rubber injection machines used to date, with considerably more electronic control ability, which will potentially allow for faster cycle times and greater precision. Watch this space!

JUST BRIEFLY

23 23 23

difference between a- ( #)& -&("!% &% )* ') * successful solution or a confl agration had both major morale and income impacts on the - ( #)& -&("!% &% )* ') * * -!## #!$!* * -!## #!$!* % && % && * ) '# %) , $ '(&,!)!&% &( % , $ '(&,!)!&% &( % , #&' *& * ** ( &%*(&# &, ( * , #&' *& * ** ( &%*(&# &, ( * % -#/ +!#* *&(! ) * % -#/ +!#* *&(! ) * * $ %+ *+( * $ %+ *+( 1* which #* ) '# %) #* $&# "! % $% #") $ % &*$ % #!**# !% &($ *!&% !) , !# # #!**# !% &($ *!&% !) , !# # #$" ' &% " #$" ' &% " ! !&" "'& $ ! ! !&" "'& $ ! %1 &+ % &+ $&# "! % $% #") $ % &*$ % ) $ "# ! & & ! ) $ "# ! & & & % &"$ , % & % &"$ , % ! " ! " +can + "$ "( $ "$ "( $ %) * * * & ) * & ) which put a business completely out of operation with business. Steven and Fred Cheetham, joint owners of *#$" ' &% " !$'&(*!% & '# )*! - )* *& '(&* * *#$" ' &% " !$'&(*!% & '# )*! - )* *& '(&* * $ )* ( '# % !) #)& !% , #&' 1 $&# "! % $% #") $ % &*$ % $ )* ( '# % !) #)& !% , #&' *!, - )* $ % $ %* )/)* $ * *!, - )* $ % $ %* )/)* $ * * * % 1 $&# "! % $% #") $ % &*$ % ! !&" "'& $ ! ! !&" "'& $ ! % "$ #' "!%' "$ #' "!%' #& "! ) $ "# ! & & #& "! ) $ "# ! & & - ( #)& -&("!% &% )* ') * - ( #)& -&("!% &% )* ') * * -!## #!$!* * -!## #!$!* % && % && '(&,!)!&% &( % (&,!)!&% &( % )* ') * " % *& # $' &-% &% !## # $ % $ %* % $ %* potentially huge fi& !( $"! nancial losses. APR, embarked)* ') * " % *& # $' &-% &% !## # on a comprehensive risk analysis process & !( $"! !& & $ * ! ! '%&$* !& & $ * ! ! '%&$* &( * &( * '# )*! ) !% +)*(/ % - '# )*! ) !% +)*(/ % - &' &' ")% "$ & % # $ & "! " & "! ! ")% "$ & % # $ & "! " & "! ! - ( #)& -&("!% &% )* ') * - ( #)& -&("!% &% )* ') * * -!## #!$!* * -!## #!$!* % && % && * ) '# %) * ) '# %) , $ '(&,!)!&% &( % * !$'&(*!% & '# )*! - )* *& '(&* * * !$'&(*!% & '# )*! - )* *& '(&* * 1 $ )* ( '# % !) #)& !% , #&' 1 , $ '(&,!)!&% &( % $ )* ( '# % !) #)& !% , #&' $ %* )/)* $ * $ %* )/)* $ * * * !$'&(*) % +% ( !%,&! '(& + *) ( !$'&(*) % +% ( !%,&! '(& + *) ( , ! " ! " “It’s diffi cult to do these things ourselves and we found that at the Beaconvale-based business in which every aspect ! $") & ! $") & ! "$ " ) %& , ! "$ " ) %& , * * * * * * * !#) -!## ( # ) !% * * !#) -!## ( # ) !% * '(& ))!% & ( / # # $ * (! #) (&$ '(& ))!% & ( / # # $ * (! #) (&$ * !$'&(*!% & '# )*! - )* *& '(&* * * !$'&(*!% & '# )*! - )* *& '(&* * 1 $ )* ( '# % !) #)& !% , #&' 1 $ )* ( '# % !) #)& !% , #&' *!, - )* $ % $ %* )/)* $ * *!, - )* $ % $ %* )/)* $ * * * & !( $"! & !( $"! !& & $ * ! ! '%&$* !& & $ * ! ! '%&$* &( * &( * '# )*! ) !% +)*(/ % - '# )*! ) !% +)*(/ % - &' &' " & "! ! "! " & "! ! #)& - # &$ % -) ) - #)& - # &$ % -) ) - , % , % working with properly trained professionals, to implement of ) the production operation was assessed. They called in ! " ! " % ( +*+( * * -!## ))!)* !% (&-!% * -!## ))!)* !% (&-!% * ")% "$ & % # $ & "! " & "! ! ) * ")% "$ & % # $ & "! " & "! ! &# ) &# ) !) -!## & #&% - / !) -!## & #&% - / & !( $"! & !( $"! !& & $ * ! ! '%&$* !& & $ * ! ! '%&$* &( *% ( +*+( * &( * '# )*! ) !% +)*(/ % - '# )*! ) !% +)*(/ % - ! $") & ! $") & ! "$ " ) %& , * &+) * * * &+) * * * !#) -!## ( # ) !% * * !#) -!## ( # ) !% * $ * (! #) (&$ # $ * (! #) (&$ -&("!% #&) #/ -!* -&("!% #&) #/ -!* * * ! "$ " ) %& , !% ( %* &' &' !% ( %* the proposals of the risk analysis, has made the process far professionals who deal with these matters and the process ! $") & ! $") & ! "$ " ) %& , ! "$ " ) %& , * * * * * * * !#) -!## ( # ) !% * * !#) -!## ( # ) !% * '(& ))!% & ( / # # $ * (! #) (&$ '(& ))!% & ( / # # $ * (! #) (&$ $&%* $&%* ) *& , #&' $ )* ( '# % * ) *& , #&' $ )* ( '# % * * * ! " ! " % ( +*+( * % ( +*+( * * -!## ))!)* !% (&-!% * -!## ))!)* !% (&-!% -!## & #&% - / !) -!## & #&% - / easier. had to change our mindset. It’s helped involved training in every aspect of potentially dangerous We have all ! " % % & $")& %'%& ! &* ! & $")& %'%& ! &* ! ! " % ( +*+( * % ( +*+( * * -!## ))!)* !% (&-!% * -!## ))!)* !% (&-!% * ) * ) &+) &+) &# ) &# ) !) -!## & #&% - / !) -!## & #&% - / us a* lot,” said Steve Cheetham. events at the plant, including ' ! & $ ! "!" dealing with hazardous ' ! & $ ! "!" ") $ ! * ") $ ! &( )$ ## )$ ## * (! ) % !%*(& + !% !% %*!, ) &( #& # * (! ) % !%*(& + !% !% %*!, ) &( #& # !% &" # !% &"

' ! & $ ! "!" ' ! & $ ! "!"* ") $ ! * ") $ ! & ( * # ( ( $ (" * &( )$ ## - ! & $ % ! * "! % & - ! & $ % ! * "! % & & ( * # ( ( $ (" * &( )$ ## * (! ) % !%*(& + !% !% %*!, ) &( #& # * (! ) % !%*(& + !% !% %*!, ) &( #& # '% ! %% % "( $! "( $! !& # !% &" !& # !% &" '(&,!% ! # &, (%$ %*) & +* % % '(&,!% ! # &, (%$ %*) & +* % % '% ! %% % !' &'$ $% , )! % * #& ##/ '(& + '(& + *) )! % * #& ##/ '(& + '(& + *) !' &'$ $% , "$& %& )"$ ! &" & $ ) & & "$& %& )"$ ! &" & $ ) & & NEWS NEWS %& % % ! (" & ! "$ %& % % ! (" & ! "$ * * $+)* '(& +( (&$ ) & % " & % " " !! % '$ % ) ! ! " !! % '$ % ) ! ! * * $+)* '(& +( (&$ ) NEWS NEWS && $ "!&$" "( $ #"$&% #"$&% %'$ % &" %'$ % &" $ % !& !!"'! & & #$" &% && $ "!&$" "( $ ! % &("!% -!* ! % &("!% -!* , #&'$ %* , #&'$ %* $ % !& !!"'! & & #$" &% & % &"$ , % ! " ! " + + "$ "( $ "$ "( $ *& ( + * & !*!0 %) * & !*!0 %) * * & ) * & ) & % &"$ , % *& ( + * )*!$+# * #& # '(& +( $ %* % % *!&% # )*!$+# * #& # '(& +( $ %* % % *!&% # -!* %&* -!* % !%, )*$ %* , #+ & % !%, )*$ %* , #+ & !##!&% !##!&% - ! ! !%& &'& "!% & - ! ! !%& &'& "!% & "( $! "( $! !& % *% !& % *% )* ') * " % *& # $' &-% &% !## # )* ') * " % *& # $' &-% &% !## # %&* , )) *& - )* $ % $ %* , )) *& - )* $ % $ %* & % &"$ , % & % &"$ , % ! " ! " + + "$ "( $ "$ "( $ *& ( + * & !*!0 %) * & !*!0 %) * * & ) * & ) *& ( + * Investigation into washplant tank still not !$'&(*) % +% ( !%,&! '(& + *) ( " !* %"$&% ! "'& $ , ! " ! " !$'&(*) % +% ( !%,&! '(& + *) ( * - ) ( , # +(!% * * - ) ( , # +(!% * * * * * & % &"$ , % & % &"$ , % ! " ! " + + "$ "( $ "$ "( $ *& ( + * *& ( + * incident & !*!0 %) * & !*!0 %) * * & ) * & ) , )) *& - )* $ % $ %* , )) *& - )* $ % $ %* )* ') * " % *& # $' &-% &% !## # )* ') * " % *& # $' &-% &% !## # %&* %&* !%!*! *!, *& +/ #& ##/ '(& + '(& + *) !%!*! *!, *& +/ #& ##/ '(& + '(& + *) , #( / % &$'# * % , #( / % &$'# * % complete !* ) ( * % !%%&, *!, '(& )) * !* ) ( * % !%%&, *!, '(& )) * * * " !* %"$&% ! "'& $ , #)& - # &$ % -) ) - #)& - # &$ % -) ) - , % , % % - 2)$ (* !*/3 !) * "!% ) % - 2)$ (* !*/3 !) * "!% ) )* ') * " % *& # $' &-% &% !## # )* ') * " % *& # $' &-% &% !## # %&* %&* , )) *& - )* $ % $ %* , )) *& - )* $ % $ %* ' !% ' !% !$'&(*) % +% ( !%,&! '(& + *) ( !$'&(*) % +% ( !%,&! '(& + *) ( " !* %"$&% ! "'& $ , " !* %"$&% ! "'& $ , ! " ! " * * * * * Recycler implements proposals of" !* %"$&% ! "'& $ , risk #)& - # &$ % -) ) - analysis process ! " % '(& + *) -!* % '(& + *) -!* ( / # &%* %* #$" &% )"$& '%& "( $ "! $ #$" &% )"$& '%& "( $ "! $ ) '! & ' % ) $ &$ &* ) '! & ' % ) $ &$ &* -&("!% #&) #/ -!* * ( / # &%* %* * !% ( %* !% ( %* %) (! ! -!## &$'# * -!* ! -!## &$'# * -!* !$'&(*) % +% ( !%,&! '(& + *) ( !$'&(*) % +% ( !%,&! '(& + *) ( ! " -&("!% #&) #/ -!* * - ) ( , # +(!% * * - ) ( , # +(!% * * * *!% * !% " !* %"$&% ! "'& $ , #)& - # &$ % -) ) - , % , % "!% ) ) ' !% ' !% %) (! $&%* $&%* ) *& , #&' $ )* ( '# % * ) *& , #&' $ )* ( '# % * * * % .* * % - 2)$ (* !*/3 !) * "!% ) % .* '(& )) !) !% '(& )) !) !% #)& - # &$ % -) ) - #)& - # &$ % -) ) - , % , % ' !% ' !% -&("!% #&) #/ -!* -&("!% #&) #/ -!* * * !% ( %* !% ( %* &$'# * -!* $'# * -!* !% * % - 2)$ (* !*/3 !) * "!% ) !% 1 - * (! & ) % ) *& 1 - * (! & ) % ) *& !% !$'# $ %* *!&% ' !% !$'# $ %* *!&% ' ) * ) * * -!## ) * -!## ) ) & $ & ! $ %&$' &'$ ! $" % ) & $ & ! $ %&$' &'$ ! $" % chemicals (or substance with which be THREE years after the tragic incident in Cape % & $")& %'%& ! &* ! & $")& %'%& ! &* ! $&%* # / * %, )*$ %* % % ( )*(+ *+( -&("!% #&) #/ -!* -&("!% #&) #/ -!* * they * !% ( %* may !% ( %* %) (! %) (! -!## &$'# * -!* ! -!## &$'# * -!* !% !% at a recycler $&%* ) *& , #&' $ )* ( '# % * ) *& , #&' $ )* ( '# % * * any * % %, )*$ %* % % ( )*(+ *+( ! '(& )) !) !% )) !) !% # / * unfamiliar), fi re and injury in which staff were trained in Town in which four workers died in a submerged washplant ' ! & $ ! "!" ' ! & $ ! "!" * ") $ ! * ") $ ! & ( * # ( ( $ (" * &( )$ ## & ( * # ( ( $ (" * &( )$ ## ! & $ % ! * "! % & ! & $ % ! * "! % & $&%* $&%* ) *& , #&' $ )* ( '# % * ) *& , #&' $ )* ( '# % * * * * % .* * % .* '(& )) !) !% '(& )) !) !% % % & $")& %'%& ! &* ! & $")& %'%& ! &* ! % ( )*(+ *+( % % ( )*(+ *+( 1 #* 1 &+ , #&' *& * ** ( &%*(&# &, ( * , #&' *& * ** ( &%*(&# &, ( * % -#/ +!#* *&(! ) * % -#/ +!#* *&(! ) * * $ %+ *+( * $ %+ *+( #* tank, &+ #!**# !% &($ *!&% !) , !# # #!**# !% &($ *!&% !) , !# # areas* ") $ ! such as emergency medical rescue, evacuation and water the investigation is still not complete. Statements * (! ) % !%*(& + !% !% %*!, ) &( #& # '% ! %% % "( $! !& # !% &" '(&,!% ! # &, (%$ %*) & +* % % '(&,!% ! # &, (%$ %*) & +* % % % * (! ) % !%*(& + !% !% %*!, ) &( #& # % & $")& %'%& ! &* ! & $")& %'%& ! &* ! '% ! %% % ' ! & $ ! "!" "( $! !& # !% &" # / * # / * %, )*$ %* % % ( )*(+ *+( %, )*$ %* % % ( )*(+ *+( ' ! & $ ! "!" * ") $ ! & ( * # ( ( $ (" * &( )$ ## & ( * # ( ( $ (" * &( )$ ## "! % & * "! % & access in the event of#$" ' &% " calamity. For ! !&" "'& $ ! instance, with much of made to police by#& "! ) $ "# ! & & personnel at the time )! % * #& ##/ '(& + '(& + *) were waylaid and #$" ' &% " ! !&" "'& $ ! % & ( * # ( ( $ (" * &( )$ ## $&# "! % $% #") $ % &*$ % % & ( * # ( ( $ (" * &( )$ ## $&# "! % $% #") $ % &*$ % "$ #' "!%' "$ #' "!%' #& "! ) $ "# ! & & !' &'$ $% , !' &'$ $% , )! % * #& ##/ '(& + '(& + *) "$& %& )"$ ! &" & $ ) & & "$& %& )"$ ! &" & $ ) & & ' ! & $ ! "!" ' ! & $ ! "!" * ") $ ! * ") $ ! ! & $ % ! * "! % & ! & $ % ! * "! % & * (! ) % !%*(& + !% !% %*!, ) &( #& # * (! ) % !%*(& + !% !% %*!, ) &( #& # '% ! %% % '% ! %% % "( $! "( $! !& # !% &" !& # !% &" +* % % *) & +* % % the equipment in the plant reaching several metres above the process had to be repeated, and then the pathologist %& % % ! (" & ! "$ %& % % ! (" & ! "$ * * $+)* '(& +( (&$ ) * * $+)* '(& +( (&$ ) & % " & % " " !! % '$ % ) ! ! " !! % '$ % ) ! ! * (! ) % !%*(& + !% !% %*!, ) &( #& # * (! ) % !%*(& + !% !% %*!, ) &( #& # '% ! %% % '% ! %% % "( $! "( $! !& # !% &" !& # !% &" '(&,!% ! # &, (%$ %*) & +* % % '(&,!% ! # &, (%$ %*) & +* % % !' &'$ $% , !' &'$ $% , )! % * #& ##/ '(& + '(& + *) )! % * #& ##/ '(& + '(& + *) & $ ) & & " & $ ) & & - ( #)& -&("!% &% )* ') * - ( #)& -&("!% &% )* ') * * -!## #!$!* * -!## #!$!* % && % && * "$& %& )"$ ! &" & $ ) & & ) '# %) *who ) '# %) , $ '(&,!)!&% &( % , $ '(&,!)!&% &( % ground, staff were trained to wear harnesses if they needed conducted the examinations of the deceased passed && $ "!&$" "( $ && $ "!&$" "( $ #"$&% #"$&% %'$ % &" %'$ % &" $ % !& !!"'! & & #$" &% $ % !& !!"'! & & #$" &% ! % &("!% -!* ! % &("!% -!* , #&'$ %* , #&'$ %* !' &'$ $% , !' &'$ $% , )! % * #& ##/ '(& + '(& + *) )! % * #& ##/ '(& + '(& + *) "$& %& )"$ ! &" & $ ) & & %& % % ! (" & ! "$ %& % % ! (" & ! "$ * * $+)* '(& +( (&$ ) * * $+)* '(& +( (&$ ) % ) ! ! % ) ! ! to ascend. way in 2021, so, astoundingly, the * forensic report is )*!$+# * #& # '(& +( $ %* % % *!&% # )*!$+# * #& # '(& +( $ %* % % *!&% # % !%, )*$ %* , #+ & !##!&% !##!&% - ! ! !%& &'& "!% & - ! ! !%& &'& "!% & "( $! "( $! !& % *% !& % *% %& % % ! (" & ! "$ %& % % ! (" & ! "$ * * $+)* '(& +( (&$ ) * $ )* ( '# % !) #)& !% , #&' * $+)* '(& +( (&$ ) & % " & % " " !! % '$ % ) ! ! " !! % '$ % ) ! ! * !$'&(*!% & '# )*! - )* *& '(&* * * !$'&(*!% & '# )*! - )* *& '(&* * 1-!* 1 % !%, )*$ %* , #+ & $ )* ( '# % !) #)& !% , #&' *!, - )* $ % $ %* )/)* $ * *!, - )* $ % $ %* )/)* $ * * -!* && $ "!&$" "( $ && $ "!&$" "( $ #"$&% #"$&% %'$ % &" %'$ % &" $ % !& !!"'! & & #$" &% $ % !& !!"'! & & #$" &% -!* , #&'$ %* , #&'$ %* APR installed own fire hoses and,#"$&% believe it or not, incomplete. As a result, no findings have been made and the !%!*! *!, *& +/ #& ##/ '(& + '(& + *) !%!*! *!, *& +/ #& ##/ '(& + '(& + *) , #( / % &$'# * % , #( / % &$'# * % its !* ! % &("!% -!* ) ( * % !%%&, *!, '(& )) * !* ! % &("!% -!* ) ( * % !%%&, *!, '(& )) * * !##!&% * $ % !& !!"'! & & #$" &% && $ "!&$" "( $ && $ "!&$" "( $ #"$&% %'$ % &" %'$ % &" $ % !& !!"'! & & #$" &% , #&'$ %* , #&'$ %* )*!$+# * #& # '(& +( $ %* % % *!&% # )*!$+# * #& # '(& +( $ %* % % *!&% # -!* -!* % !%, )*$ %* , #+ & % !%, )*$ %* , #+ & !##!&% "( $! "( $! !& % *% !& % *% its personnel were able to extinguish a fi re at an adjacent process is unresolved. & !( $"! & !( $"! !& & $ * ! ! '%&$* !& & $ * ! ! '%&$* &( * &( * '# )*! ) !% +)*(/ % - '# )*! ) !% +)*(/ % - &' &' ")% "$ & % # $ & "! " & "! ! ")% "$ & % # $ & "! " & "! ! % '(& + *) -!* % '(& + *) -!* ( / # &%* %* ( / # &%* %* )*!$+# * #& # '(& +( $ %* % % *!&% # )*!$+# * #& # '(& +( $ %* % % *!&% # -!* -!* % !%, )*$ %* , #+ & % !%, )*$ %* , #+ & !##!&% !##!&% - ! ! !%& &'& "!% & - ! ! !%& &'& "!% & "( $! "( $! !& % *% !& % *% !%!*! *!, *& +/ #& ##/ '(& + '(& + *) !%!*! *!, *& +/ #& ##/ '(& + '(& + *) , #( / % &$'# * % , #( / % &$'# * % #$" &% )"$& '%& "( $ "! $ #$" &% )"$& '%& "( $ "! $ , '(& )) * , *!, '(& )) * * ) '! & ' % ) $ &$ &* * ) '! & ' % ) $ &$ &* business premises shortly thereafter. Delays encountered In the meantime, however, management at , #( / % &$'# * % Atlantic Plastic 1 - * (! & ) % ) *& 1 - * (! & ) % ) *& !% !$'# $ %* *!&% ' ) * ) * * -!## ) * -!## ) ) & $ & ! $ %&$' &'$ ! $" % ) & $ & ! $ %&$' &'$ ! $" % !%!*! *!, *& +/ #& ##/ '(& + '(& + *) !%!*! *!, *& +/ #& ##/ '(& + '(& + *) , #( / % &$'# * % !* ) ( * % !%%&, *!, '(& )) * !* ) ( * % !%%&, *!, '(& )) * * * !% !$'# $ %* *!&% ' % '(& + *) -!* % '(& + *) -!* ( / # &%* %* ( / # &%* %* #$" &% )"$& '%& "( $ "! $ #$" &% )"$& '%& "( $ "! $ &$ &* $ &$ &* ! $") & ! $") & ! "$ " ) %& , ! "$ " ) %& , * * * * * * * !#) -!## ( # ) !% * * !#) -!## ( # ) !% * '(& ))!% & ( / # # $ * (! #) (&$ '(& ))!% & ( / # # $ * (! #) (&$ after summoning fi , #&' *& * ** ( &%*(&# &, ( * re , #&' *& * ** ( &%*(&# &, ( * fi % '(& + *) -!* ghters – of sometimes even only Recycling, where the incident took place% -#/ +!#* *&(! ) * in% -#/ +!#* *&(! ) * May 2019, have * $ %+ *+( a * $ %+ *+( 1 ) '! & ' % ) $ &$ &* #* !% !$'# $ %* *!&% ' 1 &+ #* !% !$'# $ %* *!&% ' &+ #!**# !% &($ *!&% !) , !# # #!**# !% &($ *!&% !) , !# # % '(& + *) -!* ( / # &%* %* ( / # &%* %* #$" &% )"$& '%& "( $ "! $ 1 - * (! & ) % ) *& 1 - * (! & ) % ) *& ) * ) * * -!## ) * -!## ) #$" &% )"$& '%& "( $ "! $ &'$ ! $" % ! $" % ) '! & ' % ) $ &$ &* few minutes, and potentially considerably more – can be the had to move ahead in order to recover from the setback, #$" ' &% " ! !&" "'& $ ! ! !&" "'& $ ! %!% !$'# $ %* *!&% ' $&# "! % $% #") $ % &*$ % %!% !$'# $ %* *!&% ' $&# "! % $% #") $ % &*$ % "$ #' "!%' "$ #' "!%' #& "! ) $ "# ! & & #& "! ) $ "# ! & & ! " ! " % ( +*+( * % ( +*+( * * -!## ))!)* !% (&-!% * -!## ))!)* !% (&-!% * ) * % -#/ +!#* *&(! ) * ) &+) &+) &# ) &# ) !) -!## & #&% - / !) -!## & #&% - / 1 - * (! & ) % ) *& 1 - * (! & ) % ) *& ) * ) * * -!## ) * -!## ) #$" ' &% " ) & $ & ! $ %&$' &'$ ! $" % ) & $ & ! $ %&$' &'$ ! $" % , #&' *& * ** ( &%*(&# &, ( * , #&' *& * ** ( &%*(&# &, ( * % -#/ +!#* *&(! ) * * $ %+ *+( * $ %+ *+( *!&% !) , !# # $ *!&% !) , !# #

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Classifieds Feb/Mar'2021.indd 80 Meraxis '0622.indd 11

!' &'$ $% , + '(& + *) (& + '(& + *) !' &'$ $% , JUN / JUL 2022 11 %& % % ! (" & ! "$ %& % % ! (" & ! "$ ) $ ) && $ "!&$" "( $ && $ "!&$" "( $ #"$&% #"$&% %'$ % &" %'$ % &" & & #$" &% & #$" &% )*!$+# * #& # '(& +( $ %* % % *!&% # )*!$+# * #& # '(& +( $ %* % % *!&% # & !##!&% !##!&% !%!*! *!, *& +/ #& ##/ '(& + '(& + *) !%!*! *!, *& +/ #& ##/ '(& + '(& + *) % * % % '(& + *) -!* % '(& + *) -!* ( / # &%* %* ( / # &%* %* "! $ "! $ Trade. Trade. Create. Create. Elevate. Elevate. > www.meraxis-group.com > www.meraxis-group.com 1 - * (! & ) % ) *& 1 - * (! & ) % ) *& * -!## ) * -!## ) te. vate. > www.meraxis-group.com > www.meraxis-group.com , #&' *& * ** ( &%*(&# &, ( * , #&' *& * ** ( &%*(&# &, ( * %+ *+( $ %+ *+( Trade. Trade. Create. Create. Elevate. Elevate. > www.meraxis-group.com > www.meraxis-group.com #$" ' &% " #$" ' &% " ! !&" "'& $ ! ! !&" "'& $ ! % &*$ % $ % &*$ % - ( #)& -&("!% &% )* ') * - ( #)& -&("!% &% )* ') * * -!## #!$!* * -!## #!$!* * !$'&(*!% & '# )*! - )* *& '(&* * * !$'&(*!% & '# )*! - )* *& '(&* * !% , #&' , #&' LLDPE & !( $"! & !( $"! !& & $ * ! ! '%&$* !& & $ * ! ! '%&$* - % - &' &' LDPE ! $") & ! $") & ! "$ " ) %& , ! "$ " ) %& , ) !% * !% * ! " ! " (&-!% !% (&-!%

2021/02/01 11:06 2021/02/01 11:06

2022/06/09 17:14

NEWS

Extrupet to double Phoenix food grade rPET capacity

Extrupet will double its food-grade operations by adding a fourth foodgrade recycled PET (rPET) facility, increasing its recycling capacity by an additional 33 000 tons per year

Africa’s only food-grade PET recycler will now reclaim and convert over 60 000 tons per year EXTRUPET is to double its food grade rPET operation’s capacity to over 60 000 tons per annum. Extrupet is one of the largest and most advanced recyclers of PET on the African continent. Since introducing its PhoenixPET® food-grade rPET, it has steadily expanded its recycling operations in South Africa. “Extrupet will double our foodgrade operations by adding a fourth foodgrade rPET facility, which will increase our recycling capacity by an additional 33 000 tons per year,” said

Chandru Wadhwani, joint managing director at Extrupet. “The demand for food-grade recycling keeps on increasing, especially as retailers and consumers alike opt for more environmentally friendly options. Currently, only 60% of South Africa’s PET bottles are recycled. With this increased capacity, we will be able to accommodate more of South Africa’s plastic waste and strengthen its position as a circular economy leader in Africa and the world,” said Wadhwani”. Phase 1 of the expansion is slated for

Cape Town and is expected to be fully operational in 2023. The development will cost approximately R300-million and will create additional jobs in the PET bottle collection industry. Extrupet currently recycles more than ﬁve million PET bottles every day. The rPET is sold under Extrupet’s brand name PhoenixPET®, which has received international acclaim and is certiﬁed by the European Food Safety Authority, Global Recycled Standard, BRC Packaging (AA rating) and ISO 9001:2015.

JUN / JUL 2022

New EPR legislation is a beneﬁt, not a burden – PET recycler explains AS companies navigate the new mandatory extended producer responsibility (EPR) landscape, Extrupet has revealed the unexpected ease in managing its new reporting and compliance requirements Vijay Naidu and as a producer, guided in its journey by Chandru Wadhwani, joint managing PETCO. directors at Extrupet. Describing the process of registering as a producer member of an experienced PRO like PETCO as “smooth and easy”, said Extrupet joint managing director, Chandru Wadhwani: “PETCO onboarded us seamlessly, guiding us through the process of setting and measuring targets, and making a potentially complex compliance process seem like plain sailing.” At the same time – and in a ﬁrst for South Africa – Extrupet is helping its long-time partner to develop an additional end-use market for recycled PET (rPET) in the manufacture of rPET industrial strapping. Plastic strapping is used extensively to secure unstable

goods during transit. From a circular economy perspective, both PET bottles and PET strapping can be diverted from landfill, and economically recovered and recycled into new products, without compromising the quality of the end product. Extrupet is currently the only strapping producer registered to meet its mandatory EPR obligations with the Department of Forestry, Fisheries and the Environment. “Many companies are still importing rPET strapping, so closing the loop locally provides another high-value end-use for rPET, aside from bottle-to-bottle recycling, or turning it into polyester staple fibre,” said Wadhwani. “In the past, plastic strapping has provided a viable end-use market for coloured rPET. As producers begin to move away from coloured to clear bottles for maximum recyclability, the clear bottles can now also serve as feedstock for strapping,” he said. Strapping falls into the PET flexibles category where legislated targets state that 50% of the product must comprise rPET, 10% must be collected, and 9% recycled. PETCO and Extrupet will be working together to achieve these mandated targets. www.extrupet.com

NEWS EXTRUPET-.indd 12

2022/06/09 17:15

extrupet

Doubling our contribution to a circular economy PhoenixPET® is expanding. “Extrupet is proud to announce that we will double our food-grade operations by adding a fourth food-grade recycled PET (rPET) facility, which will increase our recycling capacity by an additional 33,000 tons per year,” said Chandru Wadhwani, Joint Managing Director at Extrupet.

Protecting our environment one bottle at a time

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

Classifieds Jun/Jul'22.indd 72

2022/05/20 13:29

news

Event reconvened after 980 days

ARMSA gets Rotation show

14 JUNE / JULY 2022

ARMSA, the Association of Rotational Moulders of Southern Africa, celebrated its 30th anniversary recently in style when it managed to restart its programme after the pandemic interruption and again present its Rotation conference. The Rotation 2022 event, on 25/26 May, was held at Kloofzicht Lodge & Spa near the Cradle north-west of Joburg. It was 980 days since the last conference (the event is meant to be an annual affair) was held, said ARMSA chairman Gary Wiid, but besides the fact that so much had changed in the interim, most of the delegates looked, well, more or less the same. And for most, it was just satisfying to be involved once more.

Anton Hanekom of Plastics|SA with ARMSA chairman Gary Wiid. Anton gave a presentation about PSA’s initiatives and the state of the industry in SA; Gary did a good job organizing the conference at short notice. The ARMSA group only decided two months before the date to proceed with the event

“We are here to learn, network and grow our industry,” said Gary in a short opening address, the latter being one of the objectives which many in the wider industry sometimes forget. Gary, of Pioneer Plastics of Rosslyn, has taken over as chairman from brother Wayne, who is now chairman of ARMO, the global roto group. Roto is suited, as you know, to the production of large containers which would be impossible or extremely expensive

if blow or injection moulding were used. It is also unique in the industry in the sense that its technology is still evolving, certainly more so than with the other processing technologies, and discussions on how to produce containers and mouldings faster and more cost-effectively is the order of the day. Roto moulding varies from very basic solutions, where the entry level cost is low, to the hightech where automated solutions with

Accurate measurement and control of power useage is vital to survival in this sector

Judgement day – The judges of the Sasol Student Design Competition at Rotation 2022, all international, included Dr Gareth McDowell of 493K, a roto research consultancy in Northern Ireland; Konstantia Asteriadou of Lysis Technologies of England, a manufacturer of printing inks and graphics for plastics; and machine builder Dhanu Patell of Rheinhardt Roto Machines of India. All three also gave presentations

on the road again Most roto moulders in SA use gas for heating (some even use coal) and Dhanu Patell of machine maker Reinhardt of India pointed out that electrical heating of moulds is more efficient, but costs considerably more too. Auction for rhino conservation raises quite a bit It was Shenton Botes of BTCap who stepped into the shoes of the redoubtable Rod Cairns as auctioneer extraordinaire at this year’s Rotation event. Each year ARMSA identifies a worthy charity and raises funds accordingly through the auction format.

Cairns, of JoJo, who had done a great job but recently opted to pursue other interests, managed to extort large sums from unsuspecting delegates, and besides that he had the worrying habit of fining individuals for the flimsiest of trumped-up ‘offences’. So we all thought things would be far easier with Shenton. Haha, no such luck. He stepped into the role with ease and delegates were very soon disabused of that. In the end, R76,300 was raised for Rhino Sanctuary, for a cause that is close to the hearts of many. Well done to Shenton, and also to the bidding delegates.

The band Baardman pumped out quite a sound at the Rotation 2022 dinner, which was impressive as they only heard they were playing at 2pm on the day (the booked band got the days wrong and were planning to be there the night after)

Gary Lategan of Roto Solutions gave a presentation, during which he mistakenly imparted some of his ‘trade secrets’, here with Grant Neser of JoJo and Dhanu Patell of Reinhardt India

Ways to reduce power cost – Reinhardt Roto Machines is producing 700kW from the solar system at its plant in Valodara, India. Set-up cost is substantial, but once amortised, the yield from the installation is an attractive part of the power supply needed to produce its machines

JUNE / JULY 2022 15

enhanced controls, particularly as regards temperature measurement, offer faster production and better control of important items such as wall thickness. Consistency in the latter respect is difficult to achieve. One of the guest international speakers, Gareth McDowell of 493K of Northern Ireland, a consultancy focussed on the rote sector, pointed out that roto moulding uses more energy, mainly for heating, than the other processes. He proposed methods for monitoring energy use, failure to do so can be expensive and wasteful, so accurate measurement and control of power useage is vital to survival in this sector.

news

Tonnage consumption for roto sector declined slightly over last year

16 JUNE / JULY 2022

Market flattened off towards end of 2021, after spike in second half of 2020 TONNAGE consumption in the roto moulding sector declined in the year to end-February, from 43,500 tons for the previous period (1 March 2020 to 28 February 2021) to 40,360 tons for the current period, a decline of 6,7%. That is almost certainly a result of reduced demand for water tanks, which is by far the biggest tonnage sector in the roto market in southern Africa. It’s uncertain whether the decline was due to tank sales being lost to the blow moulding sector or other factors (see next article). There had been a spike in tank sales in the second half of 2020, when many homeowners were at home because of Covid restrictions and many decided to purchase tanks. Consumption for the most recent period was nonetheless higher than 2020, which suggests that had the ’21 spike not occurred, there would have been a steady, gradual increase in any event. But, given the slowdown in business due to the Covid effect on supply chains and economic downturns all over the world, not to speak of habit adjustments by people, as well as other factors, some

may even conclude that the result was not bad. In South Africa, however, we have come to believe that growth in demand for water tanks is impervious to the economic situation. It should be (as supply of water in the region is becoming increasingly unpredicatable), but we now see that it isn’t. The stats were produced again this year by Clive Robertson of ACD RotoFlo and presented at the Rotation ’22 conference. The figures are for the entire southern African region (including Namibia, Botswana, Zimbabwe, Zambia, Malawi and Mozambique). Drops have previously been encountered in the roto market, none more dramatically than 2019, when consumption fell by an estimated 12,000 tons. That however had been expected as the year prior to that had seen a huge increase in tank demand in the Western Cape when the province was poised to run out of water. But, after rain fell, demand evaporated, literally. Demand had increased in 2018 by a substantial amout – 10,500 tons – to 47,000 tons (highest ever for the roto sector) but then fell by an even bigger measure the following year, down 25,5%, to a level even lower than 2017. Yet exceptional growth of 16,5% took place in 2021, in spite of the effects of the Covid pandemic lockdown. Tank manufacturers were classified as

essential services for the water provision services they render and optimism escalated when the national Minister of Water and Sanitation is said to have offered to buy all the tanks that would be manufactured that year, as a gesture to support the population and creating widespread enthusiasm in the tank sector. Unsurprisingly, this didn’t happen, and her offer was not even made on 1 April. Then, according to the statistician Robertson, the market flattened off in the second half of 2021, leading to a -7,2% decline to endFebruary this year. One of the factors for this slowdown was the steep increase in polymer prices, as well as tight availability, said Clive. He estimates that material prices increased by 77% during the period, which was challenging for all involved. The fact that shipping costs went from $90 to $600 a ton presented massive difficulties to manufacturers. A further factor which may have reduced tank demand, and thus sector consumption, was the penetration of blow moulded water tanks into the South African market, estimated currently at 200 tons a month. “But at the same time a number of new tank producers have appeared on the market over the past three to four years, all seemingly with low overheads (entry to market for roto moulding is lower than for the other processing technologies), and these manufacturers have been offering tanks at ridiclulously low prices to buy market penetration,” said Roberton. “The combined effect of the increased availability of blow moulded tanks as well as of roto moulded tanks from the new smaller roto manufacturers around the country have almost certainly dented

A number of new tank producers have appeared on the market over the past 3 to 4 years

Clive Robertson of ACD Rotoflo, here with ACD general manager Brian Robertson, presented the roto sector material consumption figures for the past year, as he has done over an extended period

ACD

50000

YEAR

TONNAGE

45000

2012

28,180

40000

2013

31,100

10,36%

35000

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32,400

4,2%

30000

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30,500

-6%

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35,500

16,4%

2017

36,500

2,8%

2018

47,000

28,7%

2019

35,000

-25,53%

2020

37,350

6,7%

2021

43,500

16,5%

2022

40,360

-7,2%

Tonnes

25000 20000 15000 10000 5000

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The figure for material consumption in the roto sector in southern Africa reveals a decline for the year to endFebruary, to 40,360 tons from 43,500 for the previous year, and there is uncertainty as to why that occurred

There was a decline in material consumption over the past year, but the stats also reveal that the total usage figure was above that of 2020, meaning an overall increase

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JUNE / JULY 2022 17

the markets of the traditional suppliers,” he added. (It’s unlikely that the blow moulded tanks would have effected demand for tanks in the neighbouring states as freight costs for the blown tanks over the longer distances to those markets are likely to push selling costs up substantially, a factor in favour of regional roto tank production).

2010

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Agents for:

Mold In Graphic Systems® www.moldingraphics.com

LaPlastecnica

2019/10/01 09:23

news

Price war in roto vs blow moulding water tank market 18 JUNE / JULY 2022

Both sides have advantages and disadvantages A PRICE WAR has broken out in the water tank market, but this time it’s not between the roto tank manufacturers, it’s the roto manufacturers versus the blow moulded tank manufacturer. It sounds like many against one, but the one, tank blow moulder Africa Tanks, is capable of considerably more output than any of the roto manufacturers – and even collectively, the roto manufacturers are still facing a tough battle. The battleground is the market for

water tanks and initial salvos were fired at the point Africa Tanks entered the market in 2017. An estimated R36-million undertaking, Cullinan-based Africa Tanks commissioned a Yankang machine from China, possibly the largest blow moulding machine in South Africa, along with moulds from the same manufacturer for different tank sizes – including 5000, 4000, 2500 and 1600-litres. Its HDPE tanks, which use a 3-layer structure, began entering the market in Gauteng

from that point, although it took time for the venture to gain traction. The men behind the project, Hannes Geldenhuys and Frik Mulder, had started considering the blow moulding option when they concluded that roto tank manufacturers could not supply enough tanks for one of SA’s leading hardware store chains. They traced the technology in China, and during the course of their survey noted that blow moulding of large tanks was common there, and was apparently in the developed nations too, so in some ways it was inevitable that the technology would reach Africa. These gentlemen exited the scene just three years later when Africa Tanks was purchased by Forbes Capital in 2020, with the venture’s stated strategy at that point being to focus on the northern and eastern regions of South Africa (within a radius of 500km of Cullinan, just east of Pretoria), since transport costs become prohibitive beyond that. Africa Tanks has since installed a second Yankang machine, this time in KZN, possibly towards the end of 2021. It is understood that the Cullinan machine is being used for 5000-litre sizes and the KZN unit for the 2500 size, which suggests it has rationalised its product range. Although 2020 was a good year for the rotational moulding sector, with growth in material consumption of 16,5% recorded, it was in 2021 that the sector began to note a slowdown. Material usage reduced, although it was still higher than for the 2020 period, and a Produces 2500-litre tank in seven minutes; 5000 in just 10 – The Yankang machine at Cullinan has been in production since late 2017, now a second machine has been commissioned at Africa Tanks in KZN

Roto moulded tanks, as this tank from JoJo exemplifies, are noticeably different to the blow moulded option, specifically in terms of surface finish and design. The roto tanks are rugged and have to date met consumer demand in both rural and urban applications

number of the roto tank manufacturers began to observe that the blow moulded option was cutting into their market. But uncertainty prevails, not least because the Covid pandemic has resulted in other noticeable market changes, due to factors such as material shortages accompanied by rocketing prices and significantly extended shipping times coupled with almost crippling freight costs. A further factor which some have pointed out is that there have been several new entrants to the roto market away from the main centres in South Africa, as well as in the southern Africa region, who too have taken at least some market share from the established roto manufacturers, the latter including groups such as Eco Tanks, Rototank and market leader JoJo Tanks. Dhanu Patell of Reinhardt Roto Machines of India gave a presentation on the topic at the ARMSA Rotation 2022 conference during which he pointed out that both technologies had advantages. Plusses for roto include the fact that it can readily manage shorter runs (easier to change colours) and also that mould modifications (in the event of, for example, a need to fit inserts) are far more cost-effective. Advantages for blow moulding include that it can produce faster (for example, it can produce 2000-litre tanks at up to 10 tanks an hour) and its tanks are lighter (2000-litre tank weighs 28-30kgs of HDPE whereas the roto version comes in at about 35kgs of LLDPE), which is a cost advantage for blow.

The production of large water tanks, up to 5000 litres and bigger, by roto moulding does offer advantages for manufacturers, including the fact that moulds are a lot less expensive, as are mould modifications, and shorter runs are possible

A disadvantage for blow is that plant set-up cost is considerably higher. Establishment of the Cullinan plant was estimated at R36-million, which was then sold on just three years later for an eye-watering R47-million. Plant set-up for Africa Tanks in KZN would also have come with a hefty price tag, although we hear that Yankang had trimmed its price considerably (this was noted by a roto manufacturer who also costed out the blow moulding option). For Africa Tanks to justify its spend, it needs to get a large number of tanks out of its yards daily, wheras for the roto manufacturers the pace is a lot steadier. Ironically, Africa Tanks in KZN has employed an individual from the roto sector as part of its plant management, possibly yielding better understanding of roto technology. One of SA’s top roto moulders, who assessed the Yankang option, noted that even with the reduced price offered it would still not have been able to be costeffective In order to compete with blow moulded cycle times, roto moulders have the option to install more arms on their machines, with the arm and new mould being a relatively minor cost compared to that to build a large blow mould, added Patell.

New entrants to the roto market have also taken some market share

This 2500-litre African Tanks product has a high quality surface finish and attractive design

For now, it appears that the price was is at its height, with prices barely covering manufacturers’ input costs, and sometimes lower. It remains to be seen who will weather the storm. JUNE / JULY 2022 19

news

Exhibitors at Rotation ‘22

BTCAP, supplier of the Axel range of roto moulding release agents and mould maintenance products as well as prominent branded epoxy resins such as West System, Pro-Set and Entropy, exhibited at the conference. Shenton Botes of BTCAP was on hand to chat about his company’s products with André de Lange of Dream Weaver, a miller and compounder of materials for the roto and other converting sectors. Shenton was also the auctioneer tasked with raising funds from delegates this year, a role which he took to like a duck to water. www.btcap.co.za

Among recent developments by RotoQuip is this module with multiply threaded outlets to allow customers to test fittings in an easier manner, something the company hopes will help it as it enters the North American tank component supply market

Roto Quip exhibited the range of fittings it manufactures for the roto sector, specifically for roto moulded tanks, including water, fuel, chemical, waste water and other applications, all of which require precision to ensure effective sealing and/or conveyance. Gary Burchell of the Springs-based manufacturer showed off some of its latest products, which are injection moulded. Roto Quip has recently also commissioned a tool making and development centre at Wilderness in the southern Cape

Madi buys Pennells MADI Tanks has bought the assets of Pennells Tanks in Louis Trichardt. Maarten Venter of Madi confirmed that it had bought the machines but not the property. The machines have since been moved to other premises in the town. Established in 1974, Pennells was 20 JUNE / JULY 2022

one of the oldest roto moulding business in South Africa, and to an extent had dominance in Limpopo province, where there were few competitors. The company had at various times been owned by Lomold group and, after the implosion of that business, was sold to

Yebo Tanks. The Pennells brothers, Gavin and Howard, had been planning to retire so the purchase by Madi has effectively created the opportunity for them to do so. The former owner of the machines is understood to be now operating internationally.

KONSTANTIA Asteriadou of Lysis Technologies gave both a presentation and a demo at Rotation 2022. Most of the applications shown by her were of post-mould applications (printing directly on the PE part). Lysis also offers an in-mould spray coating solution for black on green moulding. Lysis’ revolutionary and label-free method for permanent marking and decoration of polyolefin products has become popular. These graphics, under the Tesoplas brand, are for products made by rotational, injection or blow moulding. “The Tesoplas range includes our in-mould graphics, on-mould graphics, in-mould spray ink, functional coatings, enhancers and many more,” said Konstantia. “We created the Tesoplas range in 2012 in order to serve the plastics manufacturing industry with innovative and yet multi-functional ideas and products. They are a result of hard R+D work and years of experience in the inks and coatings industry. Our product portfolio ranges from screen printing and pad printing inks to coatings that give special product attributes. Our enhancers product range includes heat accelerators and surface enhancers. “We also supply a surface perfector concentrate (similar to surface enhancer), which I believe is already very appealing to the African market due to its value and effectiveness,” she added.

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2022/06/07 09:15

news

Yet again, Pioneer wins

Product of Year Award Smart solution to transport used cooking oil for reprocessing as bio-diesel AN ENTRY from who else but Pioneer Plastics, the Reusable Oil Container (ROC) for transporting used cooking oil, took the ARMSA Product of the Year award. It’s the umpteenth time Rosslyn-based Pioneer has won the award, the ninth in a row in fact, and it’s almost as if the other roto manufacturers have given up or lost interest, or both. There were other entries, however, and with ingenious designs too which might have come up trumps anywhere else. Pioneer has got heavily involved in new product development and the company’s

Used cooking oil (UCO) into biodiesel – The gold prize this year, and winner of the ARMSA Product of the Year award, went to Pioneer Plastics for its ‘Reusable Oil Container’ (ROC), which is designed for the safe transport of used cooking oil. The product, for Neutral Fuels, makes use of seven Mold-in-Graphics decals and is moulded in PP, giving it enhanced high temperature tolerance and improved impact resistance; and (inset photo) an electronic level indicator (white component) was part of the original design all the orders so far been for the basic option without the level

22 JUNE / JULY 2022

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Silver for RotoTrainer from ACD – The RotoTrainer from ACD won the silver award. The show-jumping system was developed for the export market but Covid lockdowns and massive increases in shipping costs put a limitation on its European marketing efforts, leading to a local refocus and the RotoTrainer is currently becoming popular in the SA show jumping and coaching sector. They mouldings are lightweight, UV stable for over 10 years and available in a number of bright, eye-catching colours. CNC machining was used to produce the mould and they are safe to use in any equestrian training environment

The ‘Satchel Desk,’ also from Pioneer, took the bronze. This is, surprisingly after first observation, a backpack that doubles as a fold-out desk, talk about novel applications! The young pupil can thus arrive at class with both books plus his or her desk and chair. It is a novel item but the quality of moulding and surface finish are of a high standard. The project is part of the MiDesk Global initiative aimed at providing a service for an urgent need in Africa, where a staggering number of young pupils do not have desks at school, estimated at three million in South Africa and 95 million across the continent, the project team say. www.mideskglobal.com

strategy seems to be to take the risk, get the product to market and manufacture if it gains momentum. The fact that it designs and builds its own moulds in-house, for both steel and aluminum (the company has installed CNC systems for automated high-accuracy cutting), and has invested steadily in its toolroom is a big advantage, and allows it to keep costs in check. The Rockhot Oil Trolley, moulded in polyprop to handle potentially high temperature cooking oil as well as offering enhanced impact resistance, was developed for Neutral Fuels, which operates in Dubai, Abu Dhabi, Bahrain, India and South Africa. Disposal of cooking oil, and of any other oils, is a potentially hazardous operation that can contaminate soil or whatever medium it’s drained into. According to Pioneer technical manager Nick Swardt, yes, the item is moulded in polyprop at a nominal wall thickness of 8mm. “Even still, sometimes users do not follow instructions and throw in extremely hot oil (up to 120°C) and that is why the inlet was designed in such a way to accommodate a removable sleeve to disperse the heat. This sleeve is also roto moulded from PP. We use a 125mm screw cap from Roto Quip to seal the unit properly for transport purposes. The wheels are also rotomoulded, in LLDPE at 5mm wall thickness, and assembled onto the trolley with a 25mm stainless steel round bar,” added Nick. The mould in graphics were supplied by MIG.

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Dream Weaver Trading Customised Polymer Powders Our area of expertise is the pulverisation of polymer granules to powder for the plastic converting industry. Our areas of application include: • Supplier of polymer powders to the roto moulding, masterbatch and fluidised bed industries • Customised products and colours • Fast turnaround times • In-house QC facility to high standard compliance

www.dreamwt.co.za

Contact: Andre de Lange / Sales Manager Tel: +27 (0)72 737 1079 | Fax: +27 (0)86 533 5006 Email: andre@dreamwt.co.za Physical Address: Plot 199, Bashewa 1020, Pretoria-East Postal: Box 73419, Lynnwood Ridge 0040, Pretoria-East

Trading 355 (Pty) Ltd | Reg no: 2008/012707/07 | VAT no: 4790262036

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Plastinternational merges Jurgens plant

PLASTINTERNATIONAL of Joburg has over the last few months consolidated the plant it acquired when it purchased Jurgens Plastics, which it has owned 100% since 2018. “It was only in July 2021 that Plast restructured and started trading as a single company,” said Luca Ambrosi, MD of the Meadowdale injection moulding business. It now operates two sites in Meadowdale, spanning 3000m², including an upgraded, modern toolroom as well as state-of-theart, automated assembly facilities. Plast had bought into Jurgens Plastics in 2013 and moved the plant – including 11 machines and ancillary equipment – to Meadowdale at the end of 2017, but the converting operations were not merged until now. All the Jurgens staff had moved across too. Established in 1986, Plastinternational is custom injection moulding and assembly business which specialises in the production of valves, components and systems for the water reticulation sector, with the eezeFlow™ ball valves being among its best known products. www.plastinternational.co.za

Material being ﬂown in more often than before

QUITE a number of material suppliers have been obiligated to air freight material as a result of the extensive shipping freight delays, not to speak of the difficulty of getting material in the first place. For users of specialised material, including material compounded to specific requirements, the problem is even more pronounced, hence the need during the first half of this year to fly material in – at exhorbitant costs, but at least the supplier has the satisfaction that the customer has not been left disappointed.

Exceptional presentations Containers’ 2nd annual Insightful topics and future trends

explaining why “the world is changing MPACT Plastics Containers presented faster than you think”, giving delegates its second Smarter Sustainable much food for thought. Solutions Conference in May, an “In a fast-changing world, businesses event which – as its theme suggests – need to adapt quickly and ﬁnd out what focussed on smarter and sustainable is changing and how this effects the solutions for a range of industries – in company. Mpact Plastic Containers other words, solutions that give you offers smarter sustainable solutions in advantages. our three manufacturing facilities, and “We realized there was a gap in the one dedicated recycling factory. Last market for a platform where delegates year alone we recycled around 6 000 could network and discuss industry tons of plastic,” he said. trends. Mpact’s conference MPCSA was working closed this gap by creating ‘smarter’ by using technology a space where thought‘What are that enabled provoking ideas from you doing that partners savings for the company. different industries are will put you “If you want to be best in heard,” said MPCSA class, you have to invest marketing manager ahead of your in the best technology,” he Kammy Govender. competition?’ added. Delegates across a It is also adding features range of industries around that offer further added-value for South Africa gathered to learn customers, one of these being the more and discuss topics of relevance to active and passive ‘track and trace’ help move their businesses forward. capabilities that are used to collect MPCSA managing director Loutjie product data, allowing it to analyse de Jongh opened the conference by Mpact Plastic Containers fall into one of 5 basic categories: materials handling, environmental, jumbo bins, agriculture, and retail

JUN / JUL 2022

Banbury moves

“Moving forward” is what Ursula Webber calls it, MD of Banbury Colour & Dosing Solutions. The company has moved to another building on the same premises. The physical address stays the same (93 Springbok St, Randvaal). “Our new ofﬁce and warehouse has been speciﬁcally designed and built around our requirements. Our fully equipped Movacolor room will still see industry technicians and engineers enjoy the same technical training when needed,” Ursula adds. www.banbury.co.za

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MPCA’s multitank has a built-in pallet base for easy and safe handling, and can stack up to four at a time when full. It also has three different sizes of waterproof and airtight lids for easy ﬁlling and emptying of solids, liquids and pulp, and products preserved in liquid. It features a bottom discharge hole and a one-way valve to release internal gases, as well as an RFI tag and four label places

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at Mpact Plastic conference and better understand how customers use its crate and related products. An example of this is the live bird transport crates for the chicken industry with a reduced height that MPCSA manufactured so that they could be stacked ﬁve high, ultimately ensuring a saving for the customer. MPCSA’s latest offering is a small retail folding crate, which has excellent return logistics, is best-in-class and has a locking mechanism. The folding technology used in these crates is being explored for further applications. The company is also currently building an automated warehouse to carry over 11 000 pallets in what is an investment of over R100 million. “What are you doing that will put you ahead of your competition?” asked Loutjie. • De Jongh’s presentation can be viewed on YouTube at https://www.youtube.com/watch?v=RpPSaFHc6II Hybrid event delivers industry expert advice The hybrid event gave attendees the opportunity to view the world through the eyes of industry experts, as they presented insightful topics and future trends. Presentations on the ﬁrst day included insightful talks on a myriad subjects, including the economic outlook by

Iain Mcintosh, trade manager at Ocean Network Express South Africa, and Loutjie de Jongh, MD of Mpact Plastic Containers with MPCSA’s latest offering, a folding crate for retail which has excellent return logistics and has a locking mechanism

economist Dr Roelof Botha, who looked particularly at interest rates (a topic which of much concern to all businesses, let alone ordinary citizens); worldwide shipping trends, logistics and the impact on fresh produce (Iain Mcintosh, trade manager at Ocean Network Express), future food trends and climate change (Doris Viljoen, director of future studies at the international research facility at USB); recycling and sustainability (John Hunt, MD at Mpact Recycling), and everything about pallet pooling (Gavin Keen, strategy, market & product development at GLS Supply Chain Equipment). The second day saw even more for delegates to digest; EPR and legislation (Valeska Cloete, technical & sustainability manager at Mpact Operations); the future of online shopping (Vusi Mthethwa, founder of Tetrad), organic waste, MRFs, and the future of waste management (Bertie Lourens, CEO of WastePlan); the future of supply chain and warehousing (Floris Visser, director at Relog and Gary Benatar, CEO of Relog); and worldwide polymer trends (Nico van Niekerk, CEO of Safripol).

Nico van Niekerk, CEO of Safripol, reported on global polymer trends. He said HDPE demand growth is firmly above GDP in the medium term, while capacity growth is set to outpace demand growth in the next five years. Trends emerging include strong demand in 2020-2022, investment in Asia (China closing the gap on self-sufficiency with mega refinery-petrochemical complex). Global HDPE operating rates are under pressure, but with an improvement versus pre-pandemic levels. Integrated margins expected to be under pressure from 2024-2026, balancing the margins in the 2030s. On the PP front, he said global demand is firmly above GDP in the medium term, and with capacity outpacing the demand, global operating rates and margins are under pressure. The lower operating rate will also depress margins in the medium term, rebounding in the longer term.

The breakaway group that discussed recycling and the circular economy, included Danie Dreyer (Duco), Jaco Nel (divisional manager for agriculture at Mpact Plastic Containers), Annabe Pretorius (executive for technical operations at Plastics SA) and Walter Jordaan (founding member of Myplas)

Doris Viljoen, Director of Future Studies at the international research facility at USB, spoke about future food trends and climate change. She says that it is food systems that cause the greatest environmental damage. “The obstacle to overcoming this is good research that remains in pockets and silos, resulting in the inability to identify essential data from the massive pool of data collected.” JUN / JUL 2022 25

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Toyota plant still at standstill after KZN floods

PRODUCTION at Toyota’s plant in Prospecton, Durban, had not resumed at the end of May following the flooding that hit KZN in April. It is South Africa’s largest automotive plant and the standstill led to a 30% reduction in the country’s vehicle exports for May, showing what a large percentage of output is contributed by Toyota. The slowdown in production directly effected the large group of plastic automotive component manufacturers supplying the plant, most of them in Durban by many from further afield in SA too. Production at the Prospecton vehicle assembly plant was suspended in April, affecting supply of high-volume vehicles from Toyota, including the Hilux bakkie, HiAce taxi and Quest and Corolla sedans. The Hilux shortage, in particular, contributed to a 29.9% fall in SA vehicle exports in May. In March, before the floods, the company exported 6,837 vehicles, mainly Hiluxes. In April, this number was down to 3,629. In May, it was just 143. The result was an industry total of 25,788 exports – 29.9% down on the 36,798 of May 2021. The biggest drop, 58.9%, was in light commercial vehicles, which include Hilux and HiAce. After five months of 2022, aggregate exports were 6.2% behind last year at 143,348. Toyota retained market leadership in May by importing more vehicles to take up some slack – though its 6,664 sales were well short of April’s 8,952. At the end of May, the aggregate 2022 new vehicle market stood at 212,537, which was 12.2% ahead of last year.

Delegates were also given the opportunity to discuss in-depth industry perspectives in breakaway rooms. The break-away sessions were well received by all, and many appreciated that they were able to relate to others facing the same challenges. For some delegates, MPCSA’s export jumbo bin was on display, holding bags of apples this was their first for delegates to take home. The jumbo bin features easy, clear MPCSA conference and ownership identification with hot foil stamping, built-in handholds and have a positive interlocking foot design that permits fast and the feedback received safe stacking was positive. Networking opportunities and invaluable insights are always appreciated. And not to be outdone, the evening’s entertainment was a ‘murder mystery’ that included some great prizes for winners. To end the evening, delegates enjoyed live entertainment by an internationally renowned quartet, Sterling EQ. As we continue to move forward into the ‘new normal,’ this year’s MPCSA conference proved to be bigger and better than the last. Expectations for the next conference are even higher and Mpact Plastic Containers has no doubt that it will deliver! These presentations can be viewed on YouTube: Dr Roelof Botha https://www.youtube.com/watch?v=lkPGeqvfr1E Iain Mcintosh https://www.youtube.com/watch?v=SDNeiy9rpME Doris Viljoen https://www.youtube.com/watch?v=m-y47YFbb7E John Hunt https://www.youtube.com/watch?v=paCDpc77vkA Gavin Keen https://www.youtube.com/watch?v=Z0l9dR6EHuM Valeska Cloete https://www.youtube.com/watch?v=XsNmPeQrxSI Floris Visser and Gary Benatar https://www.youtube.com/watch?v=KBsHwkVHUy8 Nico van Niekerk https://www.youtube.com/watch?v=bTQR75ImYXg

• • • • • • • •

Winners at the murder mystery were Colyn Wilkins, Zane Sias, Siphelele Zungu, Portia Gulube, Iain Mcintosh, Mamela Luthuli, and Vuyisa Malie

Delegates really got into the swing of things at the murder mystery

Murder mystery ‘policeman’ checks on delegates

Welcoming guests to the conference at registration were, from left: Vuyisa Malie, Siphelele Zungu, Tshegofatso Marobela and Kammy Govender (marketing manager, Mpact Plastic Containers) 26 JUN / JUL 2022

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DESIGN

Worldwide shipping trends Speaking at the conference about worldwide shipping trends, logistics and the impact on fresh produce, Iain Mcintosh, trade manager at Ocean Network Express, said that port disruption around the world continued with supply chains still tight. Ongoing shocks continue to disrupt the shipping trade; Russia/ Ukraine conﬂict, China’s Covid spikes, general labour shortages in the east-west corridor, and container shortages due to delays. In 2021, 2.5-3 million TEUs were locked in delays, and in 2022 still over 2 million TEUs locked down. (One 20-foot container equals one TEU). www.mpcsa.co.za JUN / JUL 2022 27

40 years experience JUN / JUL 2022

Plastic Conversion Equipment is now supplying injection moulding machines from NPC of Ningbo City, China, a centre where many of the top Chinese plastics machinery producers are clustered. Although production of its machines was only commenced in 2009, NPC has attracted several experienced individuals and, if anything, its entrance to the market was well timed as regards integration of electronic controls through its JLINK system as well as the extensive use of servo motors. Watch this space for news of installations!

We supply converting equipment nationally. Our chief technician, Mark Varrie, qualiﬁed as a toolmaker in 1982, whereafter he trained at machine manufacturers in Europe, China and Taiwan. Mark is an expert at machine diagnostics and machine problem-solving. We oﬀer complete and guaranteed machine commissioning and service back-up services. We represent GENOX shredders; Kai-Mei blow moulding machines; M-box monitoring systems; mouldmaker Sinomould and Techmation control systems plus a range of related ancillary equipment

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031 701 2169 078 231 7486 sharon@pcesa.com www.pcesa.com

2022/06/10 11:06

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SAVA launches ‘Green Tick’ SAVA – the non-profit association representing the local vinyls industry – celebrated World Environment Day by awarding certificates of compliance and its new “Green Tick” product label to fourteen members who successfully completed and submitted their annual Product Stewardship Commitment Survey for 2022. In response to member and market feedback requesting a product label that is easier to understand and use than the ‘Vinyl dot’ (Vinyl.), SAVA announced that it changed its old Vinyl-dot product label to a new ‘Green Tick’. This new product label was also officially launched and awarded to members during the virtual meeting. “There are a myriad of positive ideas and messages that are associated with green ticks. In general terms, it is used to communicate that a task has been successfully completed, that you’re dealing with a legitimate business or that you have passed a test and received high accolades. In SAVA’s context, we want this ‘all is good’ symbol to also communicate to end markets the message of sustainability, certification of goods and services based on an independent, full life cycle assessment of conventionally produced goods from ‘cradle to grave,” explained Monique Holtzhausen, CEO.

SAVA takes up Proudly South African membership

THE Southern African Vinyls Association has taken up membership with the country’s official ‘buy local’ campaign, Proudly South African. Explaining the reason for the move, Monique Holtzhausen, CEO of SAVA says South Africa has a dynamic and burgeoning vinyls manufacturing sector that stands to benefit from displaying the Proudly South Africa logo as a recognised endorsement of local content and quality. It makes business sense for us as a company to be affiliated with the country’s ‘buy local’ movement. Proudly SA is a membership-based organisation, and only companies that have been audited and approved are entitled to carry the logo, which symbolises the adherence of that product or service to required local-content thresholds and quality standards.

Minister Creecy applauds Tubs2Classrooms project Danone’s Tubs2Classrooms project with partners Pick ‘n Pay and Interwaste WHO would have imagined that a small yoghurt tub could be converted to a strong light-weight brick to make insulated classrooms? Danone NutriDay did. This follows on from their successful year-long project in 2021 when 19 tons of plastic from yoghurt containers were transformed into making sturdy school desks. Now, from their One Desk, One Child programme, Nutriday embarks on their Tubs2Classrooms project with partners Pick ‘n Pay and Interwaste. NutriDay will set out to educate

Dow leads way to more Plant-based high performing polyolefin elastomers DOW has launched a new range of high-performing polyolefin elastomers (POEs) for the footwear industry. ENGAGE™ REN is an innovative and more sustainable brand extension to the ENGAGE™ range of POEs. The new brand is enabled by Dow’s Ecolibrium technology and will help the footwear industry to unlock a lower carbon footprint and develop more sustainable products which offer the same highperformance results. Some of the key benefits that ENGAGE™ REN will offer manufacturers in the footwear industry include: • Improved foam quality and polymer consistency • Better resilience • Lighter foams with equivalent hardness • Improved abrasion resistance and durability.

Crocs is the first footwear brand to go-to-market with this new material technology

When used alongside other recycled materials, brands will be able to offer a more complete sustainable footwear option to their customers. Soon, these products will be available to sustainability-conscious consumers thanks to Dow’s collaboration with global innovative footwear brand, Crocs. Dow has begun supplying plant-based polymers for use in Crocs’ manufacturing process of its proprietary Croslite™ material, which have an even lower CO2 impact than their current material. The company will take a mass balance approach to scaling the percentage of plant-based polymers into its footwear over time. 28

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80 identiﬁed primary schools about responsible plastic recycling. Children will be encouraged to clean and bring their used yoghurt tubs to school. These tubs will be turned into light-weight bricks to build two classrooms by the end of 2022. “What better way to prove that waste has value, than to convert used yoghurt tubs into bricks to build much-needed classrooms for our communities,” says Minister Barbara Creecy, South Africa’s Minister of Forestry, Fisheries and the Environment.

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NutriDay will set out to educate 80 identiﬁed primary schools about responsible plastic recycling. Children will be encouraged to clean and bring their used yoghurt tubs to school. These tubs will be turned into light-weight bricks to build two classrooms by the end of 2022

“The achievement of a circular economy is directly reliant on the collaboration between the government and the private sector. The DFFE would like to extend its support and appreciation for the waste beneﬁciation efforts made by Danone in collaboration with its partners. Spurred on by the new regulations, companies are committed to designing packaging for recyclability and encouraging recycling,” she adds. “Our project is geared towards doing just this, and we welcome the

Extended Producer Responsibility (EPR) regulations which aim to protect the planet’s resources. As a company that has made a commitment of zero waste to landﬁll by 2030 and 100% recyclable packaging by 2025, our Tubs2Classrooms project addresses responsible end of life usage of yoghurt tubs, delivering on our promise to protect the planet,” says Leanne Kiezer, corporate affairs manager at Danone Southern Africa. “Danone is a purposeful business

driving change for the health of people and the health of the planet. Our Tubs2Classrooms project aims to collect and repurpose close to half a million tubs this year, which is ﬁve times more than that of the previous campaign,” says Kiezer. “At Danone we believe that healthy food needs a healthy planet. Therefore, Nutriday, our ﬂagship brand boasting its best recipe yet (with essential vitamins A, B, D, E and zinc), is leading this Tubs2Classrooms initiative.”

sustainable footwear with ENGAGE™ REN Crocs is the ﬁrst footwear brand to go-to-market with this new material technology. Sustainably sourced bio-feedstock ENGAGE™ REN polyoleﬁn elastomers are produced using renewable energy and plant-based feedstocks such as used cooking oil. As only waste residues or by-products from an alternative production process are utilized, these raw feedstock materials don’t consume extra land resources nor compete with the food chain.

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ENGAGE™ REN plant-based polymers deliver equivalent performance in the ﬁnal application as fossil-fuel counterparts and therefore don’t require reformulation. “Manufacturers, brands, retailers and consumers all recognize the role they play in reducing the impact of climate change and as a result, are seeking out more sustainable options,” said Imran Munshi, Global Bio-Polymers and Consumer Market Manager at Dow. “Combining a lower carbon footprint and no compromise on performance, ENGAGE™ REN provides the footwear industry with an innovative solution that enhances the sustainability proﬁle of their products, while maintaining the same high-performance results they’ve come to expect from Dow. We are committed to enabling our customers to reduce their carbon impact and meet their sustainability targets and we are excited about how this innovation advances the market for more sustainable materials.” “As a leading materials science company, Dow continues to work towards transformational change with partners and policy makers to tackle the challenges of climate change. The introduction of ENGAGE™ REN highlights how Dow is supporting the markets we participate in, to reduce the carbon footprint and provide more sustainable, high-performing solutions to our customers,” added Munshi. www.dow.com

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Bandera celebrates

75 years

THE history of extrusion in Italy started with Luigi Bandera during the Second World War, with the manufacture of the first extruder: a 60mm screw for the extrusion of PVC pipes and profiles. An authentic, innovative idea for the time. In 1947, Luigi Bandera officially established the company, which quickly expanded, thus actively contributing to the plastics processing industry in Europe. In 1950, Costruzioni Meccaniche Luigi Bandera became a joint stock company. During the 1960s and 1970s, Bandera activities underwent remarkable expansion to reach an industrial scale production, offering a wide and diversified range of extrusion products, such as pipe extrusion lines, extrusion equipment profiles, sheet extrusion lines. Between 1980 and 1990, Costruzioni Meccaniche Luigi Bandera was acknowledged as one of the leading companies in blown film extrusion and sheet extrusion in Italy and worldwide. In 1998, Bandera received ISO 9001 Quality Certificate.

30 JUNE / JULY 2022

New R&D facilities In 2015 and 2016 was the opening of The House of Extrusion®, 3000 m2 housing R&D activities and wet tests on complete production lines. Thanks to that and to the recently renewed laboratory, EA – Extrusion Academy®, Bandera oversees the whole process: from research to industrial scale up. Costruzioni Meccaniche Luigi Bandera SpA is a worldwide leader in designing and manufacturing complete extrusion lines for packaging and converting. www.luigibandera.com

Revotech® by Bandera, a response to Circular Economy needs Italian extruder manufacturer develops twin-screw technology for recycling BANDERA has developed and finetuned a virtuous response to the Circular Economy with a 360-degree impact on the entire lifespan of polyolefins and PET, from the raw material to its processing into end-products, up to the recovery and transformation of post-consumer postindustrial recyclables into secondary raw material for extrusion, injection moulding and blow moulding. Among the existent systems for polyolefins – following the exclusive recycling/upcycling process by twin-screw technology which aims at obtaining ‘high added-value granules’ while minimizing residual odour and VOCs (volatile organic compounds) – a microwave-based technology is already available. Operating directly on the granule with no additives, it contributes to the removal of VOC residuals and odour in quick time. Odour removal is certainly a crucial aspect to promote a wider use of recycled plastics and can be particularly beneficial to the HDPE and PP market. Bandera exploits a microwave-based technology as the main vehicle to achieve an innovative extraction system able to reduce residual odours from different sources.

As prolonged treatment, extended times mean a reduction in productivity and energy efficiency, Bandera’s aim is to keep such time demands to a minimum to maximise profits, as regards customers’ success and the concept of Circular Economy demands in itself. The best way to deal with odour is to properly process post-industrial and post-consumer materials from the very beginning. The final objective is, ultimately, to obtain ‘premium’ secondary raw materials of a high quality from every point of view, which is what multinationals and retailers are asking for today. For this reason, traditional singlescrew extruder pelletizing, a favourite with converters until now, finds its natural evolution in Bandera’s HVTSE® technology: these are co-rotating twinscrew extrusion systems which feature high vacuum, minimum shear stress, larger surfaces for degassing and shorter residence times, thus offering enhanced process performance from the very beginning and ensuring the extrusion of high-quality materials also in terms of VOC and odour removal requirements. Moreover, the twin-screw technology,

Microwave-based technology operates directly on the granule with no additives, it contributes to the removal of VOC residuals and odour in quick time

Bandera is represented in South Africa by Mactec Machinery of Johannesburg.

thanks to the particular screw design developed by Bandera, offers several advantages, well beyond the high level of homogeneity (due to the excellent mixing performance), reduction in polymer degradation (minimum MFI loss, reduced shear stress and relevant crosslinking effect), controlled thermoregulation, dilution, integration of additives, minerals and fibres, which include the effective

Bandera’s HVTSE® technology: these are co-rotating twin-screw extrusion systems which feature high vacuum, minimum shear stress, larger surfaces for degassing and shorter residence times

removal of VOCs and odour (thanks to the exclusive degassing process). Twin-screw technology – including both cascade and single systems – developed by Bandera is in-tended for working post-consumer post-industrial polyolefins (HDPE, PP and LDPE also with barrier layers) as well as styrenic resins and polycarbonate. Bandera 360-degree Revotech® www.luigibandera.com

recycling technology can be either introduced gradually by manufacturers who can integrate it into their existing plants to improve performance or fully adopted for a complete revamp of their lines, with the possibility to validate results with materials supplied by customers using the industrial machinery available at THOE – The House of Extrusion – at Bandera, based at Busto Arsizio near Milan in Italy. JUNE / JULY 2022 31

MACTEC M a c h i n e r y

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Tantec surface treatment technologies for seamless plastic manufacturing processes

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GreenTech one of very few companies in the world offering all electrical surface treatment technologies GREENTECH Plastics Machinery, a South African market leader in the supply, installation and servicing of premium European-designed plastics machinery, offers a range of high quality Tantec surface treatment systems to customers across the Southern and East African regions. “As an end-to-end partner in plastic production processes, we support our injection moulding machines with bestin-class ancillary equipment to assist customers in significantly reducing time and material wastage,” says GreenTech business development manager, Martin Hollinger. “We are in fact one of very few companies in the world offering all electrical surface treatment technologies.” Danish-company, Tantec, is ISO 9001 and ISO 14001 accredited, and has more than 40 years’ experience as a leading manufacturer of quality, high-end surface treatment products for applications in automotive, pipe, medical/ life science, electronics and packaging. GreenTech supplies Tantec Plasma and Corona surface treatment systems as well as leak detection technology (LeakTEC) for the detection of a crack or pinhole in a plastic material. Innovative solutions to adhesion and wetting problems in many industries Hollinger explains that surface treatment with Tantec Plasma technology offers innovative solutions to adhesion and

wetting problems in many industries. According to Hollinger, PlasmaTEC-X and Vacuum Plasma are two popular products in the Tantec Plasma range from GreenTech. Tantec’s PlasmaTEC-X Atmospheric Plasma treatment system is built around the concept of a high voltage DC Plasma discharge in atmospheric air. The versatility of this unit allows for use in fully integrated robotic cells, as a standalone unit, and in virtually any production line. Tantec’s Vacuum Plasma range is designed for plasma treatment of a large number of different injection moulded parts. Available with both single and multiple tray configuration, this technology offers very fast treatment times and optimum adhesion properties for downstream coating, gluing, painting, and printing applications Optimises the adhesion properties on polymer-based materials Another surface modification technique, Tantec Corona treatment, optimises the adhesion properties on polymer-based materials, ensuring the bonding of the surface with printing inks, coatings and adhesives. To obtain optimum adhesion, it is essential that the substrate’s surface energy is equal to or higher than the surface energy of the material applied to it. Corona treatment is widely used as a successful surface treatment method in the plastic film, extrusion, automotive and medical industries.

Powerful electronic tool for non-destructive leak detection Tantec’s leak detection technology, LeakTec, is a powerful electronic tool for non-destructive leak detection of non-conductive single layer materials. This fully automatic test is capable of detecting pin holes even smaller than 3 microns by introducing an electrical potential between a detecting electrode and an electrical ground while the plastic part itself acts as the insulator. The LeakTEC measures a leak between a high-voltage electrode (DC) and counter electrode which can either be grounded or running opposed polarity. In the event of detecting a crack or pin hole in the plastic material, an electrical contact is established between electrode and ground. The LeakTEC ensures full process control and traceability and is typically used in field applications to surface test moulded and welded joints in medical devices like medical tubes, containers, pipettes, cannulas and extruded film for medical bags. “With a combined experience of 220 years in the industry, our highly skilled team of technicians deliver professional customer service, backed by our strategic network of offices in Gauteng (HO), Kwa-Zulu Natal, the Eastern and Western Cape as well as in Nairobi, Kenya,” concludes Hollinger. www.greentechmachinery.co.za

Mold-Masters introduces new SmartMOLD injection mould monitoring system. Real-time data driving injection moulding innovation.

PCT is new agent for Mold-Masters

Systems can be applied in applications in automotive, technical moulding & packaging areas

Feedback and insights that drive enhanced productivity Mold-Masters’ SmartMOLD is a cloudbased software platform dedicated to the

plastics industry providing real-time data to drive injection moulding innovation. Process data is collected from sensors embedded within the injection mould which offers feedback and insights that drive enhanced productivity. This solution is the first step towards predictive and autonomous capabilities within a facility. In addition to collecting sensor data, SmartMOLD software offers performance tracking, downtime tracking, scrap tracking, maintenance reminders, alerts, reporting, analytics, mould info, document storage and more. Although SmartMOLD is focused on the mould, it also has the potential to pull data from injection moulding machines. SmartMOLD is compatible with any brand of equipment. Mold-Masters is your most reliable IIoT partner that can offer local support on a global scale. Unlock your operation’s full potential with SmartMOLD. Real-time data is accessible 24/7 though the desktop online portal or on a mobile app. A major benefit of cloudbased systems is that they ensure you always have the latest version (no manual updates required) and do not require users to have their own IT team dedicated to support its functionality. SmartMOLD algorithms enables the

path to predictive and other powerful capabilities. SmartMOLD offers unlimited data storage. Data collected through SmartMOLD is displayed on an intuitive desktop and mobile interfaces. However, users also have the freedom to Pull data into existing ERP/MES systems through API’s. Additionally, data can be exported from the SmartMOLD system in various formats (Exel, csv, xml, net, etc). Flexible & economical Mold-Masters SmartMOLD is compatible with any brand of hot runner/mould. Users also have the option to use the SmartMOLD infrastructure to obtain data from their injection machines. Users can connect moulds only, injection machines only or connect everything. Users can scale the system to their facility and budget requirements and only pay for what is used. Server facilities operating in all major regions offers compliance with local data privacy laws and enhances data response times. SmartMOLD offers global installation and technical support. The agent for Mold-Masters in SA is Plastic & Chemical Trading

Side injection – The E-Multi all-electric servo driven auxiliary injection unit from Mold Masters is mounted on a mould, on any existing injection moulding machine, to allow for side injection. The system can thus be used on machines already use to enable new applications

www.plastrading.com

www.moldmasters.com

JUNE / JULY 2022 33

PLASTIC & Chemical Trading of Johannesburg has been appointed as the agent for Mold-Masters, a Canadianinternational group which manufactures plastic processing equipment and systems, specifically hot runners, temperature controllers and auxiliary injection and coinjection systems. According to Ben Cockram of P&CT, a number of Mold-Masters systems are already in operation in South Africa, in many cases on high-spec injection moulding machines in the automotive and packaging sectors where its technology is well-integrated. PCT aim to provide local service and support for all the Mold-Masters products and, since many of the users are familiar with its service team, he anticipates that the transition will go smoothly. Cockram says P&CT will focus on the E-Multi units and developing channels of cooperation on the hot-runners. “We aim to keep spares locally and ensure a smooth supply chain for companies wanting to use Mold-Masters hot-runners or for toolmakers who want an effective local hot-runner partner,” he adds. Cockram believes the Mold-Masters auxillary and co-injection technology could be applied in applications in the automotive, technical moulding and packaging areas where the units are fitted to existing machines to enable 2K or co-injection use.

NEWS

Douw Steyn of Plastics|SA was one of the delegates at the UN event in Dakar, Senegal, recently, along with Anne-Gaelle (PlasticsEurope), Delphine Garin (WBCSD), Stewart Harris (American Chemistry Council, ICCA), Christopher Olsen and Raelene Martin (both International Chamber of Commerce). They were welcomed at the airport by a protestor with a colourful disply and a ‘No to plastic bags’ sign

JUST BRIEFLY

World Plastics Council negotiating group holds ﬁrst meeting in Africa PLASTICS|SA sustainability manager Douw Steyn attended the ﬁrst meeting of the World Plastics Council’s intergovernmental negotiation committee in Dakar, Senegal, recently. Organised by the United Nations, the event was intended to start the process of coordinating better cooperation between African countries to help stymie the scourge of plastics marine litter. The gathering was funded by the UN and intended to encourage discussion between, in this case, countries in Africa, and to prepare for the intergovernmental negotiating committee (INC) on plastics pollution. Douw gave a presentation on the state of plastics in the environment to the delegates at the event from 30 May to 1 June at the King Fahd Palace, Dakar. The intention of the gathering was to build a broad instrument so “that we are not just tinkering around the edges of the problem of plastic pollution,” said Douw. The group aims to ensure close engagement and involvement of stakeholders; spur solutions for a new economy; and learn from other multi-lateral environmental agreements (MEA) and be willing to embrace new and bold innovations. 34

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Hyco expands assembly work, produces parts for renewable energy sectors Somerset East injection moulder partly fills gap left by departed multi-national THE departure of Wirquin from Somerset East in late 2021 left a gaping hole in the economy of the Eastern Cape town, a gap which local hydraulics and injection moulding company Hyco Enterprises has partly filled, in the process providing work for at least some of the 120-plus who lost their jobs as well as others new to the plastic moulding sector. Run by Yvonne Coetzee, Hyco has expanded its assembly business and is now employing 14 women in that area, the majority of who are single mothers, which has gone some way to improving the situation after Wirquin moved its plant to Uitenhage near Gqeberha in late 2021. The female workers are involved in assembly and packaging of the wide range of sanitary components manufactured by Wirquin. The parts are in fact shipped back to Somerset East from Despatch, and then returned packaged in bags, Hyco moulds components for various customers, including these seals for Wirquin. Besides that it is labelled and boxed. also producing mouldings for the solar and wind farm Yvonne had in 2002 sectors, in which respect Yvonne also oversees the qualified as a toolmaker, production of the tools

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www.hycoenterprises.co.za

Yvonne Coetzee, who qualiﬁed as a toolmaker in 2002 (one of the ﬁrst women in South Africa to do so), does the setting as well as the mould changes at Hyco Enterprises in Somerset East. The company uses two Weltec injection moulding machines, 100 and 160-ton units

engineering; welding/steel fabrication (speciﬁcally for metal bailers for local sheep farmers, where the wool needs to be compacted for transport); and injection moulding. The company initially did some moulding work for a solar energy business which set up a plant in the area. Yvonne later ran some moulds for Wirquin, so she is familiar with their standards and procedures, which could have been a factor in the awarding of the assembly contract to Hyco. The Hyco machines are now being fully utilized. Its closer cooperation with Wirquin has allowed it to expand is staff complement this year, and it is picking up some additional moulding contracts for components for the solar and wind farm sectors in the region.

JUN / JUL 2022

making her one of the first women to gain the qualification in South Africa, if not the first. Wirquin, a French company, manufactures bathroom and toilet systems, including flushing mechanisms, valves, cisterns and cistern kits and all related components. It set up its SA plant in Somerset East, some 180kms NE of Gqeberha (formerly Port Elizabeth), in 2007. Its exit from the village 15 years later was a major setback for Somerset East, but the situation has also created a springboard for Hyco. The company, established by Yvonne and her father Herman (who had worked in production at Wirquin originally), offered three main services, namely hydraulic systems

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NEWS HYCO-.indd 35

info@demaplastech.co.za

we know Granulators www.demaplastech.co.za

2022/06/10 11:14

NEWS

JUST BRIEFLY

Increase in GDP surprises THE release of South Africa’s GDP figures by StatsSA for the first quarter, on 7 June, took most in the industry by surprise. GDP increased by 1.9% year-on-year, with 60bps (basis points) of that coming from the manufacturing sector which grew by 4.9%. Within what is referred to as household consumption expenditure, transport was up 2.8%, food up 2.5%, restaurants up 6.5% and communication up 2.4%. Expenditure growth in other categories was negative, as consumers moved their spending into areas where we are all feeling the pinch. The growth in restaurant spending is driven by a Covid base effect (less activity in the period before). Exports of goods and services increased by 3.9%, but imports increased by more, at 4.9%. The exports number would’ve been influenced by negative growth in mining, due reportedly to production disruptions. Analyst InceConnect pointed out that mining contributes 2.7% of employment and 7.8% of nominal GDP, which is almost the direct opposite of construction, which contributes 7.2% of employment and only 2.5% of GDP. This talks directly to the economic attractiveness of the industries and their labour efficiencies, Ince said. So, from a manufacturer’s perspective (which is the case in the plastics, composites and rubber sectors), labour efficiency is a critical component.

Stellenbosch University novel method to Resolute in listening to what Polyco’s members need and want POLYMER scientists at Stellenbosch University have developed a novel method to break down lignin – a by-product in the paper manufacturing process – into valuable chemicals that can be used as raw materials in the chemical and polymer manufacturing industry. Lignin is one of the main components of trees and plants, but chemically it is extremely difficult to break down into simple molecules. Worldwide, the paper industry produces approximately 50 million tons of lignin per year as a byproduct. Even though it could be exploited to provide us with an alternative to fossil fuel-based polymers, most of it (98%) is simply burned to fuel the paper mills. Dr Ndumiso Sibanda, who developed the method as part of his doctoral thesis, says he is specifically interested in finding innovative and tailored scientific solutions to some of the more challenging questions facing the polymer, pharmaceutical and plastic industry. “My interest in biorefinery development was stimulated when I became part of Prof Harald Pasch’s research group in

Juan-Eric Davidtz of Igus South Africa

2017 as an MSc student. Bioreﬁnery methods are very valuable in our current society, where waste accumulation and resource depletion have negative social and environmental impacts,” he explains. Prof Pasch’s research group in SU’s Department of Chemistry and Polymer Science is regarded as one of the leading groups in this ﬁeld. Another expert in the group is Dr Helen Pfukwa, who has done extensive research on lignin valorization. On top of revalorising an agricultural waste product, this type of research opens the way for lessening our dependence on fossil fuels, by replacing fossil fuel-derived polymers with environmentally friendly bio-based polymers. Dr Sibanda says lignin has a very complex but versatile molecular structure, which makes it possible to synthesise new functional polymers that can be used as drug delivery vehicles, biomaterial synthesis and smart polymer synthesis. “Generally, polymers that have been synthesized from lignin-derived monomers and their derivatives have

Polymer linear “Gliding instead of rolling”

ADVANCED engineered-polymer manufacturer, Igus has launched a global drive to convert manufacturers requiring linear guides to new dry types with no requirement for lubricants, which have the potential to contaminate products and the environment. Ian Hewat, managing director of Igus SA, explains that linear guides are used in a variety of applications from robotics to CNC machine and 3D printers, to packaging equipment, printers and other machines that move on set axis. Until recently the biggest source of failure and premature maintenance has been friction related where the bearing meets 36

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polymer scientists develop break down lignin high glass transition temperatures (called Tg’s) and are thermally stable with good mechanical properties. This makes them appealing replacements for fossil-fuel derived styrene in the synthesis of high temperature-resistant plastics, advanced composites and resins.” The method has since been patented, and they are now working in collaboration with SU’s Department of Process Engineering to upscale the method: “We are currently at technological readiness level 5, which means we are working on an integrated approach to provide a bridge from laboratory testing and validation of the protocol to pilot testing in the factory.” How does the technology work? Lignin is a very complex macromolecule with a unique structure. The structure also differs depending on the origin of the wood and how it was pre-treated. Chemists use oxygen to break down these complex macromolecules (polymers) into smaller molecules (component monomers) in a process called depolymerisation. In the case

of lignin, however, most mild oxidative techniques do not lead to the complete conversion of lignin. Furthermore, if the process is not controlled effectively, over-oxidation may lead to structures that are even more complex than the starting lignin itself, Dr Sibanda explains. His method, which rests on the work done by Dr Pfukwa, addresses some of these challenges. While it still does not lead to complete conversion, it improves the process signiﬁcantly by preventing recombination reactions. In the case of lignin, he succeeded in converting the macromolecules to various useful chemicals, such as vanillin (the compound that gives vanilla its distinctive aroma) and syringaldehyde (an organic compound found in wood that can serve as a building block for functional polymeric materials. Syringaldehyde is also responsible for the spicy, smoky, hot and smoldering wood aromas in whisky). These chemicals have an aromatic functionality, which means they have what chemists call a benzene ring – the simplest, organic and aromatic

Stellenbosch University polymer scientist Dr Ndumiso Sibanda developed a novel method to break down waste lignin as part of his doctoral research

hydrocarbon and parent compound of numerous important aromatic compounds. Dr Sibanda says a green future for the chemical industry is possible: “We need policies that encourage the chemical and material manufacturing industries to include sustainable development in their long-terms plans. This will encourage industries to provide the same and sometimes even better quality products in a way that is environmentally sustainable. We also need more opportunities for collaborative research between industry and academia,” he concludes.

guides adopted worldwide the guide. Grease and oil to lubricate traditional bearings is also a major source of contamination in industry. The new dry linear guides have a surface that eliminates most of the friction and allows polymer linear bearings and pillow blocks to glide or ﬂoat across the surface without lubrication. The product range of lubrication-free drylin linear guides is based on the principle of “gliding instead of rolling”. “In combination with corrosion-free materials, tribo-optimised iglidur high performance polymers are used as a sliding surface. drylin linear guides traverse in dry operation and are thereby maintenance-free and are insensitive to inﬂuences such as dirt, water, chemicals, heat or impacts. “They also have very low noise because of the

materials used and the special design. With these properties, drylin linear guides can be used in a wide variety of environments, including extreme ones. The modular system allows for high ﬂexibility with different rail guides and pillow blocks,” says Igus product manager for bearings, Juan-Eric Davidtz. “Apart from improved reliability and extended maintenance requirements, other operational and productivity improvements are possible with the adoption of dry technology iglidur and drylin linear technology,” he adds. www.igus.co.za

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PEOPLE

Myplas’ John Nield marks 40yrs in recycling Sees quality of recycled materials improve continuously MILESTONES come and go and are often all but unnoticeable to anyone but those very closely connected, but one that could be of relevance to the entire industry – especially given that plastic recycling is now beginning to ‘come of age’ – is that of John Nield of Myplas, who is marking 40 years in recycling this June. Nield was better known in his earlier years as the co-founder of Polyoak group, which since he sold it in 1981 has gone on to great heights, and still does so as one of South Africa’s leading and most efficient packaging container manufacturers. Nield began recycling after that, once again back in his garage (admittedly a three-berth garage) where he had started Polyoak. That helped keep costs in check and a year later Nield formally established Proplas, which was set up as a recycler of factory scrap material, in Tokai. At the time plastic recycling was almost unheard of and few considered it to be regarded as a business at all. Proplas later moved to Elsies River as most of the convertors were in Cape Town’s northern suburbs, by which time Nield already knew he was in for the long ride as a recycler. As Proplas transitioned from being a reprocessor of factory scrap into a fully fledged recycler of post-consumer material too, the business began to develop its own market niche. A fundamental aspect of that switch was its ability to supply recycled material of a consistent quality to some of the Cape’s leading convertors, in many cases from the same businesses from which it had purchased the production scrap material. During this period Nield was at least partly responsible for some of the advances that have characterized the rollout of plastics recycling as a business segment in its own right in South Africa. Among these developments were the sponsoring of balers for collectors (a space-saving solution which makes their operations more practical); the acceptance of minimum loads of collected material (which eliminated casual or opportunist collectors); and payment by bank transfer as opposed to cash (collectors were becoming sitting ducks for hoods hanging out in the vicinity of the recycling plant). Proplas’ steady growth drew attention and led to its purchase by the erstwhile Lomold group in 2005, by which time it was processing approximately 230 tons a month, mainly of polypropylene but also of HDPE, LD and HIPS, and employing 35 people with nine granulators and three extruders. Proplas was fitted in with the various ventures of the Lomold group, which included a long-fibre injection moulding venture to produce pallets as well as a compounding business, all based at the Lomold ‘park’ in Bellville South where Proplas was relocated to. Proplas forged ahead in the ensuing years, with Nield even then as the elder statesman and chief problem solver. As in all manufacturing businesses, experience counts for a lot in

plastics recycling, not least because the quality of materials can vary considerably and changed process parameters can have significant impact on material performance. His main activity involved – and still does – patrolling the factory floor and assisting staff in improving flow and reducing bottlenecks and resolving production problems. But ructions lay ahead and the recycling business split, with the bulk of the business under the management of Johann Conradie and Walter Jordaan leaving and setting up as Myplas in nearby Stikland. Nield continued with Proplas at the Lomold premises, but the whole Lomold venture then came to a grinding halt in 2015 when its founder, Pieter du Toit, passed away suddenly. In the aftermath of this implosion, Myplas (aka Proplas, or at least the bulk of what Proplas was originally) was the only one of the Lomold group businesses which survived. It subsequently moved back to what was the Lomold premises (which space it now fully utilizes) in Fabriek Street, Bellville South, and Nield was reunited with the management team of Conradie and Jordaan. The years since have seen Myplas develop its market niche, plant throughput has increased considerably to an estimated 800 tons a month, making it one of the leading recyclers in the Cape, and employment has increased to 140. Myplas has also proved to be a home for several of the former Lomold staff, including a number of production managers, and Nield has been able to pass his expertise on to these individuals, which has yielded improved team work and overall business performance.

‘Proplas was also firstto-market on post consumer PP recycling in South Africa’

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Assured MFI rating “Proplas was also ﬁrst-to-market on post consumer PP recycling in South Africa under John’s leadership,” said Myplas MD Johann Conradie. One of the keys to Myplas’ success has been its lab, by now a fully equipped facility with its main contribution being that of viscosity tests. Although it reprocesses LD, the company’s core operation is the recycling of PP and HDPE, going chieﬂy into the injection moulding sector. Assured MFI rating is essential for these applications, and continuous MFI testing is thus vital to the integrity of the Mypolen® range of materials manufactured. “Clients send us spreadsheets of the criteria required for their materials and we match that, so they receive exactly what they require,” said Nield, who still manages some key accounts for Myplas. Given that he has achieved almost all he could expect from his four decades in plastic recycling, we asked Nield what lay ahead for him: “It’s been very satisfying to see Myplas grow as a business and become more professional, and

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Artic

Myplas has gone to great lengths to improve the quality of its Mypolen® materials. This white recyclate was achieved by careful sorting, not by the addition of white masterbatch

especially to see brand companies specify the use of recycled material in products which previously did not use recyclate. Working with the team here to achieve this objective is very rewarding, we believe that the ratios of recycled material can increase further, and that is why we are continuously trying to improve the quality and consistency of the materials we produce.”

John Nield’s main activity over the past few years has been patrolling the ﬂoor at Myplas in Bellville South, imparting the knowledge he has built up in the process of helping the business lift both throughput and quality consistency of the materials it produces

www.myplas.co.za

PEOPLE-.indd Article - Jan 2017 -39 SA Plastics Mag_FA.indd 1

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2022/06/10 11:19 2017/01/23 11:33:07

PEOPLE

Fine day for Plastomark ‘5th major’ WITH all the rain that’s resulted in one of the wettest summers on the Highveld in many years, there were some fears that poor weather could plague this year’s Plastomark Invitational, sometimes referred to as the ‘5th Major’, but any doubt was allayed as a ﬁne day dawned. The standard of golf was again good as several wellknown ﬁgures in the industry locally tried to get the upper hand on the layout at the River Club, which was again in

spectacular condition … so not a single contestant could blame the course in any way. And the dinner and hospitality at the clubhouse after the game was outstanding again as usual.

The winning team at the Plastomark Open in May included Andy Katzelberger (Demco), Darron Kensley (Mouldtech) and Sean Mcllwane (Karob), ﬂanked here by Plastomark CEO Wolfgang Raffalsky and Zelda Vikos

… and the individual winner on the day was David van Staden of Fiber Rooﬁng, a Johannesburg-based manufacturer of synthetic thatching products which has done particularly well on the Indian Ocean islands

Rob Lerena, wheelie bin pioneer in SA

Obituary

1944-2022 ROB Lerena of Otto Waste Systems fame recently passed away at the age of 78. Rob started his career in the marketing and sales of plastic components with Megapak. In 1983, together with the Otto group, he introduced the wheelie bin system into South Africa. An independent marketing and sales company, Otto Waste Systems was created and Rob was the operations manager. He promoted the waste collection system in South Africa and the company reached a dominating market share. After 1998 the production of the 40

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wheelie bins moved from Mega HiTec in Babelegi and the wheelie bins were produced in-house. Otto Waste Systems under the management of Rob as MD, expanded the range of products by winning the Heineken tender for crates. In the words of his close friend and colleague from Germany, Ulrich Beese, “Rob’s total business life was extraordinary.” Rob retired shortly after Otto Waste Systems was sold to Boitumelong Holdings. During Rob’s over 30-year association with Otto he was always

very loyal to the group and created extremely good relationships with a large range of customers in South Africa. He inﬂuenced the waste industry by implementing together, with the SABS, a very high quality product.

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Classifieds Jun/Jul'22.indd 72

2022/06/03 14:51

feature

Pipe stiffness must be adopted

as the unified classification of pipes

By MIKE SMART, PR. ENg., B.Sc. (HoNS) cIv. ENg., MSAIcE

UNITS of measurement are standardised – a metre is the same length globally – so why is pipe stiffness different? The stiffness classifications of thermoplastic pipes vary markedly: • Pipe Stiffness where -

SP = F / L – kN/m/m F = Deflection Force – kN L = Sample Length – m  = Deflection – m

• Ring Stiffness where -

SR = EI / D³ – kN/m/m E = Elastic Modulus – kN/m² I = Moment of Inertia – m  D = Diameter – m

42 JUNE / JULY 2022

• Stiffness Factor SF = EI / r³ – kN/m/m where E = Elastic Modulus – kN/m² I = Moment of Inertia – m  r = Radius – m

“E”, that varies rapidly with time, has to be estimated and “I” calculated, that is difficult for SWP (Structured Wall Pipe). Furthermore, these classifications differ from GRP (Glass Reinforced Polyester) thermoset pipe, classified by Ring Stiffness (SR) in N/m² (Pa) a unit 1000 times greater than kN/m2 and reinforced concrete pipe “D-load” classification Proof Load in kN/m of pipe per pipe diameter. This myriad of classifications is confusing and must be eliminated with a unified classification of stiffness, whatever the material. However, the different design philosophies – thermoplastic’s “its flexibility is its strength”; GRP’s “it’s a semi-flexible pipe”; reinforced concrete’s “the pipe is the structure”, are antagonistic. The Classification of all pipes, of whatever material, must be Pipe Stiffness (SP) measured in kN/m2, determined by the Compressive Test results from the Parallel Plate Test – the universal method of measuring pipe stiffness.

“You flatter to deceive”

The test is specified in the standards, including the deflection rates per pipe size. Commonly used maximum allowable deflections are: • 0.2857% (1/350th) of span (diameter) - reinforced concrete • 3% allowable deflection - thermoplastics (EN9969) • 3% allowable design strain - GRP • 5% allowable deflection - thermoplastic SWP The reduction in capacity of a circular pipe deformed to 5% is negligible as shown in CEN/TS 15223, Figure 1. The advantages of adopting Pipe Stiffness (SP) measured in the Parallel Plate Test are:

1. No mathematical manipulation of the test results, as required in Clause 8 of EN ISO 9969. 2. The mathematical manipulation varies with allowable deflection. 3. Unmanipulated Compressive Test laboratory result is a universal measurement of Pipe Stiffness (SP). 4. Elastic Modulus (E) does not have to be estimated which varies and is influenced by environmental conditions. A reinforced concrete pipe structure withstands the load and transfers it from the top of the pipe to the foundation beneath the pipe. The top half of a reinforced concrete pipe is a semi-circular arch, with fixed-end conditions at the “half-pipe” level, that transfers the load imposed on the pipe to the foundation beneath via the inverted semi-circular arch of the bottom half of the pipe – Diagram 1.

Diagram 1: Stresses on the Pipe Structure

The arch and the loading are symmetrical, so the horizontal displacement of the apex relative to the support is: Diagram 2: Parallel Plate Test Structural Regime – Point Load

= U/HB = ∫M(M/HB).ds/EI = 0

(i)

Rotation of the apex relative to the support: = U/MB = ∫M(M/MB).ds/EI = 0

(ii)

The Bending Moment at any point on the arch that subtends an angle  at the centre of the semicircle is: M = MB – WR (1 – sin ) /2 – HBR cos  M/HB = -R cos , M/MB = +1, ds = Rd Substituting in equation (i) for M, ⁴M/⁴HB and ds: ∫ [MB – WR/2 + WR (sin ) /2 – HR cos ]R² cos  d = 0 = R²∫[MB cos  – WR(cos )/2 + WR(sin 2)/4 – HR/2 – HR(cos 2)/2]d = R²[MB sin  – WR (sin )/2 - WR(cos 2)/8 – HR /2 – HR(sin 2)/4] = R²(MB – WR/2 + WR/4 – HR/4) Divide by R²/4 and rearranging: + 4MB – HR = + WR

(iii)

Substituting in equation (ii) for M, ⁴M/⁴MB and ds: ∫ [MB – WR/2 + WR (sin )/2 – HR cos ] Rd = 0 = R [MB  - WR /2 – WR (cos ) /2 – HR sin ] = R (MB/2 – WR/4 + WR/2 – HR]

Maximum BM at mid-span = WD/8 Maximum deflection at mid-span = WD³/192 EI Inflexion point = D/4

Divide by R/4 and rearrange: + 2 MB – 4HR = + WR ( – 2)

(iv)

Multiply equation (iii) by /2 and subtract it from equation (iv): H (²/2 – 4) = W (/2 – 2) or H = - 0.459W giving MB = - 0.1106WR

Diagram 3: Service Life Structural Regime – UDL

The structural capacity of a reinforced concrete pipe, is the lesser of the two values: - maximum allowable tensile stress of concrete. - deformation force required for the predetermined deflection. The reinforced concrete pipe calculations are based upon the following:

• Dimensions and mass – Rocla’s “Stormwater Systems” catalogue - Mean diameter DN = (OD + ID)/2 • Second Moment of Area of the pipe wall I = B.e³/12 m⁴/m

TO BE CONTINUED … If you are interested in reading the full text, please email tessa@summitpub.co.za

• Proof Load = D-Load.DN/1000 kN/m Allowable superimposed load W = 2BM/DN, minus the semi-circular top half of the pipe self-weight per metre • Maximum deflection with Δ = 1/350th (0.2857%) of the span D

JUNE / JULY 2022 43

Maximum BM at mid-span = wD²/24 BM at ends = wD²/12 Maximum deflection at mid-span = wD/384 EI Inflexion point = 0.211D

• Maximum BM is calculated from the General Beam Equation M/I = E/R = /y transposed to M = I./y insert maximum allowable concrete tensile stress,  = 2.94 MPa.

MIDDLE EAST

Dearth of integrated waste management systems in GCC However, Middle East has a real interest in ensu ring plastics are demonstrated to be sustainable Even when BY NIALL MARSHALL

DESPITE plastics playing a critical role in creating a healthier and more comfortable world, the negatives of plastics, including the irresponsible disposal of discarded packaging, is driving global attention back to issues around “sustainability”. While most, if not all, plastic rubbish blowing in the wind or floating in the ocean can be attributed to individuals’ behaviour, there is also no doubt that limitations in the systems for collecting, sorting and recycling of materials as well as a lack of end-of-life solutions for many materials also play a role in the highly visible waste. The buzzword is “circularity”. According to the World Economic Forum, the circular economy, which is more than just plastics, will yield economic benefits of up to $4.5 trillion in the years up to 2030. And so, as you might expect, there is a new focus on “circularising” plastics. Part of the drive for circularity and sustainability is to increase resource efficiency. For the plastics industry is approached in different ways, including down-gauging, mechanical recycling, chemical recycling, or energy recovery. For the GCC countries which, unlike Europe and North America, generally have undeveloped waste management systems, the regulatory efforts are into developing integrated waste management systems rather than polymer specific plans. For example, through the National Strategy Vision 2030, the Saudi Investment Recycling Company (SIRC) plans to increase the waste recycling rate to 85% by 2030. The UAE launched the Scale 360 Initiative in 2019, which aims to achieve circularity in plastics and electronics. High profile events like the Dubai Expo and the 2022 FIFA World Cup in Qatar are promoted as being sustainable, carbon-neutral events. Larger cities in the GCC do have integrated waste management systems. The Domestic Solid Waste Management Centre (DSWMC) at Mesaieed in Qatar is designed to handle up to 2 300 tons of mixed domestic solid waste per day. It separates out 50% of the plastics in the 44

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plastics can be separated and sorted… there is little demand for the recycled polymer in the region due to a lack recycling plants in the GCC

waste stream for recycling (as well as 90% of the metals) with remaining waste used to generate steam and electricity. Similar integrated facilities exist elsewhere, but many smaller, less populous towns only have municipal dumps with almost no sorting facilities. Plastics are disposed of together with household and commercial waste with little or no segregation. The plastics will initially be destined for waste-to-energy (WTE) plants which, unlike recycling, is modular. Even when plastics can be separated and sorted from the general waste streams there is very little demand for the recycled polymer in the region due to a lack recycling plants in the GCC. Most of the sorted polymer is exported, often at two to three times the price which could be achieved in the region. Where plastics recycling happens it is mostly by large converters who recycle a specific type of polymer (for example, milk bottles) for their own use as part of their own sustainability strategies. Less developed in the Middle East but potentially of more interest to the petrochemicals industry is chemical recycling or depolymerization. SABIC has already scaled-up an advanced recycling plant in the Netherlands to convert waste plastics into feedstock to create virgin polymers. These initiatives will undoubtedly find their way into the region, but only once efficient plastics-collection schemes are in place. Recycling plastics will be important in the future, not only in Europe and North America, but also in the Middle East and elsewhere. It is important to demonstrate the “sustainability credentials” of plastics, but even more important plastic waste is a useful feedstock, and it should be treated as such, whether mechanically or chemically recycled or even just as a source of energy. The Middle East probably won’t be leading the way, but it has a real interest in ensuring plastics are demonstrated to be sustainable.

JUN / JUL 2022

2022/06/10 11:21

TRAINING

Interpersonal skills are vital in any job

Beneﬁts of ‘soft skills’ in the manufacturing industry

BY ISABELLE BRETTENNY AND SUZANNE STEVENS OF ASPIRE INTERVENTION SERVICES

WHEN most companies report on how they are doing, one always hears about numbers; head counts, targets, return on investment and capital expenditure. Very little is mentioned about soft skills, which go hand-in-hand with being technically sound or ‘ahead of the pack’ and a desirable place to work. Manufacturing can be dangerous, intricate work and lack of skill can spell disaster. Without technicality, manufacturing wouldn’t exist. Technical skills focus on tasks employees perform every day. Companies want employees to apply the right principles, procedures, techniques and equipment to the design and production of quality goods and services. When it comes to the “world of work” both technical AND ‘soft’ skills are needed to be successful. Examples of technical (hard) skills include, for example, changing a ﬂange, stacking goods with a hyster, calibrating an instrument, and programming a computer. Technical skills can be acquired at school, college (TVET Colleges), training centres or on the job. Technical skills are objective – once you’ve successfully learned the task or information, you then own that skill. Soft skills are interpersonal skills that are vital in any job One develops soft skills over a period of time in situations which involve other people. In some, soft skills are innate, while others need to work to ﬁne tune these. We spoke to a few captains of industry about what they perceive to be important soft skills. They came up with the following list: • Communication – essential at all levels of the company, needed to articulate ideas, challenges, instructions, information and progress to others to ensure that business runs smoothly. • Time management – the ability to complete tasks timeously, punctual problem solving, communicating timeously. • Managing change • Humility – critical when working with other team members who may be asking for help. • Teamwork – able to work collaboratively and independently. • Diversity and inclusion – valuing and respecting differences and not excluding others on this basis. • Lifelong learning – being up to date with industry trends to keep products and services competitive. • Leadership – it’s important to help others with their personal development. • Initiative – able to recognize problems within systems and take action to resolve.

• • •

Attention to detail and quality orientation. Positive attitude – this goes without saying. Customer orientation – knowing that the customer is the reason for the business’ existence.

Before examining these soft skills, it is essential to know your team. We know that in bigger companies it is not always possible to know everyone, but it is certainly worth a try. We once facilitated a session with a client’s workforce. “Just speak to them, we’ve tried but can’t seem to get through”, was the brief. And “ﬁnd out what they want, and what their issues are”. We soon discovered that the workforce felt that they had worked for the company for so many years but that the owner did not know their names (this was an SME company, so knowing names was not an unrealistic expectation). A simple name badge or overall label system was implemented with the owner briefed to greet each staff member by name before launching into work instructions. At last count this was working brilliantly and if by some magic, the other “issues” slipped quietly away. The lesson here is that people thrive on recognition, and sometimes in the simplest way. Knowing that one is part of a bigger scheme of things and that one is important in the achievement of the company’s goals is vital for all employees. If this rings a bell for you – try it in your own business. Remember to address the person, regardless of both your respective ranks, by their name. Expect the magic to start soon! • Do you want to start conversations or a process within your business? Or do you want to add some of your own experiences to these soft skills articles? Email Isabelle on Isabelle.AspireIS@outlook.com or Suzanne on Suzanne.AspireIS@outlook.com

Isabelle Brettenny and Suzanne Stevens of Aspire Intervention Services are training specialists, who have a combined 50+ years of experience in industry, spanning multifaceted roles in water quality, FMCG manufacturing, R&D, packaging, strategy, business and people development. They have also started a recruitment company focusing on the manufacturing sector and assist with mentoring youths in preparation for the labour market. They believe that with evolving modes of communication, the basic principles are still relevant and important in today’s workforce. JUN / JUL 2022

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Design

innovators across the globe

showcase sustainable

46 JUNE / JULY 2022

Excel in technological advancement, responsible packaging, enhanced user experience THE Dow 2021 Packaging Innovation Awards winners were revealed in a live ceremony at the end of April. The Diamond Award went to O F Packaging for their curbside recyclable, high-barrier stand-up pouch for Brookfarms’s muesli and granola. An innovative packaging solution that answers a longstanding question – how can we recycle flexible

packaging through curbside recycling schemes? For over three decades, The Packaging Innovation Awards have honoured packaging projects from around the globe, showcasing the very best in sustainable innovation. Open to entrants across the value chain, the awards look for initiatives that excel in at least one

criteria: technological advancement, responsible packaging and enhanced user experience. The awards are an incredible opportunity for innovators across the globe to showcase their sustainable initiatives, which is why we love to share the fantastic work of our entrants with you each year.

DIAMOND AWARD

Roll ’n’ Recycle® – kerbside recyclable, high barrier stand up pouch O F Packaging, PREP Design, Brookfarm, Results Group O F Packaging were given a challenge by their client Brookfarm – to create a high barrier packaging structure to protect their delicious muesli and granola that can also be recycled through curbside recycling schemes.

Flexible packaging is typically not easy to recognize by material recovery machines and hand picking such materials becomes difficult. After 12 months of hard work with their partners PREP Design and Results Group, the Diamond Award winning Roll ’n’ Recycle® packaging became a reality, allowing consumers to transform the empty, 100% polyethylene packaging into a 3D shape suitable for their home recycling bin and enabling it to be recycled. How exactly does it work? After finishing their breakfast, the empty semi-rigid granola pouch gets rolled into a cylinder by the consumer, and the product label takes on a second life as a sticker to keep the new shape of the packaging. And voila, the rolled up pouch can now be dropped into the recycling bin ready for curbside pickup! www.rollnrecycle.com.au

packaging GOLD WINNERs

Recyclable matt polyethylene stand-up pouch Microplast-Coldeplast There’s no denying that stand-up pouches are a useful form of packaging for many products, but their ability to be recycled is limited. Microplast-Coldeplast is hoping to make a difference with their new 100% hermeticity, 100% recyclable, stand-up pouch.

The new design complies with the Store Drop Off program, allowing consumers to continue enjoying their favourite products in easy-to-use standup pouches, and also do their bit to help the planet. The innovative new pouch design

Toyo Seikan Co, Ltd Cool Shock®, a unique 3D plastic pouch moulding technology developed by Toyo Seikan, created to help packaging stand out on a crowded shelf. The traditional packaging moulding process is high cost, and high temperature, the latter being especially unhelpful in reaching sustainability goals. Not only does Cool Shock® cause less film damage by moulding at a lower temperature, but due to the unique, unheated convex mould procedure of Cool Shock®, packaging films which were previously limited to 2D printing can now take on a new dimension. There can be uniquely extensive 3D moulding on the film, which makes the packaging particularly eye-catching and attractive to consumers – ideal for a beauty brand! The 3D moulded packaging can also be shaded to stand out even more, or turned into a captivating metallic design.

www.moist-diane.jp/en/products/extra-straight.html

www.microplast.com.co

Veja Power Nature Reckitt Benckiser, Alpla, Gualapack, Flexoprint Reckitt Industrial, manufacturer of Veja products has made their foray into the world of sustainability with the new packaging for Veja Multiuso Power, their new multipurpose product, which features a bottle made of recycled plastic (PET) and a unique ‘snap on’ trigger, also made entirely of plastic. To make sure the packaging is all recycled the correct way, Veja Multiuso Power Nature also has a QR code on the sleeve label directing consumers on what needs to be done to give the packaging another life. The recycling information is an innovation too, because the consumer can look forward to an augmented reality experience taking them through the steps to prepare their bottle for the recycling bin, like easily removing the sleeve label using the handy perforation.

www.powernature.vejalimpeza.com.br

JUNE / JULY 2022 47

Three-dimensional moulded pouch

also includes a handy PE zipper, for added convenience, without hindering recyclability. The pouch’s matt finish, makes it an eye-catching addition to supermarket shelves everywhere.

Design

GOLD WINNERs

www.valgroupco.com/en

Laser engraved recycled water bottle Valgroup, Danone Waters Brazil, Bendito Design, Moldintec, Mirvi

To ensure packaging is fully recycled, the less steps that need to be taken, the better. Valgroup & Danone have made an almost frictionless journey for their new water bottles to be recycled, by removing the need for labels all together. The barcode is now engraved onto the bottle cap, and their unique laser decoration technology allows the details that would have previously been displayed on the label to be lasered right into the bottle, so there’s now no chance of missing labels and an easier route into the recycling bin. The laser engraving also saves some grams of weight per bottle, a small amount on its own, but this adds up to a lot of environmental savings during the shipping process. This incredible innovation is the first of its kind on the Brazilian market.

Circular economy pouch packaging

48 JUNE / JULY 2022

O F Packaging, Zero Co., Arne Studio A brilliant example of the growing consumer demand for sustainable options is Zero Co, an e-commerce, zero waste to landfill business that was funded entirely through a public Kickstarter campaign. Their goal was to provide refillable pouches of household and personal cleaning solutions to consumers, that allow Zero Co to keep the packaging in circulation through multiple uses. These flexible pouches needed to have two spout connections for this process, and they had to be made from as much recycled content as possible. Luckily, O F Packaging took on this huge challenge and helped Zero Co to achieve their ambitious goals. But they didn’t stop there, because when the refillable pouches reach the end of their life, they won’t get dumped into landfills, instead they get recovered by Zero Co and recycled into new products again, and again. www.youtube.com/c/ZeroCoAustralia/videos

AmLite HeatFlex Recyclable retort pouch Amcor For years the packaging industry looked at a recyclable retort pouch as a desirable, yet impossible goal. That’s no longer the case with the AmLite HeatFlex Recyclable pouch, a high-barrier, high-heat resistant packaging solution that can be easily recycled within the existing plastic recycling streams of most European countries. These pouches meet the growing demands from consumers and governments for recyclable packaging that is easier to recycle, provide a more lightweight alternative to metal cans, and are evidence of Amcor’s incredible technical breakthroughs. www.youtube.com/watch?v=G0V9cftZozo

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Design www.youtu.be/sUjScEYUxgE

GOLD WINNERs

kpNext™ R1, PET recyclable blister film kp

There is continued, growing consumer demand for sustainable products, which includes pharmaceutical blister films. These films package many over the counter and prescription drugs. Often, when switching to a more environmentally

friendly alternative, brands must compromise with slower packaging line speeds, or costly new equipment. kpNext™ R1 masterfully avoids both pitfalls as it can run as fast or faster all while using their existing tooling and

equipment. kpNext™ R1 is a world first in more ways than one – as well as being the first PET recyclable blister film, the innovation from kp also has unmatched clarity allowing consumers better views of the medicine they are taking.

sILvER WINNERs

Compostable wax pods for cleaning concentrates by etee etee, Diatom Consulting

www.vimeo.com/622880577

Most household cleaners are 70-90% water. There’s nothing special about that water, and yet, for the last several decades we’ve been trucking that water across the country and around the world, leading to unnecessary plastic packaging and emissions. Etee’s BEEPODS™ provide consumers with cleaning concentrates, sealed in an innovative, proprietary, bio-based blend of waxes and natural resins. The wax tubes can be sealed for

EcoLamHighPlus – high barrier mono PE laminate

50 JUNE / JULY 2022

Constantia

EcoLamHighPlus is a mono PE laminate designed to deliver high moisture and oxygen barrier and great machineability, with enhanced heat resistance of the external layer and excellent sealing performance. Developed to replace non-recyclable multi-material/multi-polymer specifications, Constantia Flexibles’ EcoLam can be recycled in the PE waste stream. The HighPlus grade is suitable for demanding applications in both food and personal care, for products ranging from coffee to dehydrated powders to shampoo and face creams. The decoration is provided with a reverse print, the quality, and appearance equivalent to PET or Polyamide, with either a gloss or matt finish according to marketing needs. www.consumer.cflex.com/products/ecolamhighplus/

easy transport, but are also malleable enough for the user to squeeze out the concentrate into their own container. The innovative formulation is also designed to withstand temperature variances. Etee now has eight different cleaning concentrates all shipped to the consumer in etee BEEPODS™. The packaging solution has gone viral on TikTok, with one video getting over 1.2 million views in just 24 hours!

silver WiNNers

YompBox™ COOL; inflatable insulated protective packaging for cold chain YompBox, AirxenBox

When a consumer purchases something cold, they want it to stay cold, but they may not always be thrilled with the bulky foams (EPS) used in the shipping process. The solution is YompBox™ COOL, a protective packaging solution that is inflatable and insulates the product inside. It’s reusable and recyclable, and the packaging can contain its air for up to one year. And even better, it saves so much space in the warehouse as you inflate the packaging on site using automated inflation equipment. It sounds like magic, but really, it’s just innovative packaging. www.yompbox.com

NetRoll® REC60: Industrial stretch film HIPAC SPA HIPAC’s ‘REC60’ is a new kind of stretch film for industrial packaging, which is used to secure products onto shipping pallets. HIPAC is doing things a bit differently. This stretch film is thinner than conventional films and contains at least 60% Post-Consumer Recycled Materials (PCR). Moreover, thanks to the NetRoll® technology, it is possible to eliminate the traditional paper cardboard from the reel, which is replaced by a re-usable patented plastic dispenser. This innovative packaging is certified with the Italian Green label “Plastica Seconda Vita” (Second Life Plastics) which guarantees the content to be at least 60% PCR, so that users can rest assured that they’re doing their bit to help the planet without jeopardising the safety of their wrapped goods.

UNIPAC, Syngenta Proteção de Cultivos (Syngenta Crop Protection)

This innovative and extremely technological project used the concept of plasma, that is also known as the “fourth state of matter”, in which gases and vapours are electronically excited, become highly reactive, and then create a very thin fluorine-based barrier layer over the inside of plastic packaging used to store agricultural chemicals. Why use this fourth state, you may ask. This process provides the formation of a very efficient and nanometric barrier layer over the bottle entire inner surface, with low consumption of energy and precursor gases. This coating method benefits from being environmentally friendly and allows the final product to be 100% recyclable! Developed during four years of studies, it is the first machine acquired in Brazil, this innovation in packaging guarantees the integrity of volatile solvents in pesticides formulation from entry into the packaging to use in the field. The packaging is bottled, used by the farmer and then collected, where it is possible to recover 94% of the packaging from the field through the reverse logistics system established in the country, they are recycled into post-consumer resin and used in the manufacture of new packaging for pesticides. www.unipac.com.br/noticias/embalagens/unipac-inicia-fornecimento-de-embalagens-de-plasma-a-syngenta

Recyclable polyethylene pouches Constantia Flexibles India, Hershey’s India Constantia Flexibles in partnership with Hershey’s India has developed a sustainable solution created from 100% PE to replace the multipolymer packaging previously used for their product ‘Hershey’s Kisses Milk Chocolate 30% Less Sugar’. Constantia’s EcoLamHighPlus is a sustainable barrier packaging solution specially designed for the circular economy. It is a mono-materialpolyethylene (PE) laminate solution, designed to be fully recyclable in the PE stream, while satisfying all functional and aesthetic requirements of the product. www.consumer.cflex.com/products/ecolamplus

JUNE / JULY 2022 51

www.hipac.com

Plasma barrier for agrochemicals packaging

SUSTAINABILITY

EU Commission proposal for The Sustainability Report is available online as an interactive PDF

Sustainability as a driver for Arburg

WHEN it comes to environmental protection, there is hardly a term more frequently used than “sustainability”. But how is it put into practice? Precisely that question is answered by the new Arburg Sustainability Report, backed up with a plethora of topical facts, ﬁgures and data. In an interactive PDF, a wide range of really interesting background information can be accessed online at any time. The 2021 version has been available on the Arburg website since the beginning of March 2022.The interactive document with fascinating facts, ﬁgures and data is ready to be browsed on the ARBURG website (www.arburg.com/ en/arburggreenworld) – the company has taken a conscious decision not to produce a hard printed version.

High recycling rate of PET bottles questioned in new study PET bottles used as packaging for soft drinks and mineral waters are often touted as the greenest type of plastic, with one of the highest recycling rates in the industry. But those claims are now being challenged by new research. Only a fraction of recycled PET collected from household waste is actually used in new bottles, according to new research by consultancy ﬁrm Eunomia published in February. New bottles placed on the EU market contain an average of just 17% of recycled PET, despite a recycling rate of around 50%, according to the study, conducted for the environmental NGO Zero Waste Europe. 52

THE long-awaited EC proposal for Ecodesign for Sustainable Products Regulation (ESPR) was ﬁnally published on 30 March, building upon the “Ecodesign Directive”, which currently only covers energy-related products. Part of the Sustainable Products Initiative (SPI), the proposal for ecodesign is one in a series of ambitious Commission proposals aimed at bringing companies in line with the Green Deal ambitions and EU’s sustainability goals. The framework will allow for the setting of a wide range of requirements, including on: • product durability, reusability,

upgradability, and reparability • presence of substances that inhibit circularity • energy and resource efﬁciency • recycled content • remanufacturing and recycling • carbon and environmental footprints • information requirements, including a Digital Product Passport. Based on the Regulation which provides a general framework for ecodesign requirements for products placed on the EU market, the Commission will adopt a series of delegated acts which will set criteria for different product groups – including

Converting wastewater into bio-based polymer AFTERLIFE simultaneously recovers compounds, converting organic matter into high-volume added value bio-based polymer THE AFTERLIFE project, a research team of 14 project partners from seven European countries, has successfully demonstrated a new way of wastewater treatment that simultaneously recovers compounds of interest while converting the remaining organic matter into a high-volume added value biobased polymer. The project started in September 2017, coordinated by Dr María López from IDENER (Spain), and ended in February 2022. The AFTERLIFE pilot plants have been deployed at BBEU premises in Belgium. The project consortium validated the technology at technology readiness level (TRL) 5. The BBEU team developed and operated four pilot lines for the processing of the following four wastewaters included in AFTERLIFE: 1. Wastewaters from the confectionery industry 2. Wastewaters from cheese manufacturing 3. Wastewater from citric fruit processing – fruit juice line (JL) 4. Wastewater from citric fruit processing

– essential oils (EO) line The treatment capacity of the operated pilots was one cubic metre of wastewater per day. The different pilot lines were operated sequentially and stopped at the end of August 2021. Essential oils and phenolic extracts production were comparable at lab and pilot scale. The pilot provided oils and extracts that could be tested in food products. The ﬁltration step of all the wastewaters showed good results. For PHA (polyhydroxyalkanoates) production, different alternatives were tested. These included the use of different types of bacterial cultures (pure and mixed cultures) and operation times. The results indicate the necessity of a ﬁne control system in order to achieve a stable PHA production. Two main groups of AFTERLIFE end products were obtained: Food and PHAbased plastic trays for food packaging. Essential oils and phenolic extracts were produced by CELABOR (Belgium) and tested by CTNC (Spain) in food products. For each product, the team

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Ecodesign for Sustainable Products Regulation plastics. While traditional circular economy principles focus on the end-of-life phase, the current proposal on ecodesign aims at building in sustainability throughout the entire product lifecycle, starting with the design phase. The ESPR proposal will be the cornerstone of EU environmental policy and will have a major impact on product design and market access. Given its wide scope, some product categories will be subject to additional product-speciﬁc legislation which could create additional burden for companies operating on the EU market. Some concerns are notably linked to the use of Life-Cycle-Assessment (LCA) and Product Environmental Footprint (PEF) methods, and intellectual property rights of companies. Every product placed on the EU market will have to include a machine-readable passport and be linked to a unique product identiﬁer. Information linked to composition, chemical

and material properties, as well as indications for repair must be included. The Commission will set up a product passport registry to store all the data belonging to the products.

BASF closes EPS recycling loop

SUSTAINABILITY-.indd 53

www.afterlife-project.eu/results

BASF has expanded its portfolio of graphitic expandable polystyrene (EPS) granulate. Neopor® F 5 Mcycled contains 10% recycled material and is suitable for numerous applications in buildings, particularly facade insulation. The new raw material is produced using the extrusion process and offers the same proven mechanical properties and optimised insulation performance as Neopor F 5200 Plus. BASF has developed the new raw material together with Karl Bachl GmbH & Co KG and turned it into a market-ready product. The quality of the recycled material used plays a pivotal role in meeting the exacting product demands in the various construction applications. The recycled material comes from mechanically recycled EPS waste. With Neopor F 5 Mcycled, BASF can offer an insulation raw material with a closed EPS recycling loop for the ﬁrst time. At the moment, high-quality recycled EPS material is still in limited supply.

JUN / JUL 2022

evaluated the antimicrobial, antioxidant and organoleptic properties. According to the produced results, essential oils can be useful to preserve the microbiological quality of mayonnaise and the addition of ﬂavonoids extract had antioxidant activity in, e.g., olive tapenade. Polyhydroxyalkanoates(PHA)based materials were produced by Lurederra (Spain). In order to improve the mechanical properties, the PHA were combined with another biobased polymer. CELABOR (Belgium) successfully used the obtained material for the production of plastic trays for food packaging. The full social and socio-economic analysis and other public AFTERLIFE project results can be found at

www.basf.com

2022/06/10 11:28

SUSTAINABILITY

Recycled HDPE with carbon

Approved and ready for use in automotive interiors Established TPE for interior applications containing a high recycling ratio KRAIBURG TPE is expanding its portfolio for OEMs and their suppliers, while it significantly contributes to meeting recycling rates and is offering support in reducing the carbon footprint of products for automotive interiors: With a recycling content of up to 38%, interior post-industrial recycled TPE grades provide the automotive market with a reliable and sustainable alternative to virgin material solutions. Customers will also receive the necessary information on the product carbon footprint (PCF) of the TPE. The post-industrial recycled raw material used is waste material derived from other companies’ manufacturing process for plastic products. KRAIBURG TPE uses it to produce product solutions for sustainable automotive interior applications. Possible applications include anti-slip mats, floor mats, soft components in cup holders, as well as fixation elements. The series is also suitable for 54

other applications requiring a hardness range between 60 and 90 Shore A. Strict OEM requirements for emission and odour are fulﬁlled and the material can be either combined with polypropylene in co-injection moulding applications or used as single soft component solution. In addition, Interior PIR TPE provides good abrasion resistance and excellent ﬂowability combined with low density to keep the part weight at a minimum. Approved and ready for use in automotive interiors: Interior PIR TPE

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footprint excellent

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US-based Association of Plastic Recyclers is launching a global design catalogue to help companies navigate various plastics recycling guidelines around the world. The launch in February of the APR Global Design Catalogue creates what the trade group calls “comprehensive resource to access the most current plastic packaging recyclability guidelines for countries and regions around the world.” APR’s new catalogue contains information from the European Union, Denmark, France, Germany, Netherlands, South Africa, South Korea, Sweden and the United Kingdom. Plans are to add additional countries in the near future, and to make the online catalogue interactive in the months ahead. Resins covered in the category include rigid PET, rigid high-density polyethylene, rigid polypropylene and ﬂexible PE ﬁlm. • More information about accessing the online catalogue through a subscription is available on APR’s website at www. plasticsrecycling.org/apr-global-guidance.

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RECYCLED HDPE (rHDPE) from the Spanish Suminco recycling plants in Montcada i Reixac and Venta de Baños, part of the ALPLA Group, causes up to 88% less CO2 equivalent emissions compared to virgin material. This result of an analysis by the independent management consultancy c7consult once again underlines the importance of recycling. The recycling of plastic packaging has been an important part of the ALPLA sustainability strategy for more than 25 years . The internationally active manufacturer of plastic packaging always campaigns for the closed cycle of packaging according to the “bottle-to-bottle” principle. The topic of recycling plays a major role here, giving used plastic packaging a value. After ALPLA had long established itself as a partner for PET recycling with its own recycling plants worldwide, the company also entered HDPE recycling in autumn 2019 with the purchase of the two Spanish Suminco plants.

Catalogue to help with global plastics recycling

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SUSTAINABILITY

Mattel first toy company to use SABIC’s certified renewable polymers SABIC is collaborating with Mattel, a leading global toy company, to incorporate certified renewable polymers from SABIC’s TRUCIRCLE™ programme across Mattel’s products offering. The first Mattel toy products to enter the market in 2022 using certified renewable SABIC® PP (polypropylene) polymers will be from MEGA and Matchbox, with more to follow. Heading the initiative will be MEGA BLOKS Green Town, the first-ever toy line available at mass retail to be certified CarbonNeutral. These new construction playsets, including the Grow & Protect Farm and the Build & Learn Eco House, embrace the sustainable material choice and help teach kids green behaviours. From the Matchbox brand, all Action Driver playsets and the Matchbox Recycling Trucks contain SABIC materials, which supports the brand’s Driving Toward a Better Future initiative, to make all Matchbox die-cast cars, playsets and packaging with 100% recycled, recyclable or bio-based plastic materials by 2030, in line with Mattel’s corporate goal.

MEGA Bloks® Green Town™ Build & Learn Eco House™ HCG36

Seafood packaging solution using certified circular PE from ocean bound plastic Demonstrates how ocean bound plastic can be brought back into a circular material stream SABIC has leveraged its successful ties with Polivouga, a manufacturer of flexible film products with operations in Portugal, to launch a new innovative Trucircle™ project designed to reuse post-consumer plastic waste recovered from areas up to 50km inland from waterways that has the potential to end up in our rivers and oceans. The collaboration with the Nueva Pescanova Group, a leading Spanish brand owner specialising in the fishing, farming, processing and marketing of fresh, chilled and frozen seafood products, has resulted in the development of the world’s first frozen food packaging solution using SABIC’s certified circular polyethylene from feedstock sourced from ocean bound plastic. The ocean bound plastic is converted using advanced recycling into an alternative feedstock which SABIC uses to produce certified circular polymers – SABIC LLDPE and LDPE for further processing to flexible packaging film by Polivouga. Then, Nueva Pescanova packages its frozen seafood in bags made from this film. 56

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www.sabic.com

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Recycling pilot project provides insights into SA’s informal sector Helping grassroots businesses integrate into the formalised waste recycling sector AN innovative pilot project being trialled at recycling buy-back centres across South Africa is yielding positive results just over a year in, helping grassroots businesses integrate into the formalised waste recycling sector. Project Up, an initiative of PETCO with funding support from The Coca-Cola Foundation, uses BanQu blockchain technology to digitise and record transactions between the buy-back centres and waste pickers. For the first time, buy-back centres are able to digitally track the sorts of materials coming in and the value of those materials to their businesses, while waste pickers, for their part, have digital proof of the revenue they receive for the recyclate they sell. Interim data indicates that the introduction of the technology is not only helping to integrate the informal recycling sector with the formal recycling sector, but is also helping grow the volumes of recyclable plastics and other materials purchased by the buy-back centres. “I thought the app would be a lot of work, but it makes things much more efficient with regard to data capturing, and the ins and outs and operations of my business, which I think is more important than anything,” said Refilwe Ramadikela, chief executive of Hendrina Recycling in Mpumalanga. Through the use of the blockchain, South Africa is building a national digital record of recyclables which are collected by waste pickers and sold to buy-back centres, who in turn sell the materials to recycling companies.

UP AND UP: Project Up is rolling out innovative technology which assists recycling buy-back centres like Suzan Kubheka’s Inhle Indaloyakhe buy-back centre in Gauteng. Pictured with Kubheka (second from right) are a group of her clients and staff, including (from left) Thuli Ngwenya, Nthabiseng Tladi, Musa Nkosi and Cebo Ngwevu

By providing a permanent record, buy-back centres give waste pickers digital – and legitimate – proof of the revenue they receive for the recyclate they sell, while buy-back centres beneﬁt from detailed data on the kinds of materials they receive and the value of those materials to their businesses. This knowledge enables them to pinpoint potential new recycling streams to focus on to grow their revenue. Insights to support and grow the informal waste sector According to PETCO vice-chair and Coca-Cola’s sustainability director for Africa, David Drew, one of the key beneﬁts of the BanQu system is the insights it provides into the waste economy. One of the more important relationships to understand was how factors like price and demand affected collection. For instance, the recycling industry has long known that bottles made of clear or blue PET fetch a high price for waste pickers than green or amber PET. Interim BanQu data clearly shows the impact of this price differential on collection rates. The BanQu data shows that while clear or blue PET is estimated to represent around 85% of the beverage bottle market, it represents 92% of the post-consumer PET collected and traded on BanQu. This suggests that the price premium translates into a higher collection rate for clear bottles versus green and amber PET bottles. According to PETCO CEO Cheri Scholtz, the data coming out of Project Up allows for a better understanding and ability to support the informal collection value chain – responsible for an estimated 60% of all PET plastic, aluminium can, and paper collection nationally.

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COMPOSITES

JEC World reafﬁrms global leadership, dynamism of the composites industry JEC World 2023, 25-27 April – Paris, Nord Villepinte THE global composites community reunited at JEC World 2022 from 3-5 May for three busy, rewarding days of innovation, networking and knowledge sharing. The industry was excited to reconnect in Paris after three years and the show exceeded all expectations in terms of product launches, content, business activity and attendance. Overall, the event welcomed 32 000+ professional visits, in Paris and online, from more than 115 countries and featured 1 201 exhibitors and 26 pavilions, whilst the JEC World Connect platform offered an additional way to explore the show this year. While fewer Asian participants were able to join the show this year due to travel complexities, the attendance of a high level of decision makers from 117 countries and all key players along the value chain resulted in a dynamic environment for networking and business. With more than 500 product launches during this year’s show, JEC World remains the

preferred venue to introduce new products to the global market. The JEC Composites Innovation Awards celebrated 10 collaborative projects, reflecting the dynamism and the resilience of our industry, and two Innovation Planets displayed 80 impressive applications. Celebrating its five-year anniversary, the JEC Composites Startup Booster competition is now firmly established as the best place to discover startups in the advanced composites sector. Congratulations to all of 2022’s finalists and winners who made the judges’ mission more difficult than ever. JEC World’s conference programme shone a light on this year’s theme and most impactful topic: Composites for a Sustainable World. Sustainability continues to rise as a key growth driver for the composites industry, enabling diverse application sectors to achieve ambitious sustainability goals, from energy and transportation, to building and infrastructure, and so many more.

2022 winners of JEC Composites JEC Composites Startup Booster is the leading startup competition in the world of composites. It enables companies to identify and assess innovations that may have a potential impact on their industry and complete their ongoing projects.

Launched in 2017, JEC Startup Booster has already fostered the emergence of 500+ innovative projects, from 50+ countries, 80 ﬁnalists and 30 winners.

PRODUCTS & MATERIALS

Graphene for climate Blackleaf (France)

Many have tried to make graphene possible, but cost, quality and quantities never allowed this material to become a real business case. Blackleaf closes the business case thanks to 2-pillar technology: First a green and waterbased production process. Blackleaf produces up to 50kg of high-quality graphene daily. Second, a set of patents to apply graphene as a coating on any substrates with a conventional spraying technique. Blackleaf offers an easy-way to coat any 58

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materials & geometries with graphene material: • do not require any surface preparation • easy to apply with conventional equipment (eg spraying tool) • brings highly efﬁcient performances • on polymers, metals, ceramics and glass. Fast surface heating/cooling applications or high anti-corrosion properties can be addressed with unprecedented performances. www.blackleaf.fr

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JEC WORLD 2022 KEY FIGURES

• 1,201 exhibitors • 26 Pavilions • 32,000+ professional visits • 2,733 business meetings • 80 parts and products showcased in two Innovation Planets • 10 JEC Innovation Awards winners • 4 Startup Booster winners

GET READY! JEC World 2023 25-27 April – Paris Nord Villepinte

Startup Booster unveiled PRODUCTS & MATERIALS

Making high performance materials affordable FibreCoat (Germany)

FibreCoat develops and markets highperformance fibre materials. The aluminum basalt fibre “AluCoat” is the first marketready product. Unlike currently used conductive polymer yarns, AluCoat is thermally and electrically conductive as well as temperature resistant up to 600°C. Compared to pure aluminium fibres, AluCoat can be produced at one-tenth the cost. As a result, the material has the potential to become the much-needed, affordable shielding material for the electromagnetic shielding of electric cars and 5G devices of the future. www.fibrecoat.de JUN / JUL 2022

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COMPOSITES PROCESS, MANUFACTURING & EQUIPMENT

Most advanced composites recycling technology Continuum (Denmark)

Continuum have developed the most advanced mechanical composites transformation technology in the world that allows to sustainably turn end-of-life composite materials and manufacturing waste into valuable, high performance and fully circular products for the built environment. They are currently designing their ﬁrst 36 000-ton factory together with the Port of Esbjerg, Denmark, to open in 2023. A second UK factory is planned.

www.continuum.ooo

SUSTAINABILITY PRIZE

CXP bioplastic for a green future

Dongnam Realize (South Korea) Dongnam Realize produces ‘CXP wood’, made with disposals from agriculture and forestry. It can be produced in general plastic production plants and replace normal plastic, is biodegradable and carbonized easier than regular plastics. They are selling their products through zero-waste shops with their brand, Carbon Storage.

www.dongnamrealize.com

Launch of Tepex range of composites LANXESS has expanded its Tepexbranded ﬁbre-reinforced thermoplastic composites, with a new range called

Tepex ﬂowcore. Lanxess said the new plate-shaped composites were being offered with

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The ribbing on the demonstrator model is made entirely from compression-moulded Tepex ﬂowcore with no additional injectionmoulded material

a matrix based on polypropylene, polyamide 6, polyamide 12, thermoplastic polyurethane, or flameretardant polycarbonate. The new composites are designed as alternatives to thermoset sheet moulding compounds (SMCs). Offering similar mechanical performance, they are much more ductile and, as thermoplastic systems, much easier to recycle than SMCs. Sabrina Anders, Lanxess’ project manager for Tepex flowcore, said the firm was targeting Tepex flowcore “primarily at large underbody panelling components and load compartment wells for cars, but also at components such as large casings and battery covers”.

www.lanxess.com

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COMPOSITES

Prepregs for automotive body panels New fast curing composites for high-volume automotive applications with outstanding structural part performance SOLVAY has made an important addition to complement its broad portfolio of composite materials for the automotive industry: SolvaLite® 714 Prepregs, a new-generation of unidirectional carbon-ﬁbre and woven-fabric products preimpregnated with SolvaLite® 714 epoxy resin. These innovative prepregs offer fast-cure cycles, long outlife, and have been optimized for manufacturing automotive components, such as body panels at short compression moulding cycle times in serial production runs. The new SolvaLite 714 Prepregs have been specially developed to ensure strong product robustness in largescale industrial compression moulding processes and deliver high structural part performance. They are available in a wide range of unidirectional carbon ﬁbre reinforced and woven-fabric formats. SolvaLite 714 Prepregs are currently manufactured in Europe, and will be commercially available worldwide beginning in the second quarter of 2022.

Solvay expands its Solvalite portfolio with prepregs for automotive body panels and invests in Xencor LFT production facilities

In addition, Solvay recently invested in its production capability enhancements for Xencor™ LFT (long fibre technology). The investment includes new manufacturing assets and additional capabilities in Solvay’s Oudenaarde facility (Belgium) as well as an expansion of research and development resources at one of Solvay’s technical centres in Alpharetta, Georgia. Xencor LFT is one of the key pillars in Solvay’s light-weighting portfolio, which also includes shortfibre compounds and continuous carbon-fibre composites. Xencor LFT opens up new light-weighting potential for aluminum die-cast replacement in next-generation electric vehicles. This includes several areas of metal replacement, such as those in braking and steering, electric-drive units, inverters, and battery module protection, among others. www.solvay.com

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Moulding thermoplastic composite aircraft sidewall panels using recycled carbon ﬁbre ITALIAN company Cannon Ergos, a world leader in technologies, processing equipment and mould manufacturing for the composites industries, is working with Boeing on moulding trials for the feasibility of using recycled carbon ﬁbre (rCF) for the fabrication of aircraft cabin interior sidewall panels.

The recovery and reuse of carbon ﬁbre waste during production processes and end-of-life applications, such as automotive and aeronautics, has proved to be economically viable. “For several years, together with sister companies Cannon Afros and Cannon Tipos, we have successfully undertaken numerous projects that offer new life to recycled carbon ﬁbre,” said Mattia Andolfatto, Project Manager R&D at Cannon Ergos. “By combining various technologies and production processes tailored for each application, we have been able to effectively process recycled carbon

Production line set-up for sidewall moulding trials

fibre whether impregnated with diverse resins, or already integrated within a thermoplastic matrix. The project with Boeing demonstrates the viability of fabricating interior sidewall panels with high-performance thermoplastics reinforced with recycled carbon fibre.” The project’s latest stage involves Mitsubishi Chemical Advanced Materials (MCAM), a global supplier of high-performance reinforced polymers for which Cannon Ergos has designed, manufactured, and installed a customized and fully equipped thermocompression unit. This equipment was used to produce prototype sidewall panels with the new Kyrontex® material. Typical resin matrices utilized for Kyrontex® thermoplastic composite aeronautical applications include polyamide (PA), polyetherimide (PEI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK) and polyaryletherketone (PAEK). 737 recycled carbon sidewall prototype

www.cannon.com

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New production concept for composites-intensive drone Cost-effective composite tooling and scaled-up production line

To reduce weight, a combination of carbon fibre stitched biaxial fabrics and unidirectional (UD) reinforcements are used wherever possible, with additional glass fibre-reinforced laminate sections used where radio transparency or insulation from metallic parts is required. The Cobra production engineers have also been able to incorporate glass fibre reinforcements and mounting points for the VETAL’s propulsion system and other ancillary equipment into the moulding process, minimizing the additional processing steps in the assembly and finishing stages. Currently, cost-effective composite tooling has been produced for the first Cobra-built VETAL airframes, enabling a rapid start-up to the series production, while still providing the possibility for incremental design changes before switching to CNCmachined aluminum tooling for highrate production in the future.

the construction approach used would not be able to meet all the project requirements relating to durability, production rate and price. Drawing from its decades of experience with close-tolerance moulding of EPS foam-cored sandwich components for the watersports market, Cobra proposed a hybrid solution, combining both hollow and cored sections, for the ﬂying wing. The main body of the aircraft comprises a PVC foam sandwich shell with a low-density EPS foam rib which, combined with a fully foam cored tail structure, is said to deliver a complete airframe fractionally lighter than the customer’s challenging target. In addition to an impressive cycle time reduction, the new build method also improved the impact resistance and overall durability of the VETAL platform, a key beneﬁt for industrial users who need survey drones with minimum maintenance.

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THAI company Cobra International has expanded its development and manufacturing partnership with Thai unmanned aerial vehicle (UAV) producer HG Robotics. In this latest collaboration, Cobra has supported HG Robotics with the development of an entirely new production concept for the carbon fibre composite flying wing of the VETAL vertical take-off and landing (VTOL) drone. VETAL is a twin rotor, tailsitting drone that HG Robotics recently launched for large-scale agricultural surveys, as well as general surveillance monitoring. Having developed VETAL platform’s initial flying shape, HG Robotics had initially produced the first flying prototypes using a more traditional UAV construction technique of thin composite skins, with ribs and frames supporting the hollow structure. However, although these early aircraft performed well in flight, there were concerns that

Cobra has supported HG Robotics with the development of an entirely new production concept for the carbon ﬁbre composite ﬂying wing of the VETAL vertical take-off and landing (VTOL) drone

Eco-friendly surfboard AUSTRALIAN eco-surfboard specialist Notox reportedly plans to use a bio-resin and recycled carbon fibre in its latest range of boards. The R-CARBON boards are made of 100% upcycled carbon fibre fabrics recovered from a production waste stream at Airbus, and Sicomin’s GreenPoxy 56 bio-resin. Notox previously used the bio-resins in earlier flax, cork, and bamboo reinforced boards, the company says. According to Notox, the carbon fabrics are declared unusable for aerospace applications due to short roll lengths, an inability to be pre-formed, or other defects. However, when combined with the epoxy and a hardener, they produce a clear, high gloss laminate with high mechanical properties. Notox used

a wet lamination process with vacuum bag consolidation to wet out the upcycled woven carbon fabrics and minimise resin consumption in the manufacturing process. In a life cycle analysis, using waste carbon fabrics from Airbus was reportedly more energy efﬁcient than using other recycled short ﬁbre carbon. “At Notox our mission is to produce the most ethical and sustainable boards. Providing great mechanical performance, a high plant-based carbon content, and a low carbon footprint due to local manufacturing, GreenPoxy 56 is a good solution for our new R-CARBON technology,” said Pierre Pomiers, president of Notox. www.notoxsurfboards.com.au

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WORLD NEWS BASF winds down activities in Russia & Belarus BASF is not conducting any new business in Russia and Belarus, in light of the war of aggression against Ukraine ordered by the Russian government. BASF has also decided to close the company’s remaining business activities in Russia and Belarus by the beginning of July 2022. Exempt from this decision is business to support food production. Currently, 684 employees work for BASF in Russia and in Belarus. The company has decided to continue to support its employees in both countries until end of 2022.

Plastics pollution probe launched in California, ExxonMobil issued subpoena CLAIMS of plastics’ recyclability by the petrochemicals industry are seeing increasing legal pressure in the US state of California, where Rob Bonta, attorney general in the state, launched a “first of its kind” investigation in April to examine the industry’s role in creating and exacerbating the plastics pollution crisis, and to analyse if any laws have been broken in the process. Bonta issued a subpoena to US petrochemicals giant ExxonMobil, seeking information relating to the company’s alleged role in deceiving the public and worsening plastics pollution. In 2021, a lawsuit was filed in California against several major beverage companies, alleging unlawful, unfair, and deceptive business practices with respect to claims of a 100% recyclable plastic bottle. Bonta said that for more than half a century, the plastics industry has perpetuated a myth that recycling can solve the plastics crisis, but the truth is that the vast majority of plastic cannot be recycled, and that the country’s recycling rate has never surpassed 9%, with 91% of the remaining plastics waste ending up in landfills, being incinerated or left in the environment. ExxonMobil, in a statement to the Reuters news agency, rejected the claims as “meritless allegations (that) distract from the important collaborative work that is underway to enhance waste management and improve circularity”. 64

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Lack of higher quality streams & standards

Interview with Prof Dr Hans-Josef Endres, Head of the IKK Institute (Institute for Plastics and Recycling Technology at Leibniz University of Hanover) Prof Endres, the plastics industry is often the subject of criticism. What is needed for people to appreciate the material?

We must show that our daily lives are inconceivable without plastics and make it clear that plastics make a key contribution to a sustainable economy. Plastics are indispensable for achieving our climate targets and significantly reducing our carbon footprint. One way to achieve this goal is to use resources such as energy with increasing efficiency, and another is to establish a Prof Dr Hans-Josef Endres, Head of the circular economy. Moreover, improved IKK Institute recycling technology represents a crucial tool towards achieving these goals. This task is huge and extremely multi-faceted, but it can be handled. Which areas show the greatest challenges at present? It’s a triad: we don’t have enough higher-quality recyclates yet, nor enough input streams, and there are still not enough standards in this field. All of these challenges are closely related; starting with the market: there is currently already a high demand for high-quality recyclates, but it cannot be met. Let’s take a look at the automotive industry as an example and assume that in the future there is a quota of 25 percent recyclate per vehicle. Today, the share of plastics per vehicle is around 300 kilograms. This means that 75 kilograms of recycled material would have to be used in the future. Last year, about 2.6 million vehicles were built in Germany; it was a very bad year because of the Covid pandemic. So already for this number, almost 200,000 tons of high-quality recyclate with constant colour quality and delivery guarantee would be needed for instance just to be able to meet the quotas in this one industry sector. Another example is the bottleneck of white or transparent recyclates. How do you obtain the input streams required to generate sufficient quantities of consistent recyclate quality? This is a huge task. These input flows are still a strongly limiting factor, especially in the post-consumer sector. This is because today’s users cannot yet rely on receiving sorted material in sufficient quantities with a longer-term delivery guarantee. Of course,

Reusable PET bottle cuts AUSTRIAN packaging producer Alpla and compatriot mineral water supplier Vöslauer Mineralwasser have developed a returnable, reusable PET bottle said to be 90% lighter than a glass alternative. The one-litre, 55g bottle reportedly www.alpla.com

reduces carbon emissions by 30% and is now available in stores. Made of fully recyclable PET monomaterial, with a recyclate proportion of 30%, the bottle is said to be capable of at least 12 usage cycles www.voeslauer.com

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recyclates, more consistent input

a better sorting of plastic waste is necessary to obtain singlevariety material. But it is also a matter of improving the various recycling processes. Their degrees of maturity are currently still very different. Which one is the most matured? The mechanical processes are already established. For the physical processes, during which the plastic is dissolved out of other substances by means of a specifically effective solvent, the first industrial plants are available. The chemical processes, in which the plastics are depolymerized or broken down even further into hydrocarbons still need to be improved, particularly in terms of energy efficiency and yield. However, they also have some fundamental advantages. The quality of their recyclates is high, achieving colour purity and consistent material performance. Such recyclates also obtain approval much more easily for critical applications, such as the food sector. Simply put, the higher the recyclate quality, the higher the technical effort involved, and therefore the cost.

That is not so easy to say. Basically, chemical recycling could generate large quantities of high-quality recyclate. Conversely, mechanical recycling is much more sustainable in most cases, since energy and resource input is significantly lower, and the polymer structures are also preserved. It is also difficult to determine which actors in the recycling value chain are credited with the sustainability benefits achieved in each case, for example the input supplier, the recycler or the user of the recyclate. In chemical recycling, for example, the carbon is recycled but not the actual material. In addition, the user does not get the physically recycled carbon, but receives a mass-balanced certificate which, to top it all off, has to be purchased. If users waive the certificate, they receive the same material, but minus the certificate.

Both are enormously important, and at all levels. There are already approaches – still very rudimentary ones however – on how to characterise input flows. These were essentially developed by the dual systems. In addition, we need standards for defining the resulting recyclate qualities. For example, it must be specified which volatile substances may still be

What contribution are individual processes making towards sustainability?

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What is your degree of progress in terms of setting rules and standards within recycling?

present, how this is to be measured exactly, and who is responsible. Currently, the idea is that if there is nothing to worry about in the input stream, there is nothing to worry about in the recyclate. We also need to have standards for colours. Every recyclate needs a trade name to ensure you get the same product the next time you order it. In addition, all recyclates lack information on long-term properties or specific parameters for processing or crash simulations. All this is not very difficult to realise, after all, manufacturers of virgin material are demonstrating that; they supply a great deal of information and specific parameters for each product.

carbon emissions by 30% and is estimated to remain in circulation for three to four years. With the introduction of the returnable PET bottle, Vöslauer claims it will save around 400 tons of material and 420 tons of CO2 per year. The company intends to use 100% recycled material for its PET bottle production by 2025. Vöslauer aims to use 100% recycled material for its PET bottle production by 2025 (Photo: Vöslauer)

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WORLD NEWS

Arburg Plastic Freeforming: manufacture components in half the time Freeformer software speeds up additive manufacturing by up to 55%

Applying support materials in a grid structure allows complex geometries to be achieved with a short build time. This example shows an S-shaped pipe made from white PP with Armat 12 as the support material.

www.arburg.com

The savings potential is demonstrated in a particularly impressive manner in the case of the 1:16-scale functional model of a complex toggle-type clamping unit from an Allrounder injection moulding machine that was manufactured over the eight-day duration of the K 2016 trade fair using the APF process. At that time, the build time for the ABS component including support material was over 200 hours. Thanks to the grid structure, the build time can now be reduced by 54%. The support material (600 grams) can be washed out completely in just ten minutes, leaving behind the toggle model with around 30 moving joints. • Arburg is represented in South Africa by Hestico (Pty) Ltd.

www.hestico.co.za

ARBURG has optimised the software for its Freeformer machines so that, in future, all water-soluble Armat support materials can be applied in a grid structure that is optimised for Arburg Plastic Freeforming (APF). This will shorten build times in the APF process by up to 55% – while also reducing material consumption. The water-soluble support material can then be washed out without manual finishing work. The faster build speed is possible due to the optimisation of the Freeformer software: for all components with geometries requiring a support structure, the water-soluble materials Armat 11 and Armat 12 are now applied to the moving part carrier in such a way as to create a process-optimised grid structure. Rather than a compact build-up, a fill level of only around 20% results in lightweight structures that can also be removed more quickly than before without finishing work in the next step. In this way, the grid structures save time when building up the component and removing the support material and, hence, save material and costs.

LANXESS AG and global private equity ﬁrm Advent International are joining forces to acquire Royal DSM NV’s engineering materials business for €3,7 billion euros ($3.95 billion). DSM has annual sales of about €1,5 billion and an EBITDA (earnings before interest, taxes, depreciation and amortization) margin of about 20 percent, ofﬁcials with Lanxess in Cologne, Germany, said in a May 31 news release. DSM is one of the leading global suppliers of high-performance specialty materials that address key market needs in electronics, electrical and consumer goods. Lanxess will

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Lanxess, Advent form joint venture, buy DSM Engineering Materials contribute its own High Performance Materials unit to the joint venture. HPM is a leading supplier of highperformance polymers, primarily to the automotive sector, with annual sales of around €1,5 billion. Advent will hold at least 60% in the joint venture. Lanxess will receive an initial payment of at least €1,1 billion and a stake of up to 40 percent. The firm will use the proceeds of the transaction to reduce debt and to strengthen its balance sheet. Lanxess also has the option to divest its stake in the joint venture to Advent at the same valuation after three years. The deal is expected to close in the first half of 2023. In the release, Lanxess CEO Matthias Zachert said that with the joint venture, his firm “will once again become significantly less dependent on economic fluctuations”. “With the new (joint

venture), we are forging a strong global player in the ﬁeld of high-performance polymers. The portfolios, value chains and global positioning of the two businesses complement each other perfectly,” he added. Lanxess was formed in 2004 when Bayer AG spun off its chemical division and part of its polymers business. Advent managing partner Ronald Ayles said that “joining forces with Lanxess in this industry transforming transaction is a highlight for Advent, as we have built a trusted, long-standing relationship and share the highest mutual respect.” The DSM unit makes nylon, PET, polybutylene terephthalate, copolyester and other materials. It employs 2,100 worldwide at eight production sites and seven R&D centres. Lanxess is a maker of specialty chemicals and plastics that employs 14,900 and posted sales of €6.1 billion in 2020. Boston-based Advent has $88 billion in assets under management. Its holdings include German acrylic resin maker Röhm GmbH.

Lanxess will contribute its High Performance Materials (HPM) business unit to the new joint venture

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TPE grade with FDA-reviewed PCR content US compounder Avient has introduced a new reSound thermoplastic elastomer (TPE) grade that incorporates post-consumer recycled (PCR) material and can be used for manufacturing certain food-contact articles. The US Food and Drug Administration (FDA) issued a noobjection letter regarding use of the material in certain food-contact applications following its evaluation of the material. The reSound REC TPE formulation contains 25% PCR content from recycled polypropylene, said Avient. The material has 65 Shore A hardness and offers comparable performance to prime TPEs, and can be a sustainable option in personal care items such as toothbrush grips and certain FDA food-contact items like reusable crates. The material, available in North America, is naturally grey, colourable, and suitable for injection moulding or overmoulding onto PP. Avient’s reSound REC grades are part of the company’s resound TPE portfolio, which includes both recycled content and biobased formulations. www.avient.com

BASF Venture Capital invests in sustainable plastic sourcing platform Startup offers platform for ocean, ocean-bound, and postconsumer-recycled (PCR) plastic sourcing BASF Venture Capital GmbH (BVC), the corporate venture company of BASF Group, has invested in Oceanworks, a sustainable plastic solutions provider that brings traceability and transparency through digitalization to recycled plastics. Oceanworks is based in the US and offers a powerful platform for brands looking to reliably secure high-quality sources of ocean, ocean-bound, and averted PCR plastic. For BVC this investment underlines BASF’s commitment to developing sustainable solutions to

raise the transformation towards a circular economy to a new level. Oceanworks, with its global marketplace for recycled plastic materials and products offers a sophisticated solution. The young company makes it easy for buyers to source recycled plastics likely to add to the 11 million tons of plastic ﬂowing into the ocean each year. Digitized blockchain-based traceability, material quality assurance, global logistics and marketing support are part of Oceanworks’ offer for its customers and their partners.

BASF Venture Capital GmbH has invested in Oceanworks, a sustainable plastic solutions provider that brings traceability and transparency through digitalization to recycled plastics

Automation specialist TMA to become member of Engel Group INJECTION moulding machine manufacurer Engel Austria, headquartered in Schwertberg, Austria, has acquired the majority interest in TMA Automation in Gdynia, Poland. This strategic investment sees Engel reinforce its leading position in the ﬁeld of injection moulding process automation. The two companies have already cooperated closely for many years on numerous customer projects. One regional focus is Poland and the neighbouring eastern European countries. TMA’s technologies perfectly complement Engel’s in-house spectrum of robots and automation components. Engel offers highlyintegrated and fully-automated production cells for injection moulding applications from a single source, boosting both the production efﬁciency and the investment protection for its customers with this holistic approach. One of TMA’s focuses is on automating in-mould labelling processes in the medium performance segment. In the high-performance segment, Engel will continue to cooperate with its long-standing partners for IML automation.

ExxonMobil to add 454 million kg of PP capacity in Louisiana EXXONMOBIL will add nearly 454 million kg of polypropylene resin capacity in Baton Rouge, Louisiana, US by the end of the year. Houston-based Exxon will spend more than $500 million on the project, which will double the plant’s polypropylene capacity. ExxonMobil ﬁrst announced the capacity expansion plan in early 2019. Company ofﬁcials said at the time that the project would create up to 600 jobs during construction and 65 permanent jobs once completed. JUN / JUL 2022 67

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WORLD NEWS

Iconic Boston Bottle in a more sustainable solution CONSUMERS can continue to appreciate the timeless round-shoulder design and brand display appeal that they have become accustomed to in Berry Astrapak’s Boston Bottle range, but now in a more sustainable packaging solution. In using up to 100% recycled HDPE with an increased output recycling rate of HDPE encouraged by the implementation of the EPR legislation, Berry Astrapak aims to help its customers achieve a circular economy by contributing to a closed-loop system in the manufacturing process. rHDPE inclusion can be used in the full bottle range, which includes 50ml, 100ml, 125ml and 250ml bottles for on-the-move convenience to the consumer beneﬁt of bulkpurchasing products in 400ml or 500ml sizes. Manufactured in PP, the corresponding closure options –

ﬂip top, disc top, screw top and push/pull closures in 24/410 and 28/410 – accompany the Boston Bottle family for a complete packaging solution.

Covestro extends film production in Germany Global demand for TPU specialty films on the rise COVESTRO is expanding its production capacities for thermoplastic polyurethane (TPU) Films in the Platilon® range, as well as the associated infrastructure and logistics. To this end, the company is investing a low double-digit million euro amount in its German centre of excellence for the aforementioned films in Bomlitz, Lower Saxony. This site of Epurex Films, a wholly owned subsidiary of Covestro, houses application development and production for the semi-finished products, among other things. The new capacity is intended to

meet the growing global demand for multilayer TPU Films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty ﬁlms have also proven their worth in wound care and outdoor clothing. The new facilities are scheduled for completion as early as the end of 2023. For Aleta Richards, global head of the Specialty Films segment, the expansion offers opportunities to respond

even better to individual customer needs and offer more sustainable products. “For some time now, we have also been developing customerspeciﬁc solutions with ﬁlms made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially bio-based products is therefore to become a new focus at the Bomlitz site.”

An important application for TPU ﬁlms is plasters for wound care

Covestro ﬁlm blowing line at the Bomlitz site in Germany

www.covestro.com 68

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diary Polyoak Packaging export team exhibited at Propak East Africa in Nairobi. Michelle Penlington (Sustainability), Craig Harmse (Closures & PET) and Natasha Harmse (Tubs & Buckets).

Polyoak Packaging at Propak East africa

70 JUNE / JULY 2022

POLYOAK Packaging exhibited at this year’s Propak East Africa trade exhibition in Nairobi, Kenya during May to showcase its fully recyclable plastic tubs, buckets, PET preforms and closures. Polyoak’s key account manager for PET and closure exports, Craig Harmse, was delighted with the turnout, saying, “with Kenya having a population of just over 47 million people, growing at 4% over the last four years, it is easy to see the interest of international investors into the country across various industries and markets.” Closures and preforms Craig represents Polyoak’s specialist closures division, African Closures which offers PET preforms and a diverse range of 100% recyclable 28mm 1881 PCO closures for CSD’s and beverages, as well as 38mm beverage closures. Its awardwinning Fliptop range is specially designed to eliminate unnecessary packaging, by being a one-piece, tamper evident snap on closure. Tamper evidence is a ‘must’ when it comes to food and beverage closures. Polyoak’s awardwinning fully recyclable, barrier tub range, Polyshield, extends shelf life up to 12 months

Unfortunately, this is often delivered through multiple disparate packaging components such as foil seals, collar shrink wrap and stickers which all add extra cost as more energy is used and more waste streams are created in the manufacture, transportation and disposal of each additional component. African Closures’ range of 28mm and 38mm one-piece, tamper evident Fliptop closures saves packaging material and application costs as no extra wads, liners or shrink wrap are required. Elimination of the unnecessary components makes this solution convenient for the consumer and friendlier for the environment. The 28mm Fliptop range was specially designed to fit PET bottles with 28mm 1881 necks. Application is simple as the Fliptops snap on without the need for expensive rotary capping equipment. Tubs and buckets Polyoak’s diverse range of fully recyclable tubs for the dairy industry have built-in tamper-evidence and lids that re-seal securely to protect the contents. Polyoak’s

African Closures’ one-piece, tamper evident 28mm Fliptop range – also available in 38mm neck size.

snap-off multi-packs remain popular for yoghurts and snacks. They make ideal lunch box items and can be broken apart and sold off as individual units to meet specific price points in Africa’s growing informal trade sector. Last year Polyoak launched South Africa’s first shelf-stable, long-life beetroot in a plastic tub! This special tub range, called PolyShield, provides outstanding oxygen barrier protection resulting in fresh tasting, preservative-free foods in a modern, convenient and lightweight tub which is fully recyclable. This advanced technology with superior sealing of the barrier lidding film for pasteurization extends shelf life under ambient conditions to 12 months, making it a modern alternative to tin and glass. The tub is lightweight and nests compactly for efficient transportation, unlike heavy glass jars and tins. Key account manager for Polyoak’s specialist tubs division, Dairypack Tubs, Natasha Harmse adds: “The PolyShield range has broad application potential, being ideal for vegetables, fruit, pickles, processed meat, soup and convenience foods.” Polyoak’s national executive for marketing and sustainability, Michelle Penlington, concludes, “We look forward to partnering with our customers to deliver high quality, fully recyclable packaging that is loved by consumers and is good for the planet.”

www.polyoakpackaging.co.za

“PROPAK East Africa was really vibrant this time around as we hardly had anytime to sit nor eat,” said Patrick Rutaha, key accounts manager at Safrique. “The quality of visitors was excellent coming from Kenya itself and surrounding market like Sudan, Uganda, Ethiopia Tanzania and even Zimbabwe. The location of the show, the Sarit Centre, was also great and allowed visitors to attend.” Propak East Africa was held at the Sarit Exhibition Centre in Nairobi, Kenya, from 10-12 May. Safrique was one of a number of South African exhibitors at the event. Safrique’s main goal at the expo was to network and meet with as many customers as possible, with the objective of increasing Safrique’s

Patrick Rutaha (key accounts manager, Safrique), Mr Cuong (Vinacolour, additives manufacturer), Leanette Moodley and Siyabonga Ngcobo (both Associated Additives), Diana Mariwa and Phyllis Omwange (Safrique Int East Africa agents), and Safrique CEO Mervyn Moodley

www.safrique.com

customer base in East Africa. “With our new partnership with Associated Additives, we believe this was the best platform to introduce them to the Kenyan market.” Safrique’s new Vietnamese principal, Vinacolour, a manufacturer of technical fillers and additives, was also present and it was exciting to see its products being used successfully and getting first-hand feedback from customers, added Patrick. It was also a great opportunity for Safrique to launch its range of transparent additives, which are suitable for applications in film extrusion as well as blow and injection moulding. The product was well received, with some trials conducted successfully during and after the show that led to orders being confirmed.

2022 MEFPU Expo: 7-9 June Dubai World Trade Centre, Dubai: www.mefpu.com Pre-K Trade Media Event: 13-14 June Ansfelden and Schwertberg, Austria nvanheesewijk@emg-marcom.com Wire & Tube 2022: 20-24 June Düsseldorf, Germany: www.wire-tradefair.com Manufacturing Indaba: 21-22 June Sandton Convention Centre, Johannesburg www.manufacturingindaba.co.za SMCCreate 2022 Conference: 28-29 June Hilton Hotel, Antwerp, Belgium www.smcbmc-europe.org Feiplar Composites & Feipur: 16-18 August São Paulo, Brazil: www.feiplar.com SAPPMA Pipe XIII Conference: 6-7 September Emperors Palace, Kempton Park www.sappma.co.za

Rayal Packaging exhibits at Propak East Africa AS one of the leading PET strapping manufacturers in South Africa, East Africa is a huge potential for growth. Propak East Africa is a

EVENTS

Safrique very happy with trend at Propak East Africa

great platform for us to open the door to the market, We were able to generate new potential leads from Kenya, Tanzania and Uganda.

Wire China 2022: 26-29 September Shanghai, China: www.wirechina.net K 2022: 19-26 October Düsseldorf, Germany: www.messe-duesseldorf.de Recovered Carbon Black: 16-17 November Berlin, Germany: www.carbonblackworld.com

2023 Africa Energy Indaba: 7-9 March CTICC, Cape Town: www.energyindaba.co.za

www.rayalpackaging.co.za

JUNE / JULY 2022 71

Gavin Kung, procurement manager and Jacky Wei, sales executive on the Rayal Packaging stand

ISWA World Congress: 21-23 September Sands Expo & Con Centre, Singapore www.iswa2022.org

diary

K2022: Trend Report Europe

– plastics industry braces for increased instability, higher prices, lower growth

72 JUNE / JULY 2022

Ukraine crisis weighing heavy on the plastics business THE European plastics industry is tackling challenges on multiple fronts. In packaging, by far its biggest market, it has become a victim of its own success, particularly as the ideal material for single-use applications and people on the move. Since early 2019, Covid-19 has had major effects on production, occasionally positive but mostly negative. And now, just as Europe and the rest of the world was recovering from the devastating two years of the pandemic, we have the tragedy of the Ukraine conflict. Discussing the situation in late March, Martin Wiesweg, Executive Director Polymers EMEA at consultant IHS Markit, said that, quite apart from causing a humanitarian disaster, the crisis is weighing heavy on the plastics business, in terms of cost inflation, the worsening of supply chain bottlenecks, including energy supply, while also raising the spectre of demand shock amid the fear of global stagflation. Sectors driven by consumer discretionary income like white goods, consumer products, and automotive would fare poorly as buyers try to conserve cash.

In the short to medium term, Europe could potentially see a demand contraction across polymers. Plastics processing is on course for the circular economy Germany remains the powerhouse of the European plastics industry, but some sectors are hurting all the same. According to German plastics processing industry umbrella organisation GKV, industry sales increased by 12.6% to Euro 69.4 billion in 2021, but member companies remain under a lot of pressure to produce good results. It cites “exorbitant cost explosions” for raw materials and energy, as well as the many delivery delays and resulting order suspensions, particularly in automotive supplies. The automotive sector has provided a unique set of problems. Several European car makers have temporarily shut down production in recent months, with important negative effects in the supply chain, including the permanent closure at some processors. The overall economic outlook for 2022 remains very mixed, said GKV president Roland Roth at the association’s annual results conference in early March. Around half of association members expected sales growth when poled in the run-up to the conference, but a good quarter expected further falls. Several were thinking about relocating or terminating production. Roth said recent material price increases have been “almost insane.” On average, prices for plastics in Europe increased by Some car makers cannot build cars because they are unable to obtain chips for electronics. This has had a knock-on effect upstream, putting some plastics component suppliers in difficulties

more than 50% year-on-year in the first half of 2021 and have stayed high. In February 2021, for example, virgin PET sold for around Euro 1/kg. In March of this year, the price was around Euro 1.7/k. Linear low density PE went from around Euro 1.2/kg to around Euro 1.9 over the same period. Packaging challenges High and escalating resin prices globally means the packaging market is under continuing pressure. Given that recyclable granular is now at the same price as virgin polymer was 12 months ago, the impetus to lightweight now stretches across all packaging material substrates, not just virgin polymers. The move towards tethered caps (mandatory from 2024 under SingleUse Plastics Directive, or SUPD) and extensions of Extended Producer Responsibility (effective 2023) will inevitably have a strong influence, as does the new EU Packaging Levy on non-recycled packaging waste. (Since Jan 1, 2021, the EU charges member states Euro 0.80/kg of plastics packaging waste that is not recycled.) The European plastics industry is having to contend with various pieces of legislation relating to plastics waste. For example, there is now a mandate that 55% of all plastic packaging in the EU be recyclable by 2030, as well as the levy on nonrecycled plastic packaging waste. In the UK, now outside the EU, a new tax on plastic packaging came into force on 1 April of this year. The tax will apply to plastic packaging components that do not contain at least 30% recycled plastic and that are either manufactured in the UK or imported into the UK (again, there are exemptions). The tax will be levied at a rate of £200/ton (approx. Euro 235/ton).

LyondellBasell is developing its own chemical recycling technology, MoReTec, at a pilot plant in Ferrara, Italy. Several other polymer suppliers in Europe are following suit

Recycling on the rise Plastics recyclate production in Europe was 8.2 million tons in 2021 and is forecast to grow at a rate of 5.6%/year to 2030. That compares with the 35.6 million tons of commodity plastics that entered the waste stream in 2021. That figure is most likely to rise as the plastics industry makes major investments in recycling technologies of diverse types. The picture of how to convert recycled plastics into high-value products is brightening. Thanks to horizontal networking along the value chain, converters will no longer have to downcycle materials in the future, but can actually re- or even upcycle them.

The greatest challenge is achieving comparable component performance and stabilising non-uniform material properties through intelligent process monitoring. Polymer suppliers going green European polymer producers are making major efforts to improve the sustainability of their products. Polymer suppliers have not been entirely eye to eye with European policy makers on how to move to a green economy, but opinions are converging. LyondellBasell aims to produce and market two million metric tons of recycled and renewable-based polymers annually by 2030. It has already launched plastics

What was once considered rubbish is now a useful feedstock

made from mechanically and chemically recycled plastic waste, as well as biobased feedstocks. Similar comments come from SABIC. In 2019, it launched certified circular polymers produced by upcycling used plastics. However, the reality is that there is currently greater demand for recycled plastics than the supply available. Plastics Europe Managing Director Virginia Janssens, Managing Director, Plastics Europe, says its members support the 30% EU mandatory target for recycled content in plastics packaging by 2030 and have recently announced Euro 7.2 billion of planned investments in chemical recycling by 2030 in Europe. JUNE / JULY 2022 73

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diary

Wire & Tube 2022 event delayed to June Messe Düsseldorf postpones Wire and Tube in consultation with the partners and associations involved to 20-24 June.The currently very dynamic infection patterns and rapidly spreading Omicron variant have resulted in adjustments in the Düsseldorf trade fair calender that require re-scheduling the Wire and Tube originally planned for 9-13 May. www.wire-tradefair.com

briefs

The Manufacturing event for Africans, by Africans THE Manufacturing Indaba, from 21-22 June at the Sandton Convention Centre, Johannesburg, is the leading manufacturing event in SubSaharan Africa. The event has shown impressive growth year on year and has proved its value in catalyzing business connections and helping manufacturers to innovate and grow their potential. Participate in the manufacturing conference and exhibition to learn from industry leaders, manufacturing sector experts and international speakers. Meet potential buyers through business matchmaking programme and buyers lounge. www.manufacturingindaba.co.za

SMCCreate 2022 design conference SMCCreate 2022, the design conference jointly organized by the European Alliance for SMC BMC and the AVK takes place from 28-29 June at the Hilton Hotel in Antwerp, Belgium. This unique conference about design in SMC and BMC composite materials will provide valuable insights in the entire product design process from idea to part manufacturing, targeted both at experienced designers and at designers that are new in applying these versatile materials. The SMCCreate 2022 conference will cover a wide range of subjects, all relevant for designers in their selection of materials solutions that provide performance, cost efficiency, manufacturing ability and sustainability. 15 lectures by international speakers from France, Germany, Italy, Spain, The Netherlands and the USA will present practical presentations about sustainability, part design, mobility and automotive applications. Equally current trends and developments in the European SMC/BMC market are on the agenda. www.avk-tv.de 74 JUNE / JULY 2022

ENGEL at Elmia Polymer in Jönköping ENGEL welcomed visitors to the smart factory at Elmia Polymer 2022, Scandinavia’s biggest trade fair for plastics and rubber processing, from 10-13 May in Jönköping, Sweden. The Austria-based injection moulding machine manufacturer and system solution provider, which also has a branch in Jönköping, presented both new and established products from its inject 4.0 range. Themes addressed during the four-day trade event included greater energy efficiency and the automation of injection moulding processes The ENGEL stand was devoted to the self-optimising injection moulding machine. By producing sample parts, ENGEL

vividly demonstrated how to exploit the potential for efficiency and quality that Industry 4.0 promises – fully and simply. The victory 460/120 injection moulding machine is equipped with smart assistance systems and networked for this purpose. The networking of production systems, the systematic utilisation of machine, process and production data and the deployment of smart assistance combine to enhance productivity, efficiency and quality in manufacturing while enabling processors to respond to ever-changing requirements with maximum flexibility. www.engelglobal.com

ENGEL is represented in SA by GreenTech Machinery (Pty) Ltd

With iQ flow control, ENGEL has set a milestone on the road to secure data exchanges in the smart factory. e-temp temperature control units will be fully integrated into the CC300 control unit of the injection moulding machine via OPC UA.

iQ weight control compensates for process fluctuations before rejects are produced. ENGEL vividly demonstrated the strong potential of digitalisation and networking in raising efficiency and quality by producing sample parts.

Arburg at rapid + tct 2022: High-temperature processing and process monitoring RAPID + tct 2022, North America’s largest additive manufacturing event, took place in Detroit, USA, from 17-19 May as a hybrid event. Arburg was there: Two Freeformer 300-3X models were on show at the exhibition: a standard system and a machine for processing high-temperature materials. Another highlight was the presentation of the “ProcessLog” app, which can be used to track and document jobs in detail. The free choice of materials from plastics, also used in injection moulding, has emerged as one of the decisive advantages of Arburg Plastic Freeforming. In addition, the open system allows the properties of the additively manufactured parts to be specifically adapted. Arburg’s presence at rapid + tct 2022 is intended to further expand its position, particularly in the aerospace, automotive, medical, and consumer goods industries. The focus in Detroit was on high-temperature applications, such as with the materials ULTEM or PEEK, the processing of flexible materials, polypropylene parts, hard/soft combinations, and process monitoring with the “ProcessLog” app. With its partner OTEC, Arburg showed how the additively manufactured parts achieve surface qualities comparable to those of injection moulded parts through post-processing, such as vibratory finishing and barrel tumbling. The Freeformer 300-3X can process high-temperature materials such as ULTEM 9085, which is a permanently flame-retardant and low-smoke material suitable for aerospace applications, as well as biocompatible, resorbable, sterilisable and FDA-approved original materials. At rapid + tct 2022, the high-temperature Freeformer, whose build chamber can be heated to 200 degrees Celsius, processed a medically approved PEEK granulate. Optimised temperature management provides the necessary cooling, especially for the axis drives, which very precisely position the part carrier along the x, y and z axes. The Freeformer can currently achieve strengths of up to 95% when processing this material in the x and y directions. Arburg is represented in SA by Hestico (Pty) Ltd

www.arburg.com

www.hestico.co.za

A high-temperature Freeformer 300-3X can process PEEK, for example, into individualised skull implants, including support material.

At rapid + tct in Detroit, two Freeformer 300-3X machines will additively manufacture sophisticated functional parts JUNE / JULY 2022 75

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OUT & ABOUT

Propak Africa 2022 FROM 8-11 March, the Expo Centre Nasrec in Johannesburg, saw thousands of visitors to Propak Africa – a much needed platform for buyers and sellers to connect face-to-face, business partnerships to develop, and where industry can come together and new products and services launched. Many of SA Polymer Technology readers were there too. Pam Magill of Samchem was a busy visitor to the exhibition

Mark Strydom, Gareth Larsen, Douglas Greig, Estelle Adams, Yandisa Mahashia and Lee Ann Daniels, all from “Team Tuffy”

76 JUNE / JULY 2022

Ivan Horowitz of Meraxis with Anton Hanekom of PlasticsSA

A serious demonstration of what a ZERMA granulator can do to an extremely hard chunk of plastic Douw Steyn of PlasticsSA, Lowrie Sharp of Summit Publishing and Chandru Wadhwani of Extrupet enjoying time together

Charles Goldman of Bodo Muller Chemie SA

Ruben Brandt and Loutjie de Jongh of Mpact with Pierre Jurgens of Cabletech Marketing on the Cabletech stand Patrick Bracke of GreenTech in conversation with interested visitors

Johannes Schwarz of W.Muller Blow Moulding Technology, a principal of Hestico, with Danie Strydom of Hestico

Safripol Sustainability Conference THE 2022 Safripol Sustainability Conference from 16 to 17 of March, was much bigger, better and bolder than its predecessors, with more inspiration, collaboration and action to turn “Let’s Plastic Responsibly” into real change with The Power of R – reducing, re-using, recycling, re-thinking, and re-purposing.

Tlou Sebola of Petco and Douw Steyn of PlasticsSA also attended the conference

Blessing Jiyane, Marie van der Merwe, Lesego Seabi and Ruann Wessels all of Safripol’s Durban office

Nico van Niekerk CEO of Safripol, who delivered the opening address, “Let’s Plastic Responsibly”, with Deidre Penfold (executive director, Chemical and Allied Industries Association) spoke about the “Future for the Chemicals Industry in SA with the Just Transition”, and Mamogala Musekene (deputy director-general, Department of Forestry, Fisheries & the Environment) who addressed the conference on “Curbing Plastic Pollution: The Role of Regulatory Measures” Professor Suzan Oelofse (principal scientist at CSIR) spoke about “Modelling South Africa’s approach to near zero plastics leakage into our oceans”, while Luyanda Hlatshwayo (African Recycling Organisation) presented on “Reclaimers – Everyday environmental heroes”, an excellent and interesting eye opener of a talk, with Michael Avery (Classic FM conference convener).

JUNE / JULY 2022 77

Mark Berry (commercial executive, Safripol), Michael Avery (anchor of the HOT Business show on HOT1027; host of Business Watch on BDTV and host of Business Talk on BusinessTech), and Gert Claasen (technology & innovation executive, Safripol), in conversation during a break in proceedings

Wessel Oelofse (Versapak) who spoke on “Concept to reality: Bringing Sustainability to Life”

diary

recyclable all-PE film with digital product passport REIFENHÄUSER Blown Film showcased technical solutions for the economical and sustainable production of blown film that pay off in terms of a functioning circular economy and reduction of the carbon footprint at the new GREENPLAST 2022 congress trade fair in Milan from 3-6 May. Highlights included the patented EVO Ultra Stretch production process for fully recyclable all-PE blown film, the use of digital product passports in the interests of a functioning circular economy, and technologies for the economical processing of post-consumer and postindustrial recyclate. The blown film plant specialist is thus showcasing examples of future-proof technologies that are consistently designed for the production of sustainable products. EVO Ultra Stretch, Reifenhäuser’s patented stretching unit, enables the production of mono-material composites (all-PE film) for fully recyclable flexible packaging in which the otherwise usual PET layer of the packaging is replaced by stretched PE. This is made possible by the maximum 10-fold stretch rate, which gives PE films completely new mechanical properties. There is no need to adapt further processing steps such as printing, laminating and converting. Thanks to the patented position of the stretching unit directly in the haul-off of the blown film line, the film is stretched at the ideal time and from first heat, which at the same time makes the process particularly userfriendly, stable and efficient. To make the best use of the potential of fully recyclable packaging for the circular economy, Reifenhäuser relies on digital product passports via RCycle – the traceability standard for plastic packaging. www.r-cycle.org

Reifenhäuser All-PE Pouch: A digital watermark concealed in the printed image allows waste sorting facilities to retrieve recycling-related information from the R-Cycle digital product passport.

78 JUNE / JULY 2022

Reifenhäuser EVO Ultra Stretch: The position of the stretching unit directly in the haul-off of the blown film line is patented and is a unique selling point on the market.

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UK DESIGN agency Morrama has devised a concept for a Covid-19 test that is biodegradable and fully recyclable, right down to its packaging – potentially eliminating a common source of plastic waste. The ECO-FLO test – which is, for the time being, a concept design only – would be the first in the world to be 100% recyclable and according to Morrama. • Capable • Capable ofofmaking • •biodegradable, PE fence production makingstretched stretched PE Safety Safety fence production Morrama’s proposal achieves this goal by making as well asassquare line as well square netting. netting. line1.5m 1.5m wide wide. the test itself from moulded paper pulp, and its • outer For construction • •PLC Controlled. • For constructionand and garden garden PLC Controlled. packaging from biodegradable NatureFlex film,netting. • •Dual 30:1 – 65mm Barrel & netting. Dual 30:1 – 65mm Barrel • Dual which would both break down in approximately four windup. Screws. • Dual windup. & Screws. to six weeks. • ABB Inverters. The other plastic – the swab, • ABBelements Training available. Inverters. • Moog hydraulic controllers. Training available. test tubes and•their associated Price R490,000.00 Moog hydraulic controllers. • Omron temperature Price R490,000.00 packaging – are all eliminated, negotiable. •controllers. Omron temperature as the agency rethought Injection mouldingnegotiable. controllers. Siemens Contact: every step of •the testing Motors 22Kw. machines, and • Siemens Motors 22Kw. Jacques on Contact: 084 581 4838 • Complete with stretch unit. process to minimise household moulds Jacques on 084 581 4838 materials and • Complete with stretch unit. For details contact maximise ease info@thengaplastics.co.za of use. JUNE / JULY 2022 79

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hosting theirwide PIPES XIII Plastic Pipe used 1000mm & Feipur – International Exhibition and hardlybe THE 2022 ISWA World Congress will graham@cycliq.co.za Conference in Johannesburg on R70 000 Conference on Composites, Polyurethane be live and in-person once again in 6-7 September. and Thermoplastics Composites takes • 2 x new 60mm barrels and Singapore from 21-23 September, after Topics covered by Pipes XIII will place from 16-18 August in Sao Paulo, screws 32:1 LD ratio with Bagman Classiﬁ ed physical absence. The ISWA a two-year issues to HDPE mixingembrace zones ideal for LDrelating & Brazil. World Congress is a global meeting PVC R50 pipe000 quality, materials each production and More than 15 500 visitors from about LLDPEand which includes high level plenaries, manufacturing trends, installation 30 countries are expected. In 2018, last • 2 x new 90mm barrels 32:1 LD innovative solutions, technical site visits standards and new international edition of the show, 14 900 professionals ratio R50 000 each and business to business programmes applications. This is a not-to-be missed from all over Latin America visited the • 1 x new 65mm PVC screw with where waste management professionals, event that will feature an exciting line-up event, registering an increase of 17% 28:1 LD ratio R25 000 government officials, industry leaders, of local and international experts, including • Polymers for policy sale, 1st generation, pre-consumer in the number of visitors in relation to makers, scientists and young • 1 x used 65mm screw infrom goodRadius Systems the two authors 2016). To present new technologies to all • PC/ABS 10 ton/month professionals meet to exchange views condition and R15 Kiwa000 that won best papers presented these visitors, more than 300 exhibitors and opinions advance scientific and • Black Automotive UV stabletopp 20-40 ton/mnth PPXX Amsterdam. anyinredundant companies are expected, from several If youathave technical knowledge for sustainable solid • Injection grade LDPE (red) 4 ton www.sappma.co.za equipment you would like countries such as China, the United management. Since its beginning, • White pp 20 waste ton/mnth States, Germany, Italy, England, Turkey, to sell please email a list the ISWA World Congress has been with photos and I will try France, Japan and others. During the • We also do HIPS, PC, PA, PMMA, PBT, ABS, LDPE,solid ASA considered the industry’s leading and sell on behalf of you. years of 2019, 2020 and 2021 our seminar waste management event. We are looking for clean, pre-consumer (onsite and online) gathered more than 6 www.iswa2022.org Contact: Sean Varrie polymers, Pp lumps, HDPE lumps, woven pp 200 attendees. www.feiplar.com

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FOR SALE

MALTA RECYCLING

www.morrama.com

High-quality recycled HDPE, LDPE, PP phone Danie tel: (021) 931 9658 danie@maltarecycling.com

SPORTS

GMO-free, partially bio-based midsole for hiking boots MATERIALS supplier Covestro and VAUDE, a family-owned manufacturer of outdoor equipment and footwear, have collaborated to develop a partially bio-based foam midsole for VAUDE’s new Lavik Eco outdoor hiking boot. It is based on thermoplastic polyurethane (TPU) foams from Covestro’s Desmopan® EC 33000 series, which use non-GMO raw materials. The durable foams meet the outdoor brand’s Green Shape criteria without sacrificing performance. “With the new Lavik Eco, we want to introduce our first bio-based outdoor shoe in the 2022 summer collection and the first outdoor sports shoe ever in which all components are made from more than 50 percent bio-based and recycled materials,” explains Clément Affholder, Innovation Manager at VAUDE. “When selecting materials, we paid particular attention to environmental compatibility and optimal performance under outdoor conditions.” The Lavik Eco shoe is scheduled to be available in stores as a men’s and women’s model from spring 2022. The midsole is a crucial element in a hiking boot: it must be pleasantly soft and comfortable, but also provide a firm grip and have excellent cushioning properties. TPU has already proven itself as a durable and supportive material

in midsoles for active footwear such as mountain boots. However, in this soft and hard material combination, it has not been produced with non-GMO raw materials before. Together with VAUDE, Covestro has identified and tested start-up raw material supplier Metabolic Explorer, which can supply bio-based 1,3-propanediol, a building block in the production of polymers from palm oil. The fact that the chemical raw material is not genetically modified also played a role in the evaluation. The outdoor manufacturer had already been using partially bio-based TPUs from the Desmopan® EC series for its TRK Skarvan hiking boots since 2018. In these more sustainable shoes, the bioplastic provides protection in the toe cap against injury from stones in the front of the foot and added stability from the heel cap in the back. Green Shape is the VAUDE label for functional and environmentally friendly products made from more sustainable materials. The manufacturer is focusing on more environmentally friendly alternatives to petroleum-based raw materials, the increased use of recycled materials and materials derived from natural fibres such as hemp and organic cotton, and the use of bio-based plastics from non-GMO sources.

www.covestro.com

Covestro and VAUDE have jointly developed a midsole for VAUDE’s Lavik Eco hiking boot. It is based on partially bio-based and non-GMO TPU foams from Covestro’s Desmopan® EC 33000 series

First outdoor sports shoe made predominantly from bio-based and recycled materials

SimplyEV debut Kimoa e-bike KIMOA, the sustainable lifestyle brand created by two-time Formula 1 champion, Fernando Alonso, launched its ﬁrst e-bike during the week of the Formula One Crypto. com Miami Grand Prix 2022.

SPORTS.indd 80

The Kimoa e-bike is powered by Arevo’s lineup of custom 3D-printed continuous carbon ﬁbre-reinforced thermoplastic (CFRTP) e-bikes, made-to-measure for each rider in a strong, impact-resistant, unibody frame. The Kimoa bike frame is constructed without joints or glue for seamless strength, and in addition to being lightweight, is said to be very sustainable. “At the heart of Kimoa’s DNA is our drive to create a more sustainable lifestyle,” Kimoa founder and global ambassador, Fernando Alonso, says. “The Kimoa e-bike gives people a curated step towards that active and sustainable lifestyle, tailored speciﬁcally for each rider.” The Kimoa e-bike is fabricated using Arevo’s advanced 3D-printing process

which reportedly enables an unprecedented level of customization, tailoring the frame to riders’ heights, weights, arm and leg lengths, and riding positions. With more than 500 000 possible combinations, the Kimoa e-bike is believed to be the most versatile carbon fibre bike ever made. According to Kimoa, each e-bike can be fully charged in two hours, providing up to 88.5km (55 mile) range. It features integrated data and power wiring throughout the frame, enabling a variety of electronic upgrades. Additional options include multiple riding styles (road, gravel, commuting or cruising), wheel materials (metal or carbon fibre) and finishes (turquoise, fluorescent yellow, black or white).

www.kimoa.com

JUN / JUL 2022

2022/06/10 11:44

Manufacturing of new barrels and screws Bimetallic - Nitrided – Through harden Refurbishment of Barrels, Screws, Granulators, Blow Film and T-Dies

Suppliers of recycling/pipe/proﬁle/ ﬁlm & reduction industry

MGMW Trading (Pty) Ltd Fine Fit Ofﬁce: +27 66 250 1937 Wolf: +27 82 771 7271 Gunther: +27 83 441 3206 Unit 17 Log Road - Roodekop admin@mgmwtrading.co.za www.mgmwtrading.com

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www.hitech-china.net

2022/02/17 13:13

The Home of Size Reduction

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2022/04/06 07:23