capitalcapitalequipmentequipmentnewsnews

TECHNOLOGY: ConquestXP™ – the toughest belt yet!TRAINING: Boost for South African manufacturing sectorCOMPANY PROFILE: Something BIG is on the cards for Pilot...

Komatsu thrives on hard labour

JULY 2013

Editor’s comment 1 An Olympian challenge

Cover story 2 Komatsu thrives on hard labour

Into Africa ...and beyond: Construction 4 Terex in tropical Trinidad 6 Bergmann: Hatchback dumper with added safety 9 Wacker Neuson: Powerful deployment in the African heat

Company profi le10 Pilot Crushtec: Something BIG happening

Technology12 Pneumax: Environmentally friendly dust management solutions14 Goodyear: ConquestXPTM – The toughest belt yet!

Training15 TASA: Huge boost for South African management sector

Into Africa ...and beyond: Mining16 Mining – fl exible offers from Scania18 Redpath: Ground-breaking sand tunnel20 Volvo Penta’s extended range of engines for mining

Safety23 Booyco: Collision warning system in Zambia24 Safe tunnelling with Becker Mining

Editor’s comment 1 Fuelling discontent

Cover story 2 Land, sea and air, Allcare Logistix does it all

Freight and logistics: Warehousing 4 Genie: Pick of the crop 6 Loadhog enters South African logistics market

Freight and logistics: Heavy duty 7 MANaging the toughest operations globally10 Scania: Heavy haulage tractors with AMT11 Liebherr: Sales and service centre Miami, Florida

Freight and logistics: Abnormal loads12 BTS: Mega move for Barloworld Transport Solutions

Freight and logistics: Fuels and fi lters14 Filter Focus: Dramatically improve operating lifespan of diesel equipment16 Donaldson’s Clean Fuel Corner: The need for clean fuel in new engine technology 17 Is going green the answer?20 Cummins: Redefi ning compact power capability

Fleet management22 Dapsol: Equipment Management Solutions

contents

Capital Equipment News is published monthly by Crown Publications cc

Editor: Kim Kempcapnews@crown.co.za

Advertising manager: Claudia Bertschyclaudiah@crown.co.za

Layout and design:Kristijan Srša

Circulation:Karen Smith

Successful aggregate and sand miners demand absolute effi ciency to carve a living from the bare earth, relying on effi cient and reliable machinery to bring their comparatively low cost commodity to the market profi tably. And Komatsu was there.

Story on page 2

capitalcapitalequipmentequipmentnewsnews

Publisher: Jenny WarwickPO Box 140 Bedfordview 2008 Tel: (011) 622-4770 Fax: (011) 615-6108www.crown.co.za

Printed by Tandym Cape

The views expressed in this publication are not necessarily those of the editor or the publisher.

Sold copies 1st quarter

2013

Free distribution 1st quarter

2013

Total 1st quarter

2013

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An Olympian challenge

FOR THOSE WHO have been asleep, Brazil is due to host the World Cup next year and the Olympics in 2016. Building work for both events is well under way, with refurbished and new stadia waiting to show off their combined splendour. Recently, stunning plans for the Olympic Park were unveiled, inspired by the same British designers who made the London Olympics such a resounding success, and last year, a media contingent was sent to São Paulo to view the building of a new stadium in that city.

However, protests have erupted around both events, with demonstrators particularly critical of the billions in public fi nancing being used to renovate and build stadia, arguing that a larger percentage of the country’s budget should be spent on improving infrastructure, transportation, schools and hospitals. (Sound familiar?) The difference is, that President Dilma Rousseff has proposed $25-billion in new spending on the country’s infrastructure and met with some of the protest leaders about their concerns.

After residents were moved 500m down the road to make way for the Olympic Park in Rio de Janeiro, the city’s Mayor, Eduardo Paes, was quoted as saying that residents were in “a much better place” in their new situation, but word is, that the property that they vacated will be sold off to the private sector once the event is over.

Well, at least they won’t have land standing vacant, with weeds pushing their way through the paving stones years down the line, I say…

So, on that sporting note, be informed and enjoy the read!

Seems that South Africans were not alone in questioning the viability of hosting the Soccer World Cup and the Olympics…

Artist impression: Rio de Janeiro's Olympic Park will be located next to the water's edge in the Barra area of the

city. The park will be built on the former Brazilian grand prix track in a striking triangular layout spread over 300 acres.

(image: www.dailymail.co.uk)

comment

CEN JUL2COVER

STORY

AMONG THE MORE SUCCESSFUL OPERATORS in the Gauteng region is Klipfontein Sands, which has operated in the Chloorkop area of Kempton Park for over 20 years. During this time, the company has gone from success to success using its own formula to break, excavate, process and haul a variety of sand and aggregate products to customers throughout the region.

The company has carefully selected the machinery required to work dependably within the company’s harsh, rocky environment, while delivering cost effective returns per ton moved. Not surprisingly, the mine has specifi ed Komatsu machines for all mission-critical loading operations, including both excavations and loading work.

King of the quarry

According to Klipfontein Sands’ Transport Manager, Harry Christou, the mine standardised on Komatsu excavators many years ago owing to the effi cient and unwavering reliability of the machines. Having tried a variety of other excavator brands since the quarry became operational, it was observed that the Komatsu machines are unmatched in terms of day-to-day production capability and reliability.

With a variety of different machines under his watchful eye, Harry is also an astute record keeper, with full operational records of every piece of equipment on the mine. These same records continue to contribute to the company’s ongoing decision to renew its fl eet with the latest, most suitable replacement machine from Komatsu.

He comments, “In order to be profi table, we have to work to very tight production schedules with only the best equipment. From the pit, where the PC300 excavators begin the process, to the fi nal loading with WA430 loaders, we are able to extract the maximum effi ciency with the use of the right machines for the job.”

He notes that in future the mine will have the ability to monitor performance of all the new PC300-8 excavators, as well as the WA430-6 wheel loaders, even more closely, as the new equipment is outfi tted with Komatsu’s Komtrax onboard management system. The system enables operational monitoring of each machine, as well as fuel consumption and the overall effi ciency of both the machine and the operator.

Successful aggregate

and sand miners

demand absolute

effi ciency to carve a

living from the bare

earth, relying on

effi cient and reliable

machinery to bring

their comparatively low

cost commodity to the

market profi tably.

Above: Hard at work on the Klipfontein Sands quarry, the Komatsu WA430 wheel loaders are

strong and heavy enough to undertake high-production workloads, along with the agility to

get around the quarry easily.

Komatsu thrives Komatsu thrives

CEN JUL3

Tortuous conditions

“Our quarry is a hot, rocky and rough environment. It produces everything from building and crusher sand to fi ne, medium and large diameter aggregates, as well as fi lling materials and rock for drainage and other projects,” he says.

From past experience, Klipfontein Sands’ General Manager, Bennie Botha, believes that the type of machines employed in the quarry need to be versatile, with the ability to work in fi ne sand environments one moment and later, move to back-breaking rock or shale excavations.

“In our operation, the PC300 series machines are ideal. At 31 tons with a 194kW engine, they are strong and heavy enough to undertake high-production workloads and with an overall length of 11m and a track length of just 3.7m, they are agile enough to get around the quarry easily. The advanced hydraulics also allow for fast swing and operational speeds without sacrifi cing power.”

He continues, “The WA430 wheel loaders are suited equally well to the processing yard. After crushing and sizing, the fi nal product is ready for loading and fi nal delivery. In this environment the WA430 loaders provide the right combination of power and size, in a fast and manoeuvrable package, to ensure that tipper and bulk carrying trucks are loaded quickly and effi ciently for delivery to customers.”

About the company

Klipfontein Sands is a quarry supplying bulk sand and aggregates to the building and construction industry. Since its establishment, the company has grown and expanded its operation, relying on astute hands-on management and careful selection of capital equipment.

Equally important in the success of the operation is service and back-up from its suppliers, in order to ensure minimal disruption of production for planned and unplanned maintenance.

“We can’t afford extended downtime and, as a result, select suppliers that can provide us with the type of service and support we require. Komatsu fulfi ls our requirement for quality of equipment and aftersales support and we look forward to an ongoing good relationship between our companies in future,” Harry says in conclusion.

Klipfontein Sands’ Transport Manager, Harry Christou, says that Komatsu fulfi ls requirements for quality of equipment and after sales support.

With a variety of different machines under his watchful eye, Harry is also an astute record keeper, with full operational records of every piece of equipment on the mine.

on hard labouron hard labour

CEN JUL4CONSTRUCTION

INTO AFRICA ...AND BEYOND

READYMIX (WI) is one of Trinidad’s top producers of high quality concrete and related products and was in need of a new wash plant to replace its existing plant that was challenged with ineffi ciencies, maintenance and production issues. Readymix (WI) chose to work with DUO PLC, which has more than 35 years of industry experience and is also well known within the Caribbean region. After careful analysis of Readymix’s specifi c requirements – paying particular attention to the varied high silt feed material – DUO proposed a custom Terex Washing Systems’ plant that is now effectively processing clay-bound sand and gravel to produce three aggregates and one grade of sand, while operating at 200 tons per hour.

Readymix (WI) selected a Terex plant over other options specifi cally owing to the expertise DUO and Terex offered in the fi eld and the ability to provide a comprehensive sales and support package. Ravi Singh, Quarry Manager for ReadyMix (WI), comments, “DUO and Terex thoroughly investigated the product to be processed; analysing it thoroughly and from this, designed a bespoke plant most suited to our individual needs.

“In addition, they provided a dedicated team of engineers, sales and aftersales technicians to support throughout the plant installation and commissioning process.” The plant consists of an H9 feeder; 206R screenbox; FM 200C cyclone; 146 dewatering screen; PS 200R

Terex Terex in tropical Trinidadin tropical TrinidadDUO PLC, a Terex

Wa shing Systems

global distributor

installed a custom-

built Terex® sand and

gravel washplant at the

Readymix West Indies

site in Valencia, Trinidad.

The DUO/TWS washplant set up:Natural clay bound sand and gravel feed material is fi rst delivered to an H9 feeder vibrating grid, which removes the 100m+ material. The inclined lattice frame feed conveyor, which was design and built by DUO’s manufacturing division, then delivers the material to our 206R two deck rinsing screen to get an initial effective grading. At this stage, the top deck removes the +75mm material which is stockpiled using a TC 4026 conveyor.

The bottom deck removes the 6mm to 75mm material, while the material below 6mm is pumped into a FM 200C cyclone, where a 0 to 6mm instantly salable sand is produced. The Terex FM 200C cyclone is a sand recovery unit with a centrifugal slurry pump, twin hydrocyclones, a collection

Above: This is one of many TWS plants that DUO has installed as it continues to show

that it provides a solution for the customer’s individual needs; a trait achieved through years

of expertise from rich heritage and legacy companies. Post plant installation, TWS is

committed to providing outstanding customer support which is realised through its

global distributor network.

tank and a 14x6 dewatering screen. It is capable of producing one or two grades of sand; in this particular plant the customer has opted for one grade.

Owing to the high and varied levels of silt content in the material, the aggregates require additional scrubbing to help ensure they are cleaned to specifi cation. This is achieved through the PS 200R washer unit. The system is specifi cally designed to work in the recycling industry, its versatility and design enables it to

logwasher; 165D dry screen; two lattice frame feed conveyors and four TC 4026 conveyors to achieve the customers desired grades.

Luke Talbot, International Sales Manager for DUO, comments, “We were delighted when Readymix selected DUO as its preferred supplier for the washplant, which reinforces the success of our previous projects installed in this market and shows the strength of our reputation in the region. The new plant has been very well received and will certainly add a new dimension and increased effi ciency to the overall production.”

Ravi adds, “This new plant has replaced an existing barrel type washing plant. The maintenance costs on the old plant were extremely high, which left it less cost effective for processing. However, the TWS equipment has much lower maintenance costs, has maximum effi ciency and productivity and allows us to be ultimately more competitive in the market. The newly designed plant also allows us to get a cleaner, more desirable product.”

Following a recent trip to the Trinidad site, Fergal McPhillips, Sales Manager TWS, comments, “The plant is effectively addressing Readymix’s problems. It is achieving excellent results by being much more effi cient while generating outstanding commercial output and dealing with the demands of the construction market.”

The wash plant has been in operation for one month now and Ravi, adds, “We are extremely impressed and excited about the prospects of this new Terex washplant, which is currently operating at 200tph. We can firmly say this is the largest project the company has embarked on for a long time and undoubtedly the most successful in terms of production. The entire team involved in the project at Readymix (WI) has been extremely impressed with all aspects of the plant from initial conception through to final end product, including consultation, engineering, service and aftersales support from both DUO and TWS.”

Sean Loughran, Director of TWS, says, “The Trinidad sand and gravel washplant is a demonstration of yet another complex plant offered by DUO and TWS.

“DUO is highly respected within the Trinidad market, having installed a number of other plants. It is valued not only for high quality products they sell but also for the high quality products it sells, but also for its high levels of application, technical knowledge and after sales care and support.”

Ravi Singh adds in conclusion, “What was also particularly appealing is the availability of spares if required and in addition the direct face to face contact we had with both DUO and TWS. The level of service was second to none throughout the installation and fi nal commissioning of the plant.”

be easily adapted to work in gravel applications. Dewatering screens are fi tted to either end of the machine, which consists of a trough and two spiral axles, counter rotating to each other, with exchangeable blades to intensively scrub the feed material. Friction from this

process breaks down clay conglomerates and allows scrubbed material to be stockpiled.

Once the aggregates pass through the PS 200R washer, they are discharged onto a second DUO lattice frame conveyor. These 6mm to 75mm aggregates are delivered onto a 165D – 2 deck dry screen to achieve a three-way split: classifying material into the customers desired grades, six to 10mm, 10 to 20mm and 20 to 75mm. At this point the wash plant uses settling ponds for its dirty water.

Dirty water from the FM plant, which contains material below 75 micron (silts/clays), is sent to a series of ponds. The ponds are set up so that the silt drops to the bottom and clean water weirs over the top, producing clean, reusable water. In the future, it may be possible to incorporate a Terex water treatment plant to eliminate the need for ponds altogether.

The entire plant is controlled and monitored from a central PLC electrical control panel housed within an ISO 20’ container. The panel is programmed for automated start up and shut down sequences and was fully wired and programmed before leaving the factory.

“DUO and Terex thoroughly investigated the product to be processed; analysing it thoroughly and from this, designed a bespoke plant most suited to our individual needs.”

CEN JUL6

BERGMANN MASCHINENBAU GMBH & CO. KG has introduced the new hatchback dumper 2060 plus, combining a high level of

safety, comfort, and effi ciency.

The 2060 plus is the fi rst wheel dumper with a protective roof design, making it possible to reduce the transport height to 2550mm in just a few simple steps.

Protective roof

Bergmann offers a lowerable and tested ROPS-/FOPS protective roof, providing either mechanical or electrical lowering to a transport height of just

2550mm, and obviating time-consuming dismantling of the protective roof for transportation. The modularly designed protective roof can be upgraded into a fully-fl edged cabin as needed. The improved roof design opens up new applications for dumpers, such as winter maintenance vehicles and municipal transportation.

With the ROPS-/FOPS-protective roof, the new Bergmann plus-series also meets the requirements of the Machinery Directive for compact dumpers with an operating weight of over 4000kg. Accessories for front, side and rear window shields and a driver’s door are optional.

Increased productivity

In addition to the protective roof, the 2060 plus operator’s platform is designed with modern controls and the vehicle framework comes with a spring-loaded rear axle. A multi-function joystick reduces fatigue as the operator is able to steer the various functions with ease, resulting in improved handling and greater driving comfort. The suspension system is best appreciated on uneven construction site roads. Quick, hard blows are absorbed, enabling the operator to maintain comparatively high speeds with ease. The system offers approximately 20% higher transport speed and thus higher materials handling.

New drive technology

The machine is powered by a powerful 4-cylinder Cummins diesel engine with 63kW/86hp, complying with current emission guidelines (Tier 4 Interim/Step 3B). The powerful hydrostatic four-wheel drive with automotive control is optimally adapted to the engine and chassis, ensuring a smooth, continuous drive.

The machine easily achieves a speed of 30km/h on the road. In addition, the self-locking differential, built into the axes – with a locking factor increase of 45% – increases off-road capability. It uses hydraulic oil bath disc brakes, providing the vehicle with safety and reliability even in arduous environments. It operates perfectly in all weather conditions and affords stability even on steep slopes.

Added security

The user-friendly operator’s platform was designed so that the driver has an excellent panoramic view of the machine and its environment. All instruments and operating controls are ergonomically designed and are in the driver’s fi eld of vision. Plastic hoods and coverings ensure excellent sound absorption and low noise emissions. For additional safety, the generously designed access to the operator’s platform is located over the rear of the machine, away from the articulated joint. The rear of the 2060 plus is about 30cm shorter, allowing the driver a clear view of the road when driving backwards.

Hatchback dumper with added safety

Technical Specifi cations

Payload: 6000kg

Dead weight: 4045kg

Trough content: 2.400l (dropped) 3.6m³ (heaped)

Engine: Cummins 4-cylinder, water-cooled

Performance: 63kW/86hp

Speed: Step 1: 0 to 6km/h 0 to 30km/h

Drive: Sauer Danfoss hydrostatic four-wheel drive

Operating brake: Inboard oil-bath disc brakes acting on four wheels

Parking breaks: Hydraulic released spring brakes on all four wheels

Axles: With self-locking differentials, locking factor 45% of ZF spring-suspended rear axle

Steering: Hydraulic pivot steering L/R 38

Dimensions:

Length x Width x Height: 4460x2040x3040mm

Transport height: 2550mm

Steering radius: 4.527mm (exterior)

Tyres: 405/70 R20 as profi le

CONSTRUCTIONINTO AFRICA

...AND BEYOND

THE TWO WHEEL LOADERS are deployed in Marc DeSousa’s business for loading construction materials. A powerful and stable machine is essential for loading 2-ton cement pallets or sacks of sand. Compared to backhoe loaders and compact loaders, the 850 works more effi ciently and, with its excellent manoeuvrability, can be used in small areas. The turning circle of the 850 is just 2.55m, with a load capacity of 2.3 tons and a tipping load of three tons. The 4.5-ton wheel loader is ideal for transporting heavy construction materials and, with a bucket volume between 0.85 and 1.4m3, the wheel loader can also handle larger transport loads.

An important advantage that Marc has found is the hydraulic quick-hitch, which is fi tted as standard and enables loading buckets on the pallet fork to be quickly switched, thus achieving fast work cycles. “With a special loading bucket, the wheel loader can also fi ll individual sacks with sand and concrete aggregate materials, something previously we had to do by hand. This is an enormous relief. The 850 is also able to load and unload trucks from one side. This means the truck requires much less space than previously; a defi nite plus in confi ned conditions. Using a forklift, this was previously only possible from both sides and required a lot more space,” he enthuses.

The Wacker Neuson branch in South Africa is seeing a growing interest for its compact wheel loaders: “When we introduced the wheel loaders and their technological features here for the fi rst time in 2009, we initially met with scepticism. But when we demonstrated the possibilities of the all-wheel steering and the hydraulic quick-hitch in particular, our customers were soon impressed. At the end of 2011, barely three years later, we were the market leader in South and sub-Saharan Africa with a market share of approximately 37% for compact wheel loaders,” explains Stephan Peyper, Sales Representative at Wacker Neuson South Africa.

Powerful deployment in the African heat

Two Wacker Neuson 850

wheel loaders are proving

their worth, loading heavy

construction materials in

the South African town of

Edenvale. High stability

and manoeuvrability mean

cost-effectiveness and safe

working on the premises

of the ‘Build It’ builder’s

merchant.

Above: Cost effective Wacker Neuson 850 wheel loader offers stability and manoeuvrability.

CEN JUL10COMPANY

PROFILE

PILOT CRUSHTEC INTERNATIONAL (PTY) LTD is South Africa’s leading supplier of mobile and semi-mobile crushing, screening and material handling solutions. With an annual turnover exceeding ZAR550-million and employing 160 people at its head offi ce and assembly factory in Jet Park, Boksburg, it markets its products and services in over 40 countries.

At a media briefi ng, Sandro stated that he had two announcements: “I have been very hard at work bedding down the Sandvik distributorship and, more signifi cantly, working on a deal to buy out all my partners in Pilot Crushtec. Today, I am pleased to announce that a transaction was fi nalised in February of this year and from the 1st March 2013, we began trading as a new entity called Pilot Crushtec International (Pty) Ltd. For the fi rst time since starting Pilot Crushtec 23 years ago, I indirectly own 100% of the equity in the company.”

He went on to introduce the new ad campaign, titled the ‘The Power of Pilot’. “The words big, bigger, power, more powerful, are freely used in this campaign as we believe they beautifully sum up our bigger and more powerful new products, our bigger product range, the present scale of our company and our plans for the future.

“With our new partnerships, we can now answer the market call for bigger and better products to meet the crushing and screening requirements of bigger mines with tougher rocks and diffi cult operating conditions.”

He added that Pilot’s recent partnership with Sandvik Construction, “has to be one of the most exciting events in our 23-year history, as the power unleashed by these high output machines will have an exceptional effect on our current and future customers’ productivity and profi tability. We’re setting a new course and the destination is growth.”

Owing to its continued growth, there has been signifi cant investment in improving the existing premises, with emphasis on the spare parts sales area. “We are upgrading this area to provide those customers who are collecting spare parts with a more pleasant and speedy interaction,” he said. In addition, there has been further capex approved to create shelving systems that will increase the stores capacity.

Something BIGBIG happening

Deviating from his

prepared speech,

Sandro Sherf,

CEO, Pilot Crushtec,

was upbeat when

he announced to

the media that the

company was in

for BIG things…

Above: Sandro Scherf, CEO Pilot Crushtec International (PTY) Ltd is upbeat

about the BIG future of the company.

Continuing, he said, “We are recruiting additional sales engineers and service and technical support staff which will mean a substantial increase in our fl eet of support vehicles. It will also see us increasing expenditure on training provided by our international suppliers.”

Further development is the establishment of an on-line call centre with experienced staff to provide customers with immediate diagnostic and service advice as and when required. “This will be in place within the next three months,” he said.

As space has become an issue, a move to new and larger premises or a major expansion of the existing facility is “defi nitely on the cards,” he commented, with the possibility of splitting the operation between the existing premises and the new premises.

He believes that these developments dovetail perfectly with the new advertising campaign which projects a clear and concise message: ‘One of the biggest names in the crushing and screening industries, just got bigger!’

He added that passion was a vital ingredient in the new mix and drew attention to his team, “We are passionate about our business, the products we sell and the industry. This passion will see us grow into a truly international company.”

With two dealerships already established in Tanzania and Namibia, Pilot Crushtec’s African footprint extends into Zimbabwe, Zambia, Tanzania and the DRC with its eye on expanding into Mozambique, Ghana and Nigeria.

The company aims to achieve long-term growth and sustainability in its business by creating value through leadership in every market in which it operates.

It is active in industries as diverse as coal, diamond, gold, cobalt and platinum mining, aggregate and sand quarrying, construction, civil engineering and recycling.

It provides the best industrial solutions for its customers, by sharing its vast experience and knowledge; by innovating and pushing the accepted boundaries and by always conducting business based on long term, enduring relationships, trust and perseverance.

Pilot Crushtec has a range of its own brands that are market leaders in their respective product and service niches.

These include: Sandvik Construction, with a leading position in the industry, offers an extensive product range that includes large capacity mobile products for hard rock mining and quarrying applications. These incorporate heavy and extra-heavy duty crushers and serves a broad range of customers

Twister Vertical Shaft Impact Crushers, used for manufacturing “in-spec”, high quality, cubical shaped aggregates and sand for road topping, high-strength concrete and for making fi nes for industrial and pre-milling applications

TwisterTrac, a fully mobile, diesel hydraulic, remote controlled, tracked version of the Twister crusher

Pilot Modular, a complete standard range of semi-mobile, skid-mounted, ready to run, crushing, screening and conveying equipment, designed for rapid installation and to be easily adaptable for ever-changing applications and or requirements. Turnkey plants for all requirements can be quickly and effi ciently designed, installed and commissioned within days

Rubble Master, a world leading range of high-quality, powerful compact recycling crushers designed for economic recycling of a wide variety of materials to make high value aggregate.

CDE Global, an extensive range of equipment offers customers excellent results including high quality sand, production of sand and aggregates to your desired specifi cation and recovery of up to 90% of water used in your washing plant signifi cantly reducing the volume of fresh water required.

RubbleBuster, a fully mobile, tracked, diesel hydraulic, remote controlled, loading, crushing and stockpiling machine for diverse recycling applications, including construction and demolition waste, asphalt paving, clay and concrete bricks and blocks, porcelain, ceramics glass and other solid waste

DF Ecology, specialises in the development, production and marketing of a range of dust control system equipment ideal for use by demolition contractors, recycling and construction companies.

Towerlight, the global market leader and manufacturer of the world’s largest lighting towers for all lighting applications in the construction mining, rail, airport and event industries.

Tecon Crushpactor, a tow-behind, rugged machine that simultaneously and rapidly crushes and compacts a wide variety of borrow-pit rock, aggregate and sand for sub-base and base course layers in asphalt road construction

Rapidscreen, a versatile screening media that can be retrofi tted into most mobile and static inclined screens to increase production by reducing or eliminating blinding, blocking and pegging Pilot Crushtec also has three divisions that provide the vital after market support link between manufacturer and customer for all its products:

PartsLink, provides the necessary stock and availability of replacement and wear parts

InstalLink, provides equipped, qualifi ed and experienced personnel to professionally install and commission plants

SupportLink, provides equipped, qualifi ed and experienced personnel to professionally service or repair to all its products.

“With our new partnerships, we can now answer the market call for bigger and better products to meet the crushing and screening requirements of bigger mines with tougher rocks and diffi cult operating conditions.”

CEN JUL12TECHNOLOGY

CONTROLLING DUST IS NOT SHORT-SIGHTED and mining houses will have no option but to become better informed about new environmental requirements and get up-to-speed on how best to manage dust emissions.

Although it is accepted in industry that regulations take a long time to implement and therefore infl uence business operations, the important thing to consider is, that the legislative process has started and that strategic planning around the control of dust on mines needs to start taking place.

Heathcliff Barnard, Technical Manager at Pneumax, states, “The problem of controlling dust during mining operations is increasingly coming under the spotlight as regulations in this regard are currently being fi ne-tuned by two departments of government,” that is, the Department of Environmental Affairs and the Department of Minerals and Energy. He continues, “Often, attention is focused on the environmental impacts of acid mine drainage or the lack of rehabilitation of mines, because the impact of these types of problems are immediately visible. However, what is often overlooked is the control of air quality around mines – simply because we can’t see a problem until there is an extreme impact on people in close proximity to a mine. Because the control of dust is currently not regulated in mining, mining operators often take short cuts regarding this type of pollution in order to keep operational costs down. Nevertheless, this will change in the near future.”

Raising awareness

Knowing that legislation often takes years to be fi nalised and then applied to industry, it is important to start informing and educating young engineers making their way into the economy about how the control of dust can contribute to greener mining – a subject that is becoming increasingly important throughout the world. An initiative that Pneumax has recently become involved in is the PneuDrive Challenge, a student mechatronic innovation competition which it co-sponsors with SEW Eurodrive. The theme of this year’s competition is ‘Greener Mining’ – highlighting engineering processes and solutions for engineering students not yet familiar with mining.

Controlling dust emissions

Control of dust emissions was one of the problem statements put forward in the competition and students are invited to design an application that can successfully address this problem. Bag houses are essentially large fi ltration boxes, and although uncomplicated on an engineering level, it is the use of the correct components and the engineering processes related to bag houses that are critical for the successful control of airborne particles. This is a business and engineering element of mining that students will not be exposed to at university.

Bag houses can be made up of many fi ltration units that could cover large areas on a mine. However, it is the components that make up the fi ltration units of bag houses that are essential for the effective fi ltering of dust particles. Two components from Pneumax that are critical to the effectiveness of bag houses – the Turbo Pulse Valve and the Optyma Terminal Valve – are not visible from ground level, so, to the untrained eye, it is easy to underestimate how relatively small components could mean the difference between meeting regulations or not.

Heathcliff says in conclusion, “Hopefully, by engaging young minds around the design and operation of bag houses, we can encourage students to come up with a revolutionary way of addressing this very basic mining problem.”

Environmentally friendly dust management solutions

In the past, because of a lack

of regulation, controlling

dust around mines was an

‘optional choice’ that many

mining operations avoided

because it was viewed as an

unnecessary expense.

Heath Barnard, Pneumax Technical Manager, sharing pneumatic knowledge with students.

Pneumax: Turbo Pulse Valve for Dust Collection Filtration Systems.

CEN JUL14TECHNOLOGY

WITH 100 YEARS of innovative rubber compounding research, Goodyear® Engineered Products was able to push the limits of tough when designing the ConquestXP™.

The belt was developed using computer modelling and Finite Element Analysis (FEA) software and is fortifi ed with the power of Fortress™ Technology, which makes it extremely tough against punctures and impact.

Its technology supports various cover compounds that offer enhanced protection for arduous applications. The abrasion covers available are ‘M’ Grade, which provides superior resistance to cutting, tearing gouging and abrasion in the harshest environment and is suitable for conveying ores of all kinds: granite; quartzite and other heavy sharp-edged materials; and ‘N’ Grade which is recommended for conveying slag, limestone, cement rock, iron ore, coal and other materials where metal is present.

Cover compound F+ is available. It has fi re retardant properties and is ideal for coal carrying services where plied or steel cord constructions are utilised.

“Also unique to ConquestXP™ is SHIELD™, a fi re-retardant runner compound with a low smoke density and reduced toxic gas emissions. In case of a fi re, this will result in improved visibility and lower toxic fume levels, making it ideal for underground mining applications,” explains Craig Rouhana, Sales and Marketing Director of Veyance Technologies South Africa.

ConquestXP™ forms part of the textile reinforced belt range, ensuring extreme durability, and is designed for primary crushers, secondary crushers, mainlines, pit belts, refuse and recycling, log debarkers and other high-abuse applications. The innovative patented fabric provides improved bearing and impact resistance to sustain high-abuse applications. The dual layer twill fabric delivers high transverse tear strength, which minimises tears that cause material punctures. Other features include superior rip resistance, which helps dislodge and expel foreign objects.

Goodyear® Engineered Products undergo stringent testing with the most precise equipment in the world, warranting that only the toughest belts are developed. “We are constantly pushing our boundaries to refi ne ‘tough’ in the conveyor belt industry and with the help of revolutionary technological research and development, we hope to continue leading the way in belting technology,” says Craig.

ConquestXP™

– the toughest belt yet!

Goodyear® Engineered

Products, manufactured and

sourced exclusively by Veyance

Technologies Inc., is proud to

announce the launch of its

conveyor belt ConquestXP™.

ConquestXP™ is an industry

leader in strength and impact

resistance, designed to

withstand the harshest and

toughest belting environments.

Above: ConquestXP™ forms part of the textile reinforced belt range, ensuring

extreme durability, and is designed for high-abuse applications.

THE MANUFACTURING and the supporting tool, die and mouldmaking industries struggle with serious skills shortages.

Addressing the annual general meeting of the Toolmaking Association of South Africa (TASA)  Gauteng in Midrand, the outgoing Chairperson, Mr Ron MacLarty said that 213 apprentices were currently being trained as part of the TDM Powered Foundation Phase and Apprenticeship Programmes.

“Through the efforts of the National Tooling Initiative Programme (NTIP), a wholly owned TASA company, an additional 332 apprentices started training in April 2013. This will bring the total number of apprentices in class in Gauteng in 2013 to 545 and nationally to over 1200. Direct funding expended on the TDM Powered Skills Development Programme to date is R110-million,” he adds.

“All TDM Powered apprentices were placed with companies for ‘On the Job’ training in 2012, and feedback from the companies has been very positive. By all accounts, the apprentices are, on the whole, high potential candidates. The year on year retention rate is in excess of 80%, which is well above the international standard.”

At the same meeting, the National Chairperson of the Toolmaking Association of South Africa, Mr Bob Williamson, said that more than 6000 jobs in the local manufacturing and tool die and mouldmaking industries were currently unfi lled owing to a lack of skills. He said that quality training was crucial to fi ll these posts as a single toolmaker could create up to 28 sustainable downstream jobs. He welcomed the Masters Artisan phase to be introduced as the next phase of the TDM Powered Programme.

The South African manufacturing

sector will receive a huge boost

from July 2014 when more

than 500 toolmakers, with

an internationally accredited,

government certifi ed toolmaking

qualifi cation, become

available to the sector.

Outgoing Chairperson of TASA Gauteng, Ron MacLarty congratulates the new Chairperson, Phil Sipengane. At the back is the National Chairperson of TASA, Bob Williamson.

Huge boost for the South African manufacturing sector

CEN JUL16

EVERY MINE requires a customised approach that Scania is prepared to design jointly with the operator, regardless of whether it is a local or global operation. Besides specialised mining trucks, the offer includes buses for crew transport, engines to power mining equipment and generator sets, as well as container-based fi eld workshops for on-site servicing and training for drivers and service staff.

Profi tability in mining is heavily dependent on carefully controlling capital and operating costs. Transportation often takes 30 to 60% of the total operating costs, and rising fuel prices have put fuel consumption on everyone’s agenda. Volatile mineral prices combined with the decrease in prime mineral bodies are making secondary deposits increasingly interesting for exploration and exploitation.

These smaller mines and extensions from existing mines often lead to longer transport routes from the mine to the processing plant. This provides an advantage for smaller, less expensive ‘road trucks’ that are considerably more fuel-effi cient than bigger machinery that may consume 50 to 60 litres/hour. The corresponding fi gure for a Scania truck is generally less than half.

Trucks of the size that Scania offers have benefi ts that affect cost and productivity. For on-site transport, smaller trucks have signifi cant advantages since they can operate on narrow roads that are less expensive to build and maintain. They also provide extra fl exibility in transport capacity. For outbound haulage, they can run on public roads if required.

Flexible solutions

Scania offers solutions for every stage in mining, from exploration to reclamation and everything in between, starting with rigid dump trucks up to 46 tons for in-pit mining or moving out with 120-ton outbound combinations. Scania can put the right equipment in place to optimise logistics.

Gruelling operating conditions on remote sites provide a challenge in terms of servicing and parts supply. Parts are never far off, with more than 20 regional distribution depots and 1600 service points worldwide.

Scania vehicles and components are based on a long tradition of modular designs that use around 30% fewer parts than the industry average, making for easier servicing and parts supply and positively affecting uptime and costs, as well as equipment availability. Parts that go into its truck engines are also used in gensets and buses. This facilitates recruitment and training of mechanics and technicians.

Scania’s fi eld workshops are based on a modular container system that can be put into operation a week or two after a concrete foundation has been laid, a concept that has proved its worth in many countries worldwide.

Driver training is part of the Scania offer, with a potential to contribute valuable fuel savings, as well as reduced wear and tear. The training can be adapted to suit local conditions and the level of driver competence. Scania can also tailor fi nancing, leasing and rental solutions to suit operators’ needs.

Planning services

In addition, Scania offers advisory services in logistics, transportation planning, road economics and monitoring of ongoing operations, based on Scania’s experience in lean production and ability to match vehicle confi gurations and transport capacity to specifi c operating requirements. In many cases, this can contribute to improved production fl ows and increased productivity.

MiningMining – fl exible

offers from Scania

Scania gathers all the

experience gained

during more than a century

in the heavy vehicle

industry to provide a range of

attractive solutions for mining

companies, tailored to

form vital links in their

production chains.

Above: Scania’s fi eld workshops are based on a modular container system that can be put

into operation a week or two after a concrete foundation has been laid, a concept that has

proved its worth in many countries worldwide.

MININGINTO AFRICA

...AND BEYOND

CEN JUL18

IN EARLY 2010, three independent experts undertook a resource statement for Ghaghoo, which determined Ghaghoo’s total carat resource to be 20.5-million carats with a total in situ value of US$3.3-billion.

Two blue diamonds were recovered from samples during the valuation work – a fi nd of some signifi cance in such a small parcel, given the extreme rarity of these diamonds. As a result of the fi ndings, in August 2010, Gem Diamonds presented the Botswana Government with an updated study on Ghaghoo, including the option of an underground mine. Upon acceptance, Gem Diamonds’ board approved a capital budget of US$87-million for the construction of Phase 1 of the Ghaghoo Diamond Mine project – a mammoth task, which Redpath Mining South Africa was well placed to take on.

Redpath Mining South Africa’s General Manager of Mining, Jan van Antwerp, says that the company’s overall scope of involvement in the project involved the development of a concrete-lined decline tunnel to 112 metres below the surface, at an inclination of eight degrees, using an open faced tunnel shield (OFTS), which weighs 50 tons and has a diameter of six metres.

Jan explains that the project began with the establishment of a box cut measuring 25 metres deep and 171 metres long. “Once the box cut had been developed and the portal support was in place, Redpath began excavation work for the sand tunnel, measuring 403 metres in pure sand and 121 metres in basalt. The tunnel is made up of concrete rings consisting of ten 75mm thick segments. The rings are designed to withstand a compressive force of 45mPa but are only required to withstand about 30mPa. The tunnel has a diameter of 6.1 metres.”

When completed, the tunnel will be made up of 8450 segments, consisting of 845 rings. “The width of each segment for this particular project is 0.61m, and we are aiming to move forward six segments or 3.6m-per-day,” he explains. This is accomplished by digging up to 0.7m and loading the sand onto the conveyer belt before it is fed out of the mine, and pushing the OFTS into that space.

Ground-breaking sand tunnel

Contract fi rm Redpath

Mining South Africa’s

involvement in the

sinking of a one-of-

a-kind decline sand

tunnel for junior

miner, Gem Diamonds’

Ghaghoo Diamond

Mine project in

Botswana, is nearing

completion.

MININGINTO AFRICA

...AND BEYOND

CEN JUL19

The Ghaghoo Diamond Mine is extremely remote and isolated, and the majority of the 93 Redpath staff members working on the project have been located on site. In order to maximise productivity and reduce logistical challenges, staff members work 14 days on and seven days off. As part of its commitment to social and economic development, Redpath South Africa has employed 78 staff members from communities surrounding the project. Jan says that the staff members working on site have been in high spirits throughout the project: “They’ve built up a camaraderie working together on a complex and diffi cult project.”

Gem Diamonds held numerous discussions and road shows for the local communities, in order to ensure that the population is directly involved in the project, while creating sustainable skills development in the area.

Gem Diamonds purchased the Gope Exploration Company Pty (Ltd), which owns the rights to the Gope Deposit, in 2007 from De Beers and Xstrata. It has since been renamed Ghaghoo Diamond Mine, and a mining licence was awarded to the company in January 2011. The name ‘Ghaghoo’ is historically used by the locals to refer to the area and comes from the name of an indigenous camel thorn acacia tree that is abundant in the region.

The Gope 25 kimberlite pipe was fi rst discovered in 1981, with drill shafts to date reaching 1000m into the volcanic rock. Gem Diamonds states that once the sand tunnel is complete, the decline will be extended to the kimberlite pipe, and Phase 1 of the mining will commence at 45ktpm. In parallel with this, a bankable feasibility study will be done for Phase 2 of the project.

The methodology used for the Ghaghoo Diamond Mine can be adapted to any type of softer medium, as it is the safest and most effi cient way to sink this kind of tunnel. Owing to the ground-breaking nature of this project, it will place Redpath in good standing for future projects. “It’s the fi rst time this has been done anywhere in the world,” Jan concludes.

When completed, the tunnel will be made up of 8450 segments, consisting of 845 rings.

From left: The tunnel and opening to the tunnel.

Redpath contractor operating the open faced shield at the face.

Redpath contractors removing waste at the rock face.

CEN JUL20

IN 2011, Volvo was one of the fi rst diesel engine manufacturers to receive stage 3B and Tier 4i certifi cates for its entire engine line-up. Later, the Volvo Penta 13L Tier 4i diesel engines were the fi rst engines to be certifi ed by the United States Mine Safety and Health Administration (MSHA) and the Canada Centre for Mineral and Energy Technology – Mining and Mineral Sciences Laboratories (CANMET-MMSL).

A full range

With its new extended – and completed – range of engines for mining applications Volvo Penta has made it easier for manufacturers of machines and vehicles for mining. Now, no one has to dig any deeper to fi nd a perfect Volvo Penta engine match for any given installation.

All in all the new engine line-up consists of 18 engine variants, nine certifi ed for Tier 2 and nine certifi ed for Tier 4i. The Tier 2 engines are the TAD 941/1340/1341/1342/1343/1344VE-series ranging from 300 to 479hp and the TAD1640/1641/1642VE-B-series which ranges between 551 and 700hp.

Outstanding ventilation rates

A major part of total costs in underground mining is ventilation of the mine. This fact is cause enough for manufacturers and mining operators to pay close attention to the remaining nine Volvo Penta Tier 4i engines in the new range. With a ventilation rate of around 30 CFM/hp, they deliver the maximum ventilation rate available for a conventional diesel engine. In other words: it doesn’t get any better.

The Tier 4i engines in the new range are the TAD1360/1361/1362/1363/1364/1365VE-series going from 348 to 551hp and the TAD1660/1661/1662VE-series between 551 and 70hp. All these Volvo Penta Tier 4i engines are equipped with a SCR (Selective Catalytic Reduction) unit.

Selective Catalytic Reduction

The SCR technology is the choice Volvo Penta has made to comply with current and future emission legislation. Since Volvo Penta introduced its fi rst SCR engines in 2006, the benefi ts for users have been increased power and lower fuel consumption – by fi ve to10% compared with corresponding engines. And, since the catalytic converter was designed to last the life of the engine, Volvo Penta SCR systems haven’t demanded an increase in service intervals, or caused any additional downtime.

The SCR system is based on high-effi ciency combustion that reduces fuel consumption and results in low levels of particulate matter (PM), and in high levels of nitrogen oxides (NOx). The exhaust NOx is converted into harmless nitrogen gas and water vapour. This is made possibleby the SCR system which automatically injects up to 5% AdBlue®, a diesel exhaust fl uid, to the exhaust gases. The gases are then passed through a catalytic converter before they are emitted to the environment. The extremely low levels of particulate matter in the emissions make exhaust gas fi ltration (DPF) unnecessary.

Volvo Penta’s Volvo Penta’s extended extended range of range of engines engines for miningfor mining

Above: The new Volvo Penta engine range for mining applications provide outstanding

ventilation rates.

With the introduction of a

number of new engine variants,

Volvo Penta can now offer the

mining industry a complete

range of engines approved for

underground mining applications.

The selection of nine Tier 2

engines and nine Tier 4i engines

– which provide outstanding

ventilation rates – enable

manufacturers and users of

mining equipment to make the

perfect Volvo Penta engine choice.

MININGINTO AFRICA

...AND BEYOND

CEN JUL23 MINING

SAFETY

THE CWS 800 COLLISION WARNING SYSTEM, recently supplied by Booyco Electronics to a copper mine in Zambia, increases situational awareness and minimises accidents by actively alerting the operator and mineworkers to imminent threats.

“We have a strong footprint of installations in South African mines, but this is the fi rst cross-border order we have received for the CWS 800. The system, which is currently being installed, will service all underground miners,” says Managing Director of Booyco Electronics, Anton Lourens.

A single blind-spot accident, even without injuries, can put mining operations on hold for days. The resulting repair costs, equipment downtime, administrative requirements and lost productivity all have a signifi cant impact on the bottom line. That is why collision warning and intervention is high on the list of priorities for mining companies.

As attention on the health and safety of mineworkers continues to escalate, mines are forced to provide employees with tools that enhance their wellbeing. “A Mining Industry Occupational Safety and Health (MOSH) focus group, known as the Transport and Machinery Adoption Team, is recommending processes to address the widespread adoption of safe practices. It would therefore behove mine management to consider automated accident prevention technology,” Anton points out.

Currently, as the largest supplier of collision warning systems in South Africa, Booyco Electronics has 35 000 miner lamp installations in South African mines. “However, in order to comply with legislation, a substantial increase in the number of systems on mines is required. We have noticed that other cross-border countries, such as Zambia, are taking note of the positive results the CWS 800 collision warning system produces in improved accident containment on our local mines,” Anton adds.

He explains that a collision warning systems consists of a sensor that detects the presence of an object, an interface that provides an audible and/or visual alarm to the equipment operator and wiring between the two. “Very low frequency (VLF) technology is best for warning pedestrians who work near moving machinery, while ultra-high frequency (UHF) signalling is applied to warn the operators. The CWS 800 system employs both technologies for increased accuracy and reliability.

“Supplying dependable safety systems to the mining sector is a top priority at Booyco Electronics. Our strategic alliances with VAK Technical Solutions and Selectronic Funk-und Sicherheitstechnik GmbH ensure that Booyco Electronics is able address the specifi c needs of the industry. We will continue to service the needs of the local market, whilst concurrently expanding into sub-Saharan countries,” he says in conclusion.

Collision warning system in ZambiaCollisions between heavy

and light vehicles, as well as

underground vehicles and

pedestrians, are amongst

the most common types

of accidents on mine sites.

These accidents, caused

primarily by poor visibility,

can be reduced or

even prevented.

Left: The CWS 800 collision warning system was recently supplied by Booyco Electronics to a copper mine in Zambia.

CEN JUL24MINING

SAFETY

ACCORDING TO JOHANN SMIT, Chief Sales Offi cer, Becker Mining South Africa (Pty) Ltd, “The company’s commitment to providing a critical service to the mines and general industry, encompasses the design and manufacture of products and systems, using the latest technology. A specialised consulting, training and support facility ensures optimum effi ciency of a wide range of equipment and total safety for workers underground. Mine safety is signifi cantly enhanced by the implementation of one or a combination of Becker’s specialised multi-technological solutions.”

Becker steel arch support systems are designed for use in friable ground in tunnel applications, including haulages, incline shaft portals and special shafts. These mine support systems are critical for the safety of any mining or tunnelling project and Johann expects sales growth to remain positive, “as long as mines expand and new operations are opened,” he adds.

“Becker Mining South Africa specialises in the manufacture of steel arch supports, but the company’s German and Polish subsidiaries also manufacture long wall coal mining shield support systems for European, Asian and North American coal mines. South Africa’s strata conditions are not suitable for long wall mining, which is why the company only manufactures steel arch supports,” he explains.

The Becker steel arch support system fi nds application in all types of mining owing to the adaptability of the design which fi ts into any shape of excavation. This engineered structure is timeless because of the characteristics of steel used and the mechanical properties derived for the shape of elements of the roof support system.

“More and more applications for these well engineered and adaptable systems are being developed for customers who require long term stand-up support solutions for friable ground conditions,” Johann says.

Local applications for these steel arch support systems include gold and platinum mines, as well as underground civil engineering projects like the Gautrain. Becker’s roof support systems have also been exported recently into Australasian and African mines, with Zambia as a key user.

Becker Mining South Africa also provides specialised training to customers for the assembly and installation of steel arch support sets.

The company’s specialist manufacturing operation at the Chamdor factory in Krugersdorp, is committed to the most stringent quality control procedures during production. These standards conform with the expectations and demands of the global mining industry, including ISO 9001:2008 specifi cations. Rigorous tests, which include the chemical and mechanical verifi cation of materials, are performed throughout each production process.

The production line is capable of moving 250 tons of TH profi le a month. The factory is equipped with four bending presses, one of which is semi-automatic. All arch sets are pre-assembled and inspected prior to delivery.

The local operation benefi ts from Becker’s ongoing research and development programme locally and in Germany. Close international ties guarantee the edge on product design, impeccable manufacturing standards, cost effi ciency, safety and reliability of equipment.

Becker Mining South Africa’s extensive product portfolio – which complies with government mining regulations and mining house specifi cations – includes: shaft safety components; underground and tunnel supports; transport systems and communication and collision avoidance systems. The range also encompasses pumps, electrical and electronics systems, mechanical equipment, as well as lifting and maintenance equipment.

Safe tunnelling with

Becker MiningBecker MiningBecker Mining South

Africa plays a key role in

ensuring optimum quality,

performance and safety

standards in the local

mining sector.

Becker steel arch support systems are designed for use in friable ground in tunnel applications,

including haulages, incline shaft portals and special shafts.

Transport Freight and Logistics

Land, sea and air, Allcare Logistix does it all

July 2013

Redefi ning compact power capability

Managing the toughest operations globally

Sales and service centre in Miami, Florida

Fuelling discontentOnce again fuel hikes are decimating the economy, with no reprieve in sight...

Editor’s comment 1 Fuelling discontent

Cover story 2 Land, sea and air, Allcare Logistix does it all

Freight and logistics: Warehousing 4 Genie: Pick of the crop 6 Loadhog enters South African logistics market

Freight and logistics: Heavy duty 7 MANaging the toughest operations globally10 Scania: Heavy haulage tractors with AMT11 Liebherr: Sales and service centre Miami, Florida

Freight and logistics: Abnormal loads12 BTS: Mega move for Barloworld Transport Solutions

Freight and logistics: Fuels and fi lters14 Filter Focus: Dramatically improve operating lifespan of diesel equipment16 Donaldson’s Clean Fuel Corner: The need for clean fuel in new engine technology 17 Is going green the answer?20 Cummins: Redefi ning compact power capability

Fleet management22 Dapsol: Equipment Management Solutions

Editor’s comment 1 An Olympian challenge

Cover story 2 Komatsu thrives on hard labour

Into Africa ...and beyond: Construction 4 Terex in tropical Trinidad 6 Bergmann: Hatchback dumper with added safety 9 Wacker Neuson: Powerful deployment in the African heat

Company profi le10 Pilot Crushtec: Something BIG happening

Technology12 Pneumax: Environmentally friendly dust management solutions14 Goodyear: ConquestXPTM – The toughest belt yet!

Training15 TASA: Huge boost for South African management sector

Into Africa ...and beyond: Mining16 Mining – fl exible offers from Scania18 Redpath: Ground-breaking sand tunnel20 Volvo Penta’s extended range of engines for mining

Safety23 Booyco: Collision warning system in Zambia24 Safe tunnelling with Becker Mining

Capital Equipment News is published monthly by Crown Publications cc

Editor: Kim Kempcapnews@crown.co.za

Advertising manager: Claudia Bertschyclaudiah@crown.co.za

Layout and design:Kristijan Srša

Circulation:Karen Smith

Allcare Logistix cc is a dedicated and specialised freight forwarding company, capable of offering a personalised and professional service in the South African clearing and forwarding industry.

Story on page 2

Publisher: Jenny WarwickPO Box 140 Bedfordview 2008 Tel: (011) 622-4770 Fax: (011) 615-6108www.crown.co.za

Printed by Tandym Cape

The views expressed in this publication are not necessarily those of the editor or the publisher.

Sold copies 1st quarter

2013

Free distribution 1st quarter

2013

Total 1st quarter

2013

13 3699 3695

Look for us on LinkedInand read our blog.

...on the fl ip side: TFL

WITH ANOTHER FUEL HIKE in place by the time this is published – bringing the price of petrol to about R13 per litre and a currency that is fast becoming good enough only to paper billboards – consumers are running the risk of slicing themselves in half with their belt-tightening strategy to survive.

Every single person who has taken the time to read this will be impacted. I’ve come to realise that the fuel price is the ‘great leveller’, as it effects everyone, from hawker to minister.

85% of our goods are transported by road – that means trucks people – and we all know that 40% of fl eet operating costs goes to fuel. It’s just unfortunate that truckers will bear the brunt of our collective ire, but without a comprehensive rail system in place, who really is to blame? Well, we know that answer…

Not to mention the e-Tolls hanging like a rusted gantry over our heads…

When is this going to get better?

Talking of getting better, I was thinking, when Mandela fi nally slides off his perch, maybe, just maybe this could be the ‘great unifi er’ that this country has needed so badly since that magical period of the Soccer World Cup in 2010? For once, looking to the past for inspiration could be a good thing.

Maybe this time we will all stand together to honour our famous statesman and maybe, just maybe, fi nd less time to fuel discontent and more to celebrate our similarities, our amazing country, our incredible spirit?

Are you listening JZ and company?

So, on that hopeful note, be informed and enjoy the read!

contentscomment

TFL JUL2COVER

STORY

HEADQUARTERED IN JOHANNESBURG, Allcare Logistix is an expert in all aspects of the clearing and forwarding industry. It controls operating elements in sea freight, airfreight, transport, warehousing and distribution.

According to Bela Steyn, Member, “The company boasts an experienced management team that is actively involved in the day to day running of the company. Our senior management adopts an ‘open door’ philosophy, and is intimately involved in the operational aspects of the business, with a staff complement boasting 50 years collectively, of experience, in import, export, customs clearing and forwarding.”

The company is known for its impeccable standards of managerial and fi nancial integrity, enjoying a close association with leading overseas organisations, in order to offer its clients immediate access to the most advanced methods in cargo movement.

Bela continues, “The company offers a high level of customer liaison, and we pride ourselves in the partnerships we have established.”

Allcare Logistix cc is a 100% South African owed company, complying with the broad-based BEE codes of good practice, holding a Level 4 rating.

Scope of services

“Freight and transport forwarding services are provided from any place in the world, bringing markets together through global logistics, without frontiers. We believe that cargo – of whatever nature – is never considered too big or too small to handle,” she attests.

Sea freight

“We offer intermodal transport from door-to-door in a time-precise environment, utilising reliable carriers, based on effi cient pre and on carriage arrangements, irrespective of whether the cargo is less than container loads (LCL) or full container loads (FCL).”

Working out the most suitable transport arrangements, providing appropriate and best priced solutions, every aspect of the client’s shipment needs is considered and catered for.

Air freight

“We handle inbound and outbound air freight from all South African international airports to major airports around the world. Arranging customs clearance and obtaining the SARS fi nal release prior to the arrival of the aircraft is our top priority, ensuting a speedy delivery to the fi nal destination.”

Project transport and cross trades

The company caters for all types of outsized dimensions in/out of South Africa including: heavy weight; unitised; loose and/or bulk cargo; as well as global cross trade transport.

“We ensure careful planning, organising, controlling and directing, in order to accomplish specifi c and one-time targets with timelines. Detailed checklists are used to defi ne the project in compliance with statutory regulations. Checklists account for alternatives in routing, scheduling,

Land, sea and air, Allcare Land, sea and air, Allcare Allcare Logistix cc

is a dedicated and

specialised freight

forwarding company,

capable of offering

a personalised

and professional

service in the South

African clearing and

forwarding industry.

Logistix does it all

TFL JUL3

different transport modes, ports, airports and railhead terminals, handling, storage requirements, collections and deliveries of components, required packing materials, availability and suitability of intended transport equipment, in a process of continuous feedback from customers and suppliers,” she explains.

Customs clearance

Bela adds, “Customs clearance services are provided for cargo in/out of South Africa through our ports and airports (mainly Johannesburg, Durban, Cape Town and Port Elizabeth). Services are also provided for cargo transiting South Africa to our neighbouring states such as Lesotho, Botswana, Swaziland, Zimbabwe and Mozambique. Our customs clearance division can provide customised solutions for each shipment.”

Allcare Logistix’ trained staff can handle every aspect, from single window clearance documents to complicated carnets.

Railway/road transport

“With a powerful network of road/rail transport services from major centres to gateway ports backing our door-to-door operations, we arrange for part load and full truck load transportation into South Africa and neighbouring states, namely, Lesotho, Swaziland and Botswana.

“Our inland transport is available by road and rail and additionally, we specifi cally cater for special demands such as rail-road combined transport to meet the time-precise logistics,” she says.

Warehousing

“Allcare Logistix provides bonded warehousing facilities at select state-owned and private warehouses. We have an extensive network of warehouse facilities which effi ciently handles a wide range of cargo, varying from consumer to commercial goods. We ensure utmost care, safety and concurrence with our regularity in cargo handling.

“In addition, our warehousing service offers features such as arranging palletisation, shrink-wrapping, fumigation, labelling and re-marking, inspection, transit and distribution.”

Distribution

There are daily port terminal and airport collections and deliveries of outgoing and incoming shipments, including transit shipments to neighbouring states and adjacent countries.

Besides operating locally with its own vehicles, Allcare Logistix operates in partnership with reliable and reputable local truck operators.

Cargo insurance

On request, Allcare Logistix, customers and suppliers can benefi t from cost effective insurance premiums, on all types, categories and nature of cargo.

In conclusion Bela says, “We strive hard in this competitive world and it is our mission to offer an outstanding service to our valued clients.”

Logistix does it allLogistix does it all

“Freight and transport forwarding services are provided from any place in the world, bringing markets together through global logistics, without frontiers. We believe that cargo – of whatever nature – is never considered too big or too small to handle.”

TFL JUL4FREIGHT AND LOGISTICS

WAREHOUSING

GENIE QUICKSTOCK™ vertical mast lifts are compact, low-weight machines suited to increasing productivity on the job. The QuickStock™ lift is designed to make inventory picking faster, easier and safer than rolling stairs or manually propelled lifts.

The features and benefi ts of the QuickStock™ include:

• a safer, more effi cient alternative to ladders;

• drivable when fully elevated;

• small working envelope for manoeuvring around corners;

• automatic 25A battery charger for easy charging;

• up-front mounted joystick for excellent viewing when driving;

• 4 and 5m models come standard with a rear workstation tray;

• retail version includes obstruction sensing pad and dual fl ashing beacons.

Goscor Hi-Reach CEO, George Landsberg, says that he is pleased with the manner in which this stock picker range has been accepted in the South African market. “The Genie QuickStock™ is a solution whose time has come and it is pleasing that we have started achieving the same sort of successes here in South Africa as this product has achieved worldwide,” he says.

Carl Van Dyk, Goscor Hi-Reach Sales Executive, adds that Goscor Hi-Reach is running hands-on demonstrations of how the QuickStock™ works and that anyone interested should contact the company.

Pick of Pick of the cropthe crop

With safe effi ciency increasingly

the ‘rule of thumb’ in the South

African warehousing and retail

environments, it is no wonder

that the Genie Quick-Stock™

stock picker is fast becoming

the pick of the crop.

Above: The Genie Quick-Stock™ stock picker from Goscor Hi-Reach.

About Goscor Hi-Reach

Operating from its headquarters in Alrode, Johannesburg, Goscor Hi-Reach supplies mobile elevated work platform machines, equipment, spares, ongoing maintenance and repairs as well as full refurbishment of machines for its customers across southern Africa. The company is part of Imperial’s Goscor Group.

FREIGHT AND LOGISTICSWAREHOUSING

WHEN ONE OF SOUTH AFRICA’S LARGEST ONLINE STORES wanted a faster, safer, more effi cient and economical way to handle new category products, while complementing its current products and methods of picking and transporting products internally, Corporate Renaissance Group Supply Chain Services (CRG SCS) suggested the Loadhog Pally.

The 800x600mm robust Pally, with a 250kg capacity, fi tted the bill and the fi rst contract was signed. Hundreds of Pallys were supplied to this store and now transport a range of goods internally in Kalahari’s distribution centre in Cape Town. Following signifi cant growth, a further quantity of Pallys is being rolled out to Cape Town, with a substantial quantity purchased for its second centre in Johannesburg.

Unlike any other pallet, a one foot press on pedal at either end of the stackable Pally transforms it from a pallet into a wheeled dolly, for instant mobility. A second pedal press returns the Pally to a pallet, lifting the wheels clear of the fl oor, transferring all the weight onto the pallet bearers to create a stable, secure unit for easy and fast product picking.

Annes Schreuder, head of operations at Kalahari, said: “The Pally is a great solution when we need fl exible storage and movement options, especially in an environment with low levels of automation and high product variability.”

CRG SCS offers complete turnkey projects, not only including software and tracking systems but also the racking and material handling equipment and the operationaliation of the solutions specifi ed, in partnership with their clients. The company has continued to grow, following its success in servicing the local market and has worked on projects for the MIH group, which includes Kalahari. Since then, Loadhog South Africa has been established to provide material handling solutions, extending the Loadhog capability into the local market.

Above: Offering a truly one touch, supply chain/merchandising solution, the Pally

seamlessly integrates all the features of both a pallet and dolly in one ingenious,

patented design.

Above right: With one foot press-on a pedal at either end of the 800x600mm robust, stackable Pally, transformed it into a fully

mobile, wheeled dolly, allowing instant mobility for effi cient movement.

Loadhog enters the South African logistics market

CRG SCS, a logistics and

operational solutions service

provider within South Africa

and Loadhog’s partner,

answered the call for a

wheeled pallet solution from

Kalahari.com, South

Africa’s largest online store

for the sale of books, fi lms,

games and electronics.

With confi dence, CRG SCS

recommended the

Loadhog Pally.

TFL JUL6

TFL JUL7 FREIGHT AND LOGISTICS

HEAVY DUTY

CLIMATIC CONDITIONS, the state of the roads or the great stresses on vehicle and axles in daily use, contribute to regional differences in overseas markets. This is why MAN has the TGS, TGS WW and CLA series in its range of products; they are designed especially to cope with the challenging transport tasks outside Europe.

Premium truck for the toughest of operations

Particularly rugged suspension and frame components distinguish the MAN TGS WW as semitrailer tractor, chassis and tipper. For the most demanding operation outside Europe, the MAN TGS WW has been equipped with attention to the many details that have proven themselves in practice. These include a stoneguard in front of the radiator, radiators suitable for the tropics, protective grilles on headlights and rear lights, air intakes directed upwards with pre-fi lter, stone guards for the fuel tank or 24” tyres.

Whether it’s two, three or four axles, gross weights of 19 to 44 or 50 tons, on-road or off-road drive, the range of choices is a big one. Customers can choose from three different design heights, hypoid or planetary hub reduction axles, and leaf or leaf/air suspension. In the product range of the robustly designed TGS WW, the effi cient tool can be found for on-road transport in short- and long-haul as well as off-road on construction sites or surface mines.

MAN offers cabs in three different sizes for the TGS WW series: the compact M cab is suitable for work on construction sites and surface mines. It is also fi tted on municipal vehicles or trucks operating in short- and long-haul transport. If the driver occasionally has to sleep over or rest in the vehicle, or if space is needed to store equipment in the cab, then the 400-millimetre longer L-cab is the one to choose. It has a comfortable 2050mm long and 750mm wide bunk behind the seats. On longer trips, the high LX cab provides the optimal space for alternating between work and relaxation. The cab has space for a multifunctional shelf or a second bunk.

MANaging the toughest operations globally

Rugged and effi cient trucks from MAN Truck & Bus meet the highest demands of markets outside Europe.The differences in typical requirements from region to region are far bigger in overseas markets than they are in European markets.

Above: Whether it’s two, three or four axles, gross weights of 19 to 44 or 50 tons, on-road or off-road drive, the range of choices is a big one.

TFL JUL8FREIGHT AND LOGISTICS

HEAVY DUTY

Both longer cabs, the L and the LX, have two capacious stowage compartments that can be accessed from the outside via big fl aps. The driver can also reach the contents of the left-hand stowage compartment comfortably from the inside.

As far as power is concerned, operators can rely on effi cient MAN D20 and D26 series in-line six-cylinder engines with the common-rail injection that has demonstrated its reliability thousands of times over. Depending on registration regulations, the TGS WW engines comply with the Euro II, III or IV exhaust-gas emission standards. The developers of the engines have taken into account that fuel quality varies, in particular that the proportion of sulphur in diesel fuel outside Europe is often higher (up to 2000 parts per million). MAN offers engines with outputs of 265kW, 294kW, 324kW as well as 353kW and for certain applications, 397kW.

In the Euro II and Euro III versions, the exhaust-gas treatment of these MAN engines does not require the additive AdBlue®. This makes the driver’s daily routine easier. For compliance with the Euro IV standard, MAN uses maintenance-free SCR (selective catalytic reduction) technology. Whenever a rugged chassis that meets the requirements of the Euro V or Euro VI emission standards is needed, the MAN TGS series usually fi ts the bill.

The engines are coupled with precise, comfortably shifting transmissions. The synchronised manual transmission has 16 speeds. Twelve-speed MAN TipMatic® automated transmission provides the highest level of shifting comfort. For off-road vehicles, the MAN TipMatic® in off-road mode offers a performance-orientated shift strategy with faster shift times.

At the IAA 2012, MAN presented the TGS WW for heavy-duty operation with a torque converter clutch. This enables 250 tons gross train weight. The driveline comprises a Euro-IV-compliant 397kW engine, an automated 12-speed MAN TipMatic® transmission and WSK 440 torque converter clutch with primary retarder and auxiliary radiator. This makes it possible for the driver to execute precisely controlled and practically wear-free starting and manoeuvring with heavy loads. In automatic mode, drivers don’t have to operate the clutch or change gears, so they are able to concentrate fully on driving with their oversized cargo.

Rugged and reliable

With its MAN CLA series, MAN is aiming at markets in Asia, the Middle East and Africa. The MAN CLA is successfully operated in over 25 countries. These are extremely resilient

two, three and four-axle chassis for a multitude of usages as platform trucks or semitrailer tractors. Customers can also obtain complete vehicles via MAN, with tipper, refuse collection or concrete-mixer bodies. MAN rounds off the CLA range at the top with

a four-axle tipper chassis for a gross vehicle weight of 31 tons, initially for the Indian market. This vehicle is especially suitable for heavy-duty work on construction sites or surface mines.

Reliable MAN components are the basis of the MAN CLA. With its robust chassis, economical engines and 20 and 22.5-inch tyres designed for

poor roads, the MAN CLA covers the weight class from 15 to 31 tons. Day and sleeper cabs provide the driver with an ergonomically designed workplace equipped with air-sprung seat and optionally available air-conditioning system. MAN also produces the reliable six-cylinder in-line engines, renowned for their long

service life, as well as the rugged, resilient planetary axles. Alternatively, hypoid rear axles are installed for long-haul operation.

Available engines range from 162 to 206kW. The engines comply with the Euro II and III exhaust-gas standards and can be run on diesel fuel with a maximum sulphur content of 500 parts per million.

Production of the MAN CLA takes place in one of India’s most modern commercial vehicle plants, in Pithampur, Madhya Pradesh. This plant delivers either complete vehicles with or without bodies to customers or CKD kits to the regional assembly plants for MAN vehicles.

Above: Available engines range from 162 to 206kW. The engines comply with the Euro II and III exhaust-gas standards and can be run on diesel fuel with a maximum sulphur

content of 500 parts per million.

In the product range of the robustly designed

TGS WW, the effi cient tool can be found for on-road transport in short- and long-haul

as well as off-road on construction sites or

surface mines.

TFL JUL10FREIGHT AND LOGISTICS

HEAVY DUTY

PERFORMANCE CAN BE TAILORED to a wide variety of needs and all servicing can be handled via the Scania service network. Scania’s strongest components combine into a highly effi cient and competitive tractor with numerous confi guration options.

The new family of heavy-haulage tractors can be specifi ed with Scania’s most powerful 3500Nm and 730hp 16.4-litre V8, Scania’s extra heavy-duty overdrive gearbox, Scania Opticruise automated gearchanging, nine or 10-ton front and tag axles, 32-ton hub reduction tandem bogie, drum or disc brakes, air suspension or parabolic leaf springs and heavy-duty fl itched frame. The 8x4 version is ready to take on gross train weights of up to 180 or 250 tons, depending on the choice of axles, local regulations, etc.

Scania’s V8 engine is offered in outputs from 520hp. An interesting option for some applications is Scania’s new 13-litre inline six-cylinder engine, with up to 2550Nm and 490hp, an engine renowned for its high torque-to-power ratio.

Engines are available that comply with emission levels Euro 6/5/4/3 and EEV, as well as Japanese regulations, all based on a common platform with uniform architecture, that simplifi es servicing and parts supply.

The mechanical transmission, without torque converter, makes the powertrain highly effi cient with excellent fuel economy in tough conditions. The 12+2-speed overdrive gearbox has twin crawler gears for easy starting, yet provides main road cruising at reasonable engine revs. Sophisticated clutch control allows smooth starts to be accomplished with minimum slip. A special manoeuvring mode offers control with millimetre precision. A torque converter gearbox is offered as an option.

Six, eight and ten-wheelers are offered. Steered tag axles can be specifi ed in front of or behind the bogie. The compact rear axle set-up allows the wheelbase to be as short as 3300mm on the four-axle. All-wheel-drive 6x6 and 8x8 can be specifi ed (8x8 to special order). Front and rear trailer couplings can be specifi ed.

Sleeper cabs

Heavy-haulage tractors are often specifi ed with high-roof sleeper cabs, such as the Scania Topline, partly for comfort and partly to connect naturally to the special rack behind the cab housing hydraulics, air tanks, fuel and other specialised equipment. Lower and shorter cabs are available, including fl at-roof cabs designed to maximise space above the cab to carry an overhead crane, for example. The high-mounted R-series cab range is mandatory in combination with the V8 engine, whereas the medium-high G-series is an option with 6-cylinder engines.

A bonus is the comprehensive use of parts and components out of the Scania modular toolbox, components that are familiar to any Scania service workshop. All parts are available via the 1600-strong global Scania service network.

Heavy-haulage tractors with AMT

The new heavy-haulage

tractors that can take on

GTWs of up to 250 tons are

based on components from

Scania’s standard modular

product range. They involve

signifi cant savings in initial

investment, as well as gains

in repair and maintenance

cost and uptime for heavy-

haulage professionals.

Heavy-haulage tractors are often specifi ed with high-roof sleeper cabs, such as the

Scania Topline, partly for comfort and partly to connect naturally to the special rack behind the cab housing hydraulics, air tanks, fuel and

other specialised equipment.

TFL JUL11

THE STATE-OF-THE-ART FACILITY is located in Hialeah Gardens just off Okeechobee and the Florida Turnpike. It will serve as a major hub for Liebherr’s maritime cranes division and will further strengthen business relations to Central and South America and to the Caribbean region.

In terms of logistics, the sales and service centre is ideally located: the port of Miami and Miami International Airport are in close proximity to the new site. This allows Liebherr to respond to customer enquiries within a short time and to accelerate the distribution of parts and services.

During the course of the event, guests were able to view Lieherr’s innovative power and high technological standards. Besides a variety of machines, including a crawler crane, a piling and drilling rig, reachstackers and mobile cranes, Liebherr presented its latest technologies in a separate area. One of the highlights was a model of the company’s new, eco-friendly hybrid drive, Pactronic.

The complex is situated on a total property area covering about 40 000 m2. The building has a total area of 3800m2, with 2100m2 of this as offi ce space and 1700m2 as storage area. During the course of 2013, about 52 staff members will be working in the new facility.

The sales and service centre accommodates a fully furnished workshop with a 10-ton (9 metric tonne) overhead crane, two fully equipped 6m welding containers, one 6m wire rope reeling container and two fully equipped mobile harbour cranes commissioning containers. In addition, it houses special tools and equipment for after sales service. For serving greater Miami, the Fort Lauderdale area and the surrounding ports, service personnel have six service trucks at their disposal.

The sales and service centre was completed a mere 15 months after the fi rst sod of soil was turned; total investment sum for the building was approximately $20-million.

“The facility perfectly meets the requirements for further improving our sales and service performance in North and Latin America”, emphasised Gernot Schranz, President of Liebherr Nenzing Crane Co.

Sales and service centre in Miami, Florida

On June 11, 2013 in Miami,

under the motto ‘Meet

Diversity and Innovation’,

Liebherr celebrated the grand

opening of its new sales and

service centre. The ceremony

was attended by more than 300

invited customers and guests.

The ceremony was attended by more than 300 invited customers and guests.

The new premises comprises a total area of 3800m2, with 2100m2 of this as offi ce area and1700m2 as storage area.

TFL JUL12TFLTFLTFLTFLT JUJUUULLLLTFL JUL12FREIGHT AND LOGISTICS

ABNORMAL LOADS

NEIL HENDERSON, CEO OF BARLOWORLD TRANSPORT SOLUTIONS says that the acquisition is a good fi t. ‘’It aligns with our strategy to offer clients a wide range of smart, reputable and reliable transport solutions in southern Africa. It expands our services and capabilities in this specialised area. There are many synergies within our businesses and we look forward to leveraging these to enhance our services to clients into Africa.’’

TCS will fall under the specialised business unit of BWTS, which is led by Andrew Nicholson. Rogan Brent and Jason Christie, the current MD and Operations Director of TCS will continue to head up this business. TCS was formed 16 years ago and has the skills, experience, regulatory requirements and a large fl eet confi guration with the capacity to move a maximum payload of 90 tons. TCS has depots in Durban, Johannesburg, Harare and Lusaka.

BWTS, which incorporates the Manline, Manline Energy and Timber24 brands and is part of Barloworld Logistics, has a fl eet of over 800 vehicles, 1700 employees and more than 30 depots across southern Africa. TCS will be re-branded Manline Mega to build on the strong cross-border footprint, expertise and brand presence that Manline already has in the market.

Commenting on the transaction, Rogan Brent, MD of Manline Mega says, ‘Our team is highly experienced in planning, loading and delivering machinery, specialised equipment and project cargo. This is a competitive space with great growth opportunities for us. Joining the BWTS group is an exciting development for our business and our client base. We look forward to working and sharing best practices with our new colleagues to create more fl exible, optimised and sustainable transport solutions for a wide variety of customers and sectors.’’

The deal was concluded and became effective on 5th June 2013.

Mega move for Barloworld Transport Solutions

Barloworld Transport

Solutions (BWTS) has

concluded a transaction

which has resulted in the

acquisition of TCS Logistics

(Pty) Ltd, a transport

company that specialises in

moving abnormal loads for

clients into and around

Sub-Saharan Africa.

Rogan Brent (MD Manline Mega on the left) and Neil Henderson (CEO Barloworld Transport

Solutions) signing the deal.

TFL JUL14FREIGHT AND LOGISTICS

FUELS AND FILTERS

ALTHOUGH EURO SPEC ENGINES with more sophisticated fl uid designs, higher operating pressures, and tighter clearances have made modern day diesel equipment more effi cient, it has also made it far more susceptible to fl uid contamination.

These factors greatly increase the need for cleaner fl uid systems throughout the lifecycle of the product. Solid contaminants known as ‘fi nes’ are found in counts of 10-million and higher per litre of diesel, or unused oils. These are measured in the four-micron range, a range of contaminant sizes, generally not addressed with standard in-line fi ltration. A modern diesel engine is a reliable workhorse; however contamination in any form is detrimental to performance and profi t-generating capacity.

Filter Focus Chief Operating Offi cer, Craig FitzGerald, points out that contaminants and particles as small as two to fi ve micron can result in premature wear and effi ciency loss. “Contamination directly impacts on the lifespan of oil, as well as that of the component in which it is operating. The goal is to implement contamination control systems and practices that maximise machine and lubricant life, while minimising capital and operating expenses, to provide the greatest overall value.”

According to him, all oil is contaminated to some extent when purchased. “The storage and handling practices will then determine the actual cleanliness of the oil, before it is placed into operation. Particulate contamination measuring in the millions will be present in new oil, even before starting operation and, during operation, each contaminant has the ability to create up to four metal wear particles, thereby creating a cycle that continues to grow exponentially. Standard original equipment (OE) fi lters are generally capable of only addressing solid contamination above 10-micron, thereby being largely ineffi cient.”

In 2006, Filter Focus demonstrated to a large cellular operator, that in as little as one hour of operation after an engine oil service, the oil was unfi t for further use. Considering that as much as 20% of the dirtiest oil remains in the engine compartment after draining, better measures need to be put into place that will ensure fl uid systems are protected.

He does however note, that continuous offl ine fi ltration will successfully remove the majority of contaminants, not addressed by standard OE fi lters. “The successful removal of all solids, semi-solids, free water, dissolved water, depleted additives, varnish and sludge, will result

Dramatically improve operating lifespan of diesel equipment

As excessive levels of

fl uid contamination

in machinery results

in unnecessarily high

operational costs

and unscheduled

downtime periods

in the South African

industrial sector, wear

control specialist,

Filter Focus, offers

comprehensive advice

to combat this trend.

15TFL JUL

in reduced operating temperatures and less propensity to foam, oxidise or chemically alter. Preventing contamination from entering oils will drastically increase the operating life of lubricants too, as oil integrity is kept within specifi cation for longer periods, leading to improved effi ciency and machine availability.”

How to quantify oil cleanliness

The ISO 4406 standard establishes the relationship between particle counts and cleanliness. This internationally recognised model uses a code system to quantify contaminant levels by particle size in micrometers (µm). Using ISO 4406, a machine owner or operator can set simple limits for excessive contamination levels, based on quantifi able cleanliness measurements. This standard allows for the quantifi cation of current particulate cleanliness levels, and setting targets for cleanup.

Keeping oil clean on a consistent basis

There is no getting away from the fact that contaminated oil destroys machines, and Craig stresses that clean oil is one of the most important factors in extending the service life of the lubricated components of all machinery. “In hydraulic systems, clean fl uid is essential for successful long-term operation. Although machines equipped with rolling element bearings are sensitive to particulate contamination, machines using fl uid-fi lm bearings are not immune to such damage. Even modest improvements in lubricant cleanliness can result in a signifi cantly extended machine lifecycle.”

He maintains that each machine class should be evaluated for cleanliness levels that are appropriate to its application. What industry has previously accepted as normal, needs to seriously be addressed, if improvements to effi ciencies and performance are to be gained.

Although the precise improvements in machine life as a result of cleaner oil are specifi c to each individual machine and application, Craig says that studies on improving lubricant cleanliness in numerous industries have shown dramatic extensions in expected machinery lifecycles. “In one example, a reduction of particles larger than 10µm from 1000/ml to 100/ml resulted in a fi ve-fold increase in machine life. An additional benefi t of cleaner oil is that it is much easier to detect subtle changes in the amount of wear debris than in dirty oil.”

What’s more, he says, studies undertaken by the Society of Automotive Engineers (SAE) have shown engine wear reductions of 50% when fi ltering crankcase oil to 30µm, and up to 70% when fi ltering to 15µm - when compared to the industry standard of fi ltering to 40µm.

Bearing this in mind, Craig stresses that fi ltration, storage and handling procedures are the key areas of focus in oil clean up. “It is important to measure and evaluate current cleanliness levels to establish baselines for comparison. From there it is advisable to examine and evaluate current storage and handling practices, before setting cleanliness targets that are based on goals for longer machine life and reduced maintenance and downtime costs,” he concludes.

Filter Focus Chief Operating Offi cer Craig FitzGerald points out that contaminants and particles as small as two to fi ve micron can result in premature wear and effi ciency loss.

Above left: Graph illustrating lubrication quality and its impact on equipment life and maintenance.

Filter Focus are successfully established as global leaders in Reliability engineering and Wear control; offering industry substantial and quantifi able performance improvements to plant and equipment. By combining expertise in the fi elds of fi ltration, lubrication and tribology; Filter Focus yields considerable fi nancial benefi t to its customers, while diligently conserving the environment.

TFL JUL16FREIGHT AND LOGISTICS

FUELS AND FILTERS

TODAY’S ENGINES use what is called ‘high pressure common rail’ (HPCR) fuel injection systems that operate upwards of 40 000psi (2800 bar). These systems require very clean fuel to operate as-designed for their entire service interval. Unfortunately in most cases, new fuel does not mean clean fuel.

Fuel contamination can be separated into two broad categories: inorganic and organic. Inorganic contaminant is typically hard particulate (dirt) picked up throughout distribution. From the refi nery, fuel is typically clean, but as it gets transported throughout distribution (which can include pipelines, terminals, and delivery trucks) it becomes increasingly dirty. Once onsite, as it’s stored in bulk tanks and moved for distribution and use, it picks up contaminant from the infrastructure as well as ambient conditions.

Organic contaminant represents anything carbon-based, typically longer hydrocarbons with various chemicals attached. These organic contaminants can come from a variety of sources at, or downstream from, the refi nery, including: lubricity improvers; cold fl ow improvers; biodiesel; corrosion inhibitors, etc. It is important for fuel additives to be dosed at the correct levels and under the right conditions to ensure the best overall fuel stability, otherwise additives can become insoluble and therefore ‘fi lterable’.

Generally speaking, hard particulate (inorganic contaminant) will cause permanent damage to the injector system, while softer particulate (organic contaminant) will cause fouling, namely, deposits build up on the injectors. In both cases the engine does not run as-designed and can result in a decrease in fuel economy, an increase in emissions, and a decrease in power.

Most fuel is delivered to storage tanks 500 to 1000 times dirtier than what is allowed in these injection systems. Traditionally, only on-engine fi lters would be used to remove the contamination in the fuel to meet injection system fuel cleanliness specifi cations, but the requirements for HPCR fuel are so high, that a two-step approach is needed to achieve consistent cleanliness: fi rst fi lter fuel in the bulk storage tank, prior to use in the equipment and then with the on-engine fi lters.

Bulk fi lters should remove contamination in the fuel down to a cleanliness level of ISO 14/13/11, whether the contaminant present is hard or soft. It should be noted however, that all fuel fi lters are designed with the goal being to remove the hard inorganic particles, so while they will also fi lter the soft organic materials, life may be greatly reduced in comparison.

Besides meeting HPCR fuel cleanliness requirements, the use of bulk fi ltration also provides the necessary protection against any highly contaminated fuel that may be delivered (ongoing or as a one-time occurrence). By fi ltering prior to use in the equipment, the bulk fi ltration system will stop excess organic and inorganic particulate from being delivered into your equipment’s tanks, ensuring the onboard fi lters can meet the expected service intervals. If a fuel problem should exist, it may plug up the bulk fi lters, but not the on-engine fi lters. This eliminates costly unscheduled downtime and makes operation and maintenance much more predictable.

Today’s engines are more sophisticated and require cleaner fuel than before. Investing in a bulk fuel fi ltration system will protect your equipment against dirty fuel, eliminate unplanned downtime, and keep you running optimally.

The need for clean fuel in new engine technologyBy Deena Kasavelu, Sales Manager – Donaldson Clean Fuel & Lubricant Solutions

Welcome to the Clean Fuel

Corner. This column is an

opportunity to learn more

about how evolving diesel

engine technology is driving

the need for cleaner fuel.

While that may seem to

be fairly straightforward,

delivering clean and dry fuel

consistently to the engine’s

fuel injection system can be

a challenge. On a monthly

basis we’ll explore these

challenges and how they

can be overcome, with a

focus on handling fuel prior

to being pumped into the

vehicle. Written from the

angle of a global fi ltration

company, the focus will be

on the role of fi ltration in

achieving the necessary OEM

specifi cations, but we’ll also

mix in some important info

on other topics like storage

tanks, pumps and engines.

CLEANCLEANFUELFUELCORNERCORNER

TFL JUL17

WITH GLOBAL CONSCIOUSNESS AROUND EMISSIONS, and the associated challenges to decrease the effects of particulate matter, there has been a surge of advances around purifying fuel, or, at the least, lessening the impact of impurities on humans and engines alike.

Biofuel is being held aloft as the emissions elixir, with Truck OEMs going toe-to-toe in an effort to produce engines that not only emit lower Nox and CO2 gases, but also don’t jeopardise vehicle effi ciencies.

Overview

Because biofuels are renewable, their sources can be regrown. Advanced biofuels can also offer environmental benefi ts such as lower carbon emissions and lower sulphur, compared with fi rst-generation biofuels and conventional petroleum-based fuels.

From food crops such as corn and sugar, ethanol is produced. There is no excess or ‘waste’ ethanol, so produce it , crops need to be grown specifi cally, which can be an energy, water, and land use intensive process.

On the other hand, vegetable oil, is used extensively by the food preparation industry, but there is waste from the process, so vast amounts of vegetable oil would be discarded if not used for fuel.

While this is great for the biofuel pundits, the industry has its naysayers who argue that crops and arable land should rather be used to feed the starving masses. Given the demand for global energy, tens of millions of tons of biomass are required annually to produce enough fuel to make a difference, putting signifi cant areas of land under biomass crops.

The costs of cultivating, harvesting and transporting biomass is high, and large-scale production must be economical to be viable. To enable market acceptance, advanced biofuels must be compatible with existing infrastructure and the vehicles that it is intended to power.

Some claim that biodiesel releases almost as much pollutant as petrol. In most categories, however, including particulate matter, long-chain hydrocarbons, ozone, and carbon monoxide, biodiesel has consistently been shown to range from lower to substantially lower in emissions. Nevertheless, in some tests (but not all), it has been shown to be higher in nitrous oxides, which is obviously not a good thing. While biodiesel is much better than petrol overall, it appears that it is not perfect.

There also seem to be potential problems when using it in vehicles. Biodiesel blends can show an increase in water separation and fuel foaming, compared to pure fossil fuels. In addition, blending with low-stability biodiesel can lead to fuel system problems, such as higher levels of injector deposits and corrosion arising from the generation of low molecular weight acids.

In addition, advanced direct injection engines may lose signifi cant power when poor quality biodiesel blends are used.

It is also claimed that it releases equally as much CO2 into the atmosphere as fossil fuel.

So what do the OEMs say?

The Volvo Group products are almost exclusively driven by fossil diesel fuel. For many years the company has tried to break this dependency on this source of fuel and to increase the use of renewable fuels. Thus, it is consistently developing and offering a number of

IsIsthe answer?the answer?

Getting away from the

image of belching black

clouds of exhaust gas has

been the aim of every

manufacturer since the

planet became aware of the

hole in the ozone layer and

pollution in general.

going greengoing green

TFL JUL18FREIGHT AND LOGISTICS

FUELS AND FILTERS

solutions adapted for different applications and commercial conditions. It stresses that none of the existing alternative fuels is optimal for all applications and all situations, and that offerings will be extended to more fuel alternatives, if commercially viable.

Volvo’s current view regarding trucks and buses is as follows: for long distance transport, crude oil derived diesel fuel with increasing renewable and synthetic components will remain the dominant fuel. Liquid methane and DME/Methanol are prioritised complements. (DME is an acronym for Di-Methyl Ether Chemical formula.)

For regional transport, compressed and liquefi ed methane fuel will grow, owing to price and security of supply. Biogas will grow slowly but total volume will be limited.

In the not too distant future, short distance transport will lead the shift to electricity, especially in urban areas. City buses with plug-in or full electric solutions will be followed by urban delivery and municipality utility trucks. Compressed methane, later followed by DME, will also be important, owing to low noise and particulate matter (PM) emissions.

Biodiesel is preferred as low blends fulfi lling diesel fuel standards. Synthetic diesel, including hydrogenated vegetable oil (HVO), may be used, blended or pure, in standard diesel engines. However, volumes are limited, owing to high cost of production.

Methane, natural gas and preferably biogas, are viable fuels for urban applications. Liquefi ed gas will be needed to reach long distance transport viability.

DME has effi ciency benefi ts and is a strong candidate for a more long-term alternative, while electricity – starting with plug-in hybrid solutions – will gain importance for urban applications. Dynamic charging may extend this use into long distance transport.

Available methanol volumes should be used as low blend fuel, while ethanol production will be limited and available volumes should also be used as low blend fuel.

Hydrogen as fuel for HDV propulsion remains questionable in the near and medium term future.

Rory Schulz GM, Corporate Planning and Marketing, is very clear on what UD Trucks’ position is on biodiesel.

He says, “When we take the standard published by the SABS for automotive diesel in South Africa, through regulation, it allows specifi cally for the following: ‘where fuel is blended with biodiesel, the biodiesel shall not be more than 5% volume fraction of the total blend’ (Reference SANS342).

“Generally speaking,” he adds, “this level of blend has no adverse effects or impact on the operation of a vehicle, so the advantage of using less fossil fuel is apparent, as well as having a sustainable source of alternative fuel.”

He stresses that it is important to note that the biodiesel added must comply with SANS 1935 and quality controls according to SANS833 for biodiesels, or operators may experience major problems.

He continues, “The problem with, and one reason why, it has not been allowed, or considered in greater percentages than fi ve percent – let us say for argument’s sake, between 6% to 30% – is that certain prerequisites and specifi c service requirements for the vehicles come into play and create a decrease in operational cost effi ciency.”

Some of these prerequisites include: a higher specifi cation of engine oil must be used; the viscosity grade of the oil needs to be increased and the biodiesel must comply with SANS 1935.

Advanced direct injection engines may lose signifi cant power

when poor quality biodiesel blends

are used.

TFL JUL19

When servicing the vehicle and the fuel is changed from diesel to bio diesel, the following applies: the fuel tanks must be cleaned out and initially, the fuel fi lters need to be changed three times at around 2000km intervals, and thereafter, as per the requirement as laid out below:

• The interval for the oil and the oil fi lter change needs to be reduced by 50% (or by half when normal diesel is used) or after six months, depending which occurs fi rst;

• The fuel fi lter housing needs to be changed after 12 months;

• Engine mounted fuel pipes and seals need to be changed after 12 months;

• Fuel tanks need to be cleaned after 12 months;

• The fuel level gauge apparatus in the tank and the internal tank fi lter need to be changed after 12 months.

“It becomes clear therefore, that with a blend exceeding 5%, the maintenance and servicing factor is basically doubled, whichwill impact negatively on the lifecycle cost of a vehicle, as well as its level of up time, in a world where service intervals are getting longer rather than shorter.

“Thus our advice to run optimally, is to stick to the fuel that only has 5% biodiesel content as per the regulations,” he advises.

According to Eric Parry, Product and Sales Engineering Manager, TG Truck Products, outlines MAN’s stand on the issue: “Owing to the lower energy content (compared to conventional diesel), using biodiesel results in additional fuel consumption of up to fi ve percent.

“Although biodiesel reduces the emission of particulate matter, compared to petroleum diesel, the content of harmful substances remains comparable to conventional diesel. The emission of nitrogen oxide (NOx) tends to be higher.”

Since biodiesel contains solvent-like properties, for trucks , special rubber and plastic parts must be installed in the fuel system. On the other hand, because of biodiesel’s better lubrication properties, the component wear in the fuel system may be reduced.

Some advantages of biodiesel include: lower complexity and costs for engine conversion; mixed biodiesel/diesel operation is possible as is alternating biodiesel/diesel – depending on the cultivation and manufacturing process – and reduction of greenhouse gas emissions may be a by-product.

Also, there are no problems with handling of the product, while vehicle operating costs can be lowered.

There are however, a number of disadvantages according to this OEM, the most obvious being production of biodiesel competing with the foodstuff supply. But so too, damage to agricultural lands owing to monocultivation and over-fertilisation; high water consumption is required in the production process; exhaust gas emissions are not better than conventional diesel and there is additional consumption owing to the lower energy density of the end product.

MAN’s conclusion is: D08, D20 and D26 engine series can be operated with up to 100% biodiesel when shortened maintenance intervals are observed.

So, is the strive to ‘go green’ enough to change to biofuel? If industry’s view is to be considered, while biodiesel has its limited place, it’s going to take a while longer before it’s more widely accepted and indeed, if it is totally accepted at all…

Vegetable oil is used extensively by the food preparation industry, but there is waste from the process, so vast amounts of vegetable oil would be thrown away if not used for fuel.

TFL JUL20FREIGHT AND LOGISTICS

FUELS AND FILTERS

Redefi ning compact power capability

The new Cummins QSF3.8

engine is ready to meet EPA

Tier 4 Final and EU Stage IV

emissions regulations.

THE QSF3.8 simplifi es machine integration by meeting near-zero emissions standards with a Selective Catalytic Reduction (SCR) only aftertreatment system. With Particulate Matter (PM) reduction focused in-cylinder, the QSF3.8 avoids the need for either a Diesel Oxidation Catalyst (DOC) or a Diesel Particulate Filter (DPF).

The innovative SCR-only system features an extra-high effi ciency catalyst able to convert Oxides of Nitrogen (NOx) emissions at lower exhaust temperatures, while requiring only low dosing levels of Diesel Exhaust Fluid/AdBlue.

The higher effi ciency of the SCR-only aftertreatment also reduces the amount of cooled exhaust gas being recirculated (EGR) by the engine, with a corresponding reduction in engine loading and cooling demand. The lighter fl ow EGR system enables the performance potential of the QSF3.8 to be fully realised, with the 98kW output leading the below 4-litre engine class. Peak torque of 488Nm is effortlessly delivered by the simple, but effective Cummins wastegated turbocharger used for all QSF3.8 ratings.

The QSF3.8 continues to uphold the enviable reputation established by the popular Cummins QSB3.3 at Tier 4 Interim/Stage IIIB emissions regulations. Although it is larger in displacement and meets stricter emissions standards, the QSF3.8 achieves fuel effi ciency similar to that of the 3.3-litre engine while providing 10 percent higher power output and increasing peak torque by 18 percent.

The QSF3.8 is equivalent in engine size and weight to the current QSB3.3, providing an easier transition from Tier 4 Interim to Tier 4 Final for compact equipment installations.

The new 3.8-litre engine will be available for equipment manufacturers ahead of EU Stage IV standards commencing October 2014 and Tier 4 Final taking effect January 2015 for engines within the 56 to129kW category.

Smaller meets stronger

The QSF3.8 is built with exceptional strength at the heart of the engine, capable of the same peak cylinder pressure as the larger Cummins QSB4.5. This means the QSF3.8 is designed to operate at relaxed ease, resulting in higher in-service reliability and engine durability than equipment operators or rental companies will have experienced before from a compact engine, enhancing the residual value of their QSF3.8 powered equipment.

The QSF3.8 also takes a design lead from the Cummins QSB4.5 engine by featuring a rear gear train, providing superior mounting stiffness and lower gear noise. The high strength cast-iron block is a sculpted design, allowing unnecessary weight to be removed while retaining maximum rigidity. The use of composite material for the valve cover and oil pan brings a further weight reduction, contributing to the impressive power-to-weight credentials of the QSF3.8.

Less to service

Servicing is made simpler through remote mounting of the Electronic Control Module (ECM) for easy plug-in diagnostics and data downloads. The oil fi ll, lube fi lter and fuel fi lter are set up for rapid service, with 500-hour intervals. The QSF3.8 features the Cummins Direct FlowTM air fi ltration system, providing greater dust-holding capacity in a smaller package and a fi lter element change interval at least twice that of a conventional air fi lter. The fi lter also features an embedded smart sensor to fully integrate air-intake fl ow with the engine

TFL JUL21

combustion. The engine is equipped with a robust high-pressure common-rail (HPCR) fuel system driven by Cummins full-authority electronic controls, delivering dependable and fuel-effi cient performance.

To protect the fuel injectors against fuel contaminated with hard particles, a two-stage fuel fi lter system with Cummins latest NanoNetTM media traps almost 99 percent of all particles as small as fi ve microns, so that the fi lter works more effectively for longer with less fuel-fl ow restriction.

The QSF3.8 crankcase ventilation system eliminates blow-by gas emissions to provide an ultra-clean engine. The system is a patented design, integrated into the camshaft with no service requirements.

The engine lubricating pump is driven by the crankshaft rather than by gear from the camshaft. This approach benefi ts the design through its simplicity and packaging benefi ts. Noise is reduced and oil fl ow improved during cold starts. A compact cooling module on the engine brings together the water pump, oil fi lter and oil cooler, leading to improved pressure management and better reliability.

The new 3.8-litre engine will be available for equipment manufacturers ahead of EU Stage IV standards commencing October 2014 and Tier 4 Final taking effect January 2015 for engines within the 56 to129kW category.

TFL JUL22FREIGHT AND LOGISTICS

FLEET MANAGEMENT

ACCORDING TO BRIGITTE RADFORD, Technical Director, Dapsol Management Solutions, “The solutions we offer cater for the capturing of all related business critical information, for the smallest to the biggest of companies, in an extremely user-friendly, real-time environment, for immediate outputs and reporting. Our international support team, covering all time zones, offers 24/7 end-user support and enables us to service the entire global market with rapid response times.”

The software provides companies with a powerful, all-encompassing tool to optimally manage and effectively control their entire equipment division at all levels, address key problem areas and offer signifi cant benefi ts.

Continuing, she adds, “Consolidated data eliminates duplicate data capture and results in greater effi ciency, improved accuracy and absolute reliability of information and outputs. Our consulting base of 26 years, personal industry experience and working knowledge, positively impacts clients’ return on investment with specialist development and best operating practices, increasing overall productivity and profi ts, together with substantial savings for your business.”

The maintenance challenges of retaining existing equipment for longer, owing to diffi culties in obtaining fi nance, are addressed via the availability of comprehensive real-time management information for holistic analysis, forecasting and tendering. Confi gurable system parameters, key equipment business indicators and module dashboards further assist in this area.

Explaining further, Brigitte says, “A lack of trained artisans and stringent emission controls brought with it a need for reliable systems to control when and what is done to equipment, to ensure continuity and systemised succession planning. Comprehensive, applicable maintenance practices are also provided for, with greatly enhanced maintenance planning, problem area identifi cation, measured labour productivity and management exception reporting.

“The system allows you to maximise equipment condition, utilisation and availability with signifi cantly reduced downtime and failures. Enhanced defect logging, planning, scheduling, repairs and maintenance, assists with operator training issues and the need for prompt problem area identifi cation, corrective action and follow-up mechanisms.”

Total cost control with advanced monitoring, detailed plant costing, warranty management and labour optimisation assists in addressing current economic challenges. Fuel quality issues and strict component lubrication requirements to maximise component life are dealt with via product usage deviation warning fl ags, accurate monitoring and stringent control of fuel, lubricant and parts stores.

“Our software solutions comprise a series of modules that can be selected based on clients’ business requirements. Standard modules available include: administration and data confi guration; equipment management; planned component replacement and component tracking; defects and incidents; stock/fuel and lubricant utilities; contracts; hire management; invoicing; repairs and maintenance; purchasing; life cycle costing and many interfaces,viz. accounting, oil sample analysis, etc.”

In conclusion she says, “We also undertake customising of all-encompassing solutions to your specifi c requirements and in line with your unique business practices.”

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Equipment Management Solutions