Sa plastics '013 12 for web

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www.saplastics.co.za

GAUTENG Lowrie Sharp

t: (011) 793 4691f: (011) 791 0544c: 082 344 7870

e: [email protected]

KZN Lynne Askew

t: (031) 764 2494f: (031) 764 0676

e: [email protected]

Printed by: Tandym Print, Maitland, Cape Town

SA Plastics Composites + Rubber Technology is published six times a year and focuses on these industries in South

and southern Africa. We welcome news, articles, technical reports, information in general and photographs about

events and developments related to the plastics industry. The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessar-ily those of the Plastics Converters Association, Institute of

Materials or Association of Rotational Moulders either.

Copyright: All rights reserved.ISSN number: 1684-2855 (ISDS Centre, Paris)

Summit Publishing: CK 9863581/23VAT reg: 4600187902

Plastics Institute of Southern Africa

PET Plastic Recycling South Africa

Plastics Federation of SA

Association of Rotational Moulders of South Africa

Plastics Converters Association

Institute of Materials

Publisher: Martin Wells([email protected])

Editor: Tessa OHara([email protected])

Editorial assistant: Heather Peplow([email protected])

Financial manager: Lisa Mulligan([email protected])

Designer: Jeanette Erasmus Graphic Design([email protected])

Industry needs to make its activities more visibleWOOLWORTHS packaging manager Kiril Dimitrov congratulated Annab Pretorius and the SAPRO team on their achievements in the SAPRO best recycled product programme, and added: Please make sure that the plastic industry and recyclers also promote their activities to the public and the consumer. A different strategy is needed for that, as so far polymer groups appear to be mainly focusing on business-to-business marketing and communication. Lack of visibility of plastics recycling activities give a viable step to be the visible collection of plastic bottles (milk and beverage)!

Bizarre electrical increaseCONVERTORS in the Eastern Cape were shocked to receive exhorbitant electricity accounts recently, in some cases of double the usual amounts. And if that wasnt bad enough, the reaction from the local municipality was even more shocking: a municipal spokesman said larger companies could afford to absorb bigger increases, and they had thus decided to levy a higher increase rate on these enterprises and a lesser rate on smaller businesses. When last did you hear such boloney? The bigger companies employ more people, pay more tax and

management in the Eastern Cape is ludicrous

GPS essential in Durban CBDMUNICIPAL staff in Durban must be very switched on, with GPS navigation systems and so on: what else can you conclude from the rampant renaming of streets in the beautiful citys CBD? My street guide isnt that old, but virtually no street in the area compares with even the 2009 edition. Obviously people want to acknowledge ancestors and heroes, and to some extent the names of colonial era bigwigs may not be appropriate, but the wholesale renaming is excessive. But then Stalwart Dlamini Boulevard may mean nothing to many others either. And the renaming of streets is hardly going to achieve economic transformation.

Lights out in Jozi, nothing new"#$%&&'*'*yesterday: its been going on for ages. Motorists in the city appear to remain calm at these delays, which possibly explains why they drive like maniacs the rest of the time. But seriously, irrelevant street renaming

;*'&do absolutely nothing for economic growth, in our view. Please lets focus on workable solutions in 2014.

BY THE WAY . . .

IF YOU HAVE SOMET

HING

TO SAYLook at the b

right side: if you

have some gem of wisdo

m to

impart, please write to us

at

[email protected]

One view this way, another the other way

It depends which way youre looking in Mozambique: if you look out to sea youll get spectacular vistas of Indian ocean vistas off Bilene, but look sideways over the fence at your lodge and you get a highly undesirable view of discarded PET bottles and other packaging. The Mozambique people just dont seem to notice.

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

s3IMULTANEOUSREADOUTOFTEMPERATUREset-point and actual value

s#LEARARRANGEMENTOFOPERATINGANDindicating elements

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s!LLCOMPONENTSEXPOSEDTOWATERAREmade of non-rusting materials, hence long service-life

s!CHIEVESESTIMATEDREDUCTIONINREJECTSANDINCREASEINPRODUCTIVITY

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DECEMBER 2013 / JANUARY 2014

Contents

www.evonik.com

ON THE COVER

!Plexiglas will remain free from yellowing for up to 30 years; for coloured products (like the Evonik Plexiglas XT pictured on the cover), colour fastness will remain for up to 10 years. The material can be processed in all conventional thermoplastic processes and is 100% recyclable. Evonik Acrylics Africa (EEA) began producing extruded Plexiglas sheets in Elandsfontein, Johannesburg, in August. With an initial 20 employees and a new extrusion facility, some several thousand per year for the African market.

Find out more at www.saplastics.co.za

VOLUME 11 NR 6

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46

6

8

36

22

23

44

56

78

80

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88

96

INDUSTRY NEWSTrioplastics commission

PET, PVC sheet lines

Enviroserv starts Cape tyre recycling line

ADDIS turns 100!

UV Tooling celebrates 25 years

Alpine grows

New grade of PhoenixPET soon

K2013Many visitors from the East,

and unusual sources

ASSOCIATION NEWSSAPRO: Recyclate value via additives

Plastics|SA spearheads recognitionof prior learning initiative

SAVA visits Germany for recycling tour

WORLDLanxess on track withEPDM project in China

SPORTSWinning cinnovation for

performance yachts

58

12

70

WITH 13 of the 19 gold, silver and bronze awards available in six categories (in the four main packaging groups, glass, metal, paper & board and plastics), plastics entries took well over half the awards at the IPSA Gold Pack Awards in October and capped that with the IPSA Gold Pack Trophy for 2013 too.

That was one of the most obvious positives for the industry over the past year, and there were certainly numerous positive developments during the period a time when trading conditions have been tough in virtually all sectors. Here we =&

&>JQY

Top showing by packaging convertorsZ[&\Gold Pack performance by the plastics packaging sector overall. The Astrapak group, which is in the process of a major rationalisation process, surprised by its outstanding success in the Gold Pack programme, where it took four gold awards, [&well structured can produce the goods. The Astra companies JJ Precision, Marcom and Plastop KZN all got gold, and JJ was also a co-winner of the overall Gold Pack trophy.

There were top performances as well from the Polyoak and Nampak groups as well as other independent &_&particularly the high quality of print and labels, has helped this sector gain market share. In the process, several [[

`about the Gold Pack successes on pages 12-19.

Agreed, plastics do offer more creative and variation opportunities than rival materials at present, but you still have to make it happen. The result was testament to the exceptionally high standards prevailing in the local plastics packaging manufacturing sector.

Statistics show that packaging now accounts for a higher

percentage of total tonnage converted in South Africa, up to 55% from an estimated 50% over the past few years. That result is partly due to the fact that the technical moulding sector has not progressed as rapidly, but you cant take the shine off the very impressive performance by the packaging manufacturers.

Aspirant designersNext on our short list of highlights for the year are the design competitions presented by the professional associations. `|Z}&`|&Z&~_}_`~Z}&Z&~Z`}`Organisation) and others presented competitions which attracted enthusiastic responses from students around the country. Plastics|SA and POLYCO sponsored or co-sponsored a number of these competitions, which helped generate interest from the students.

The fact that students today are far more adept at using electronic design systems (and electronic communication media in general), which make the process of design far more dynamic, is a big advantage. Most of the older guys in the industry struggle to a greater or lesser extent with electronic systems, so its a big positive to have interest coming from younger individuals.

Earlier in the year, skills development specialists Chris Vorwerk and Fiona Farquhar-son conducted an industry research programme (com-|`Z_Z~which they found that, surprisingly, more young people were being employed in the industry than expected as well as that [

[`#[

COM

MEN

T

Many of the convertors have also got smarter and managed to create a situation where theyve got the buy-in of their staff, and are now looking forward to brighter things

THIS ISSUE

Positive news for plastics materials and the industry overall

on golden note!Industry ends year

4 DECEMBER 2013 / JANUARY 2014

1

2

Martin Wells, Publisher

DECEMBER 2013 / JANUARY 2014 5

3

4

5

The winning entry in the ARMSA Student Design Competition in August, Strider by Daniel Carstens and Dillon Farrell of the University of Johannesburg, is a solar-powered catamaran with suspended net "#$&'"'*#$+/

novel solutions, in this and other design competitions, creating enthusiasm for the future of our industry

The research survey did not achieve an overwhelming response from the industry, but it stands to reason that com-panies who responded would generally speaking be the more effectively managed operations. This is a very encouraging development. One could conversely say that, if an industry is not attracting young people, it would slowly be regressing.

`#and investing in young people, that these successful com-panies may also be on a path which is going to take them further ahead of companies who do not pay attention to these _'[*&&all to achieve, is worth aiming towards.

Plastics|SA, SAPRO environment programmesZZ`[*environment projects that could be loosely described as image building for the industry. Besides various clean-up #ZZ[than is expected of them and still faced on-going criticism for, particularly, plastics litter. It might seem a thankless task, but Steyn and Co are always upbeat and always ready to undertake projects any project for that matter, so long as its positive for the industry.

Z`[*wonders in building up the plastics recycling sector. Their two main successes have been in the area of developing new applications for recycled material (in which area they have managed to get the buy-in of brand owners such as Unilever and Woolworths) as well as the increased sale of recycled material into the neighbouring states. The latter has proved a big boost for several of the recycling operations, and likewise provided an advantage for convertors in Namibia, Botswana, Zambia, Zimbabwe, Mozambique and other countries in our region.

Well done!

The top groups, and top individualsOur observation is that, although there are an estimated 1800 companies, and possibly more, involved in the plastics, composites and rubber moulding sectors in Southern Africa, a relatively small percentage of these are actively driving the industry. Our estimates suggest that approximately 100 compa-nies are responsible for the bulk of progress made. In fairness

to these companies, we wont identify them here, but most who are in production will know who the leaders are. Possibly more relevant is the fact that that group of businesses is in turn led by a similar number of individuals lets call it a few hundred guys (and yes, it is mainly male) who make the machines turn.

And the main characteristic of these gentlemen is the ability to map out a strategy and implement it: this requires tact, foresight, good sense, the ability to motivate and incentivize people and a lot more. A good sense of humour and at least a little bit of luck helps a lot too. Another hallmark of many of these individuals is the fact that they simply dont believe that they are responsible for whats been achieved. Well, you can remain anonymous guys, but we salute you!

Our products are good!Convertors in southern Africa have in recent years been largely out-competed by Chinese manufacturers, who have *&&&*imports are possible. With price being one of the top criteria for consumers, our manufacturers have struggled to compete but that is not in the area of quality. If anything, the quality of SA-made products has erred on the too high side.

Heres an example: Im now on to my fourth pool umbrella (a necessary accessory for the eco pool installed in my yard in 2012). They were all unbelievably cheap, but the other less welcome feature has been that they havent actually worked. Just look at the thing the wrong way and something breaks! Where-as my vintage SA-made umbrella is still steady and strong.

At the same time, manufacturers have had to operate in an environment where excessive labour legislation and the aggres-[&&[&But many of the convertors have also got smarter wiser after the setbacks of 2011 and managed to create a situation where theyve got the buy-in of their staff, particularly top production and sales personnel, and are now looking forward to brighter things.

The fact that the rand has weakened in value against major international currencies means that imports will be more costly, and exports more feasible, so our belief is that its time for Made in SA to become a lot more popular and that, bit by bit, we can grow the industry and support our many customers in the huge range of industries we supply in building a better future for all!

Seasons greetings to all our readers!

TRIOPLASTICS made one of the biggest investments in the industry in Southern Africa this year with the commissioning of its new PET and PVC sheet extrusion lines at its Krugersdorp plant in November.

The multi-million rand investment sees Trio migrating from the supply market (it has up till now mainly imported sheet for resale) to full-on converting.

A ribbon-cutting ceremony was held at the plant in Chamdor on 31 October to mark the start-up of the lines: the PET system can _Q

&&the PVC line operates by the calendaring *the country of this type.

Calendared PVC material offers a number

&[ high gauge consistency (tolerances on

Ywhereas conventional PVC extrusion is estimated to have a tolerance of 10%);

high gloss and quality; ;'

in the material results in less degradation &;'thermoforming process.The high level of gauge control means

the sheet is well suited for lamination &&credit cards.


An enduring story lessons in manufacturing in South Africa

Bob on the job Bob Boden mounting one of the motion-activated cameras in the Magaliesberg. The cameras take photos of passing wildlife, often at night when nocturnal creatures such as leopard are active. To date Bob has captured images of ="

Venica Rossouw of Trioplastics, the >?Q[Extrupet

BOB Boden has been putting his retirement

*&preservation and conservation.

&"*Coextruded Film Technologies and after

close to half a century in the industry Bob retired in 2010. Disillusioned with the human race and feeling the need to repay nature for many hours in the bush recharging his

in protecting and preserving [[Panthera pardus

When a sub-adult leopard was found dead on the side

&`

$research how the animal had arrived there. The autopsy stated that the sub-adult had not been involved in a road

accident and that there had been no sign of captivity. Well-known for its ability to survive and go undetected in relatively built up indicated that there was possibly a leopard presence in the area between Lanseria

claimed sightings.

At this point Bob launched the initiative ;&'_[aimed to identify the presence and sustainability of the population through [the end goal being the creation of a natural leopard sanctuary.

\\

Trioplastics commissions

INDUSTRY NEWS

Bob Bodens out to trap leopards

$Q\Q\1150mm wide and from 0,1-0,8mm thickness at rates up to 800 kg an hour in clear, ]>[

$Q$^#_`{^]}``]~>$*Q$Q\>Q$Q$Q$

soon cooled after a year of work there was no proof of a resident or transient population. *[sightings were dated two years back. Having initially planned the geographic spread of the initiative to cover the area from Lanseria to

Z*

Bob moved the research to Broederstroom and centred on the Glen Afric Lodge with incredible support given by the lodge owners. Glen Afric has a large cave on their property which had in the past seen leopard presence. Camera traps were set up both at the cave and on game paths in the southern Witwatersberg Mountains. To date the work [&****and porcupine.

Whilst the camera surveillance will continue

&&the scope of the project will increase to cover the area of Hekpoort and then into the Magaliesberg.

Bob explained that the cameras used [&*=[coloured daylight pictures and black-and-white night photos. The setting up of the cameras has been a learning curve! Initially the cameras were producing thousands of pictures of grass and bushes waving in the wind!

All the photos are real time with transmission to both cell phone and email.

Bob said that while acceptance by

for the initiative is growing slowly and the aims for creation of a natural sanctuary continue. Bob can be reached on bodenrg@

telkomsa.net or 082 801 9332.

$*Trio CEO ]? had operated as an accountant for 20 years prior to starting a contract packaging business in 2003. That led to his association with \ and the &&_>JJ_'&;Z['competitive sheet supply market.

The sales personnel Mike Wright and \ joined in 2009 >JQJ[said Moonsammy.

Z_'the supplier of choice to a steadily increasing number of sheet ;'>JJ&&achieved with the recent plant start-up.

The company has achieved double-digit sales increases over the &[&[

In late 2011 Trioplastics moved from premises in Roodepoort to _premises in Jacobs Street were ironically occupied previously by &&The Chamdor site offers considerably more space as well as greater

the potential to expand further.

The commissioning of the two sheet lines in November mark the &&&|

_\[&[&

_

*increasingly at exports into other countries in Southern Africa.

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###[


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The trio in Trio $&*$*&Q'*?]]?\\

PET, PVC sheet lines

on camera

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calendaring process, which means the material is milled and kneaded and then

fed through a series of rollers before introduction to the extruder


Aerontec, MMS Technologyplays vital role in award-winning international project

INDUSTRY NEWS

ENVIROSERV, one of South Africas biggest waste management groups, is setting up a tyre recycling plant in Cape Town, one of its most ambitious projects yet.

Enviroserv has up until now focused

began looking for alternative solutions,

;'[&[

category tyres clearly fall. Even with the REDISA tyre recycling plan currently being implemented, large quantities of discarded tyre casings have been left abandoned around the country. With one of Enviroservs

main strengths being its logistics and transport abilities, the group is able to accept used tyres from existing customers and then recover the valuable materials.

_investment, caters for this need. The commissioning of the line is being managed by Enviroserv consultant Peter Waldburger, ;'&&[

[as many as eight major recycling projects around the country.

A complete tyre reprocessing line from South Korea has been installed at the Enviroserv premises in Bellville. The site was previously occupied by Albert Moore

Industries, a plastic recycling business. Enviroserv was leasing the property for use as its Cape depot, but purchased the site earlier this year.

A multi-stage process is involved: the &&&following which the casings go through a

Enviroserv startsCape tyre recycling line

Accepts used tyres and recovers valuable materials

Mid-stage Metal and other tyre reinforcement material needs to be removed from shredded material during the process

Crumbs Processed rubber crumb material is used in surfacing of roads or paths as well as a variety of other applications

Bulk rubber crumb at the Enviroserv plant in Bellville

The British Antarctic Surveys Halley VI research station is the sixth facility to occupy the site on the ="^km from the edge of the South Atlantic. Halley VI is made up of four-legged modules linked by enclosed walkways and designed to house up to 52 people

BRITISH architects Hugh Broughton Architects Ltd design of the Halley VI Antarctic Research Station has been crowned as the British Construction Industrys International Project of the Year [design translated into reality were South African composite companies, Aerontec and

MMS Technology.Aerontec supplied all the vacuum

bagging and vacuum-resin-infusion materials and consumables for Halley VI. MMS Technology manufactured the GRP panels. According to the architects, MMS Technology was awarded the contract partly because it was one of the

few manufacturers capable of creating both steel frame and GRP cladding as a complete package, and partly because of the technology it used to make the GRP.Cracking a cladding conundrumIn designing the new Halley Research Station for environmental science organisation the British Antarctic Survey

U-turn The plant was originally designed for in-line processing, but the size of the hall available dictated that a U-shaped layout

be used, which Peter Waldburger believes is effective

(BAS), architect Hugh Broughton pioneered the use of glass-reinforced plastic (GRP) on the building, which opened in January 2013.

|

blue for the science and sleeping quarters, and a vivid red for the largest, central module, which forms the bases social hub.

The advantages of GRP are obvious. It forms large panels and is light, making it easy to handle and install. It is used in cryogenic applications, so can withstand low temperatures. But this project pushed GRP technology to its limits.

MMS used a vacuum method of infusing the resin, allowing the design team to develop large panels and create a semi-monocoque \

Early test castings were encouraging, but there were problems caused by the &To meet these the design team added a ;

'_has the effect of giving off water vapour in a [&

Broughton is delighted with the result. Valuable knowledge has been accumulated on using materials in extreme conditions. &`'properties that a new station he has designed for the Spanish in the Antarctic will be entirely of GRP construction, with no supporting steel frame.Source: The Architectural Review, July 2010 | By Ruth Slavid

Johannesburg inland port status challengedTHE city of Johannesburgs status as ;South African Revenue Service. Up till now, containerized cargo could move direct to City Deep in Johannesburg (as an inland port) upon arrival in the country under cover of a manifest, but its been proposed that a new declara-&[

manifests. A debate on this took place during public hearings in Parliament on the draft Customs Control and Customs Duty bills in October. Freight forwards and importers suggested the change could cause chaos at the Dur-ban port. SARS said it was necessary for importers or their agents to clear goods on arrival in the country, and that this would help prevent the arrival of illegal or risky goods.

Shipments of sand

THE moment you werent waiting for A number of polymer traders in the UK and Germany have fallen victim to Oriental hoods and received shipments of sand, a problem encountered by a number of unfortunate importers earlier this year in South Africa. A Chinese trad-ing company going by the name of Habei Leiao, claiming to be an agent for Sinopec, sent containers of sand in 25kg PE bags instead of polymer to at least two traders

+!^{Q

Q#$deals were apparently paid for in advance, and the unwelcome shipments arrived in #$its very costly.

Astrapak recovery on trackASTRAPAK results for the half year =;&progress on the groups turnaround strategy with debt reduced to R248.5-million.

&`Plastics, fell 5.7% to R 252.3 million.

AA R295.4-million provision for insurance proceeds was previously ment of R311.4-million was agreed with no restrictions on utilization. The $East Rand Plastics.

www.aerontec.co.za

www.mmstechnology.co.za


reduced to 50-70mm particles. Thereafter the material passes through two mills where the particles are further reduced in size, following which the batches go through a granulator during which the particles are reduced to rubber crumb with a particle size as little as &*path surfacing applications.

`[&

particles takes place at several points along \

Further processing can yield rubber crumb powders which can be used for surfacing of sports tracks, playgrounds and buildings as

;'

www.enviroserv.co.za

The granulator stage is '[reduction of the tyre shreds. Waldburger ''in the blade design, using experience from earlier recycling applications. Here we see him with Heinz Preusker, who was also at Hoechst SA group in ^`}`

JUST BRIEFLY

INDU

STRY

NEW

S

POLYURETHANE expert Urethane Moulded Products (UMP) has substantially increased its existing production capabilities, while expanding into engineering and fabrication services as a result of its advanced new R12-million manufacturing facility in Johannesburg.

The upgrade of the ISO 9001 accredited factory which was opened at a ceremony hosted by the company in November has resulted in UMPs scope of polyurethane supply expanding to include products, in addition to the fabricated steel components.

UMP director Trevor Carolin said: In the past, complex moulding required the client to supply steel inserts for their polyurethane. These inserts are now fabricated and machined on our premises, &

or rubber-lined, then bolted, assembled and crated for delivery.

Carolin highlighted the fact that the factory upgrade also forms part of UMPs ongoing plans for expansion in South Africa and beyond.

The expansion has resulted in the UMP factory more than doubling in size from 2300m to 5000m, which has allowed for the creation of additional workshop space and new machinery for the polyurethane and engineering divisions.

According to Carolin, the UMP engineering and fabrication division is now able to service considerably larger projects.

We now have the ability to lift components that are up to 12,5 tons in weight and up to 10m in height under one crane. In the past, these types of projects would have been outsourced, as a result of our limited capacity. We are in a position to manufacture anything from machines to structural components.

Improved internal manufacturing capabilities lower the cost of production thanks to an increase in volumes, while improving QC, as a result of all processes remaining entirely in-house.

UMP will increase its focus on pipelines as well as expanding into the export

markets across Africa, North America and South America.

UMP is currently in the process of establishing a dedicated North American branch in Ontario, Canada, to service the well-established mining sector in the region. With development taking place in the South American mining market, I believe that UMP can gain market share in the region by consolidating on its success in Canada, he added.

From a local point of view, Carolin pointed out that the South African market remains relatively subdued, despite showing signs of recovery.

&|as the most prospective market for new projects and growth possibilities. As a result, we will continue to place a high emphasis on expanding our reach in this market moving forward, he added.

About UMPFrom humble beginnings in 1974, UMP today is recognised as one of the most established polyurethane moulding companies in South Africa, and remains one of the largest urethane pipelining companies, with over 200km of urethane lined pipes being supplied since 1980. UMP manufactures and serves the local and global markets in base metals, gold, coal, diamonds, platinum and power generation. PU Mouldings and medium to light engineering are just two distinct services that UMP offers to its clients.

www.ump.co.za

UMPs state-of-the-art factory opens


The expansion has resulted in the UMP factory more than doubling in

size from 2300m to 5000m, which has allowed for the creation of additional workshop space and new machinery for the polyurethane and engineering

divisions at the Edenvale company

UMP sales manager Dion Simonato with CEO Trevor Carolin, who said the companys increased capacity offers clients a value-added service offering as everything is completed according to its exact

Leap of Condence? Yes! Right equipment & team behind you

For further information contact:Pierre Jurgens: +27 (0) 83 276 197810 Staal StreetKya SandsRandburg

TEL: +27 (0) 11 704 0824 FAX: +27 (0) 11 462 2108 E-MAIL: [email protected] WEBSITE: www.cabletech.co.za

Cabletech gives you the competitive edge

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Huayan

THIS YEARS Gold Pack Awards, presented at a posh night at the Wanderers Club in Johannesburg on 22 October, showed again the prowess and world-class standards of the South African packaging sector with plastics entries grabbing by far the biggest share of the awards.

Of the 19 gold, silver and bronze awards available in six categories in the four main packaging groups (glass, metal, paper & board and plastics), plastics entries took over half the awards presented on the night (13 out of 20) as well as the IPSA Gold Pack Trophy for 2013. The trophy the top accolade in the local packaging sector went to tool designer/manufacturer Spec Tool & Die along with convertor JJ Precision, the Astrapak group injection company, for their closure for Robertsons Spice new spice container cap for Unilever South Africa. The top trophy was shared with Consol Glass, which manufactured the lightweight glass bottle.

Besides that, the overall Gold Medal for Plastics went to Nampak Megapak for its Poltek bird crate, an entry which was not a winner in the transit & secondary packaging category in which it was entered.

Of the plastics winners, the Astrapak group achieved exceptional success with four gold and several other medals.

&received special mention recognition from the judges.

_[[including Afripack, Astrapak, Mpact, Nampak and Polyoak as well as some of the smaller independent companies (T3, Tropic, Pouch Dynamics, Miller Methods) is translating to technical advances on the ground that is in the design rooms and production halls around the country.

It is possible that more entries were submitted by plastics convertors around the country, since the rival material packaging sectors tend to be dominated by fewer and bigger operations, but plastic packaging manufacturers can and should take pride in the achievements of 2013 well done to all the players!

Spec Tool & Die, JJ win the main award

Gold night! Vanessa van Holdt and Bill Marshall were the stylish compres of the Gold Pack banquet at the Wanderers Club in October. The programme was shorter than in previous years, with only the winners receiving their medals on stage, which left more time for the guys in their penguin suits to waddle around err, network later that night


www.spectool.co.za www.astrapak.co.za

GOLD PACK TROPHY 2013

Top showing at Gold Pack Awards

Overall winner! The winner of the IPSA Gold Pack Trophy for 2013 was the new Robertsons Spice container from Unilever SA. This is a two-piece container with plastic cap and glass bottle. The

mould for the closure was designed and built by Spec Tool & Die and moulding was handled by JJ Precision, both Durban companies. JJ is part of Astrapak group. The 100ml container is 10% lighter than its previous version, which in itself was an accomplishment, but the real feat was the construction of the mould for the orientated #$was to prevent cross-contamination and extended shelf life, but achieving that in a fast cycling multi-cavity mould was daunting for Dave Murgatroyd and the Spec team. The two covering lids need to "]mould cores as a result needed to be adjustable. The result is this neat container that achieves practically zero moisture penetration. The container was also the winner of the Ambient Food category

DE

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2013 / JAN

UA

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2014 13

2013 winners! Ashwin Ramsudh, R+D packaging development manager at Unilever; Dave ?$>'\"manager and GM respectively of Astrapak JJ Precision Plastics. Their companies were partners with Consol Glass in the production of Robertsons Spices new spice container which won the Gold Pack Trophy, the top award in the packaging industry in Southern Africa for 2012/13

INDUSTRY NEWS

Gold for plastics The Gold Medal for the plastics categories overall went to Poltek for its Live Bird Crate. Moulded by Nampak Megapak in partnership Custom Moulders (owner of the Poltek brand), the crate is used to transport live chicks,

with the intention that this be handled in a humane and hygienic manner. The crate was designed locally, but the mould

was built in China. The lightweight crates halves separate and are stackable, which also allows for easy cleaning. The white mesh hatch is moulded separately for post-assembly, with the entrance opening fully to allow the young birds to exit easily after transport. The $Q]category

CATEGORY GOLD MEDAL WINNERS

Beverage Nampak Bevcan

Ambient food JJ Precision (Astrapak) / Spec Tool & Die / Consol Glass

Perishable food

Marcom Plastics (Astrapak)

Health & Beauty

Plastop KZN (Astrapak)

Household African Closures (Polyoak)

Transit & Secondary

Nampak Cartons & Labels

GOLD MEDAL PLASTICS

www.custommoulders.co.za

www.nampak.com/Plastics-Megapak

GOLD

Packaging Achiever of the Year The man from Nam, Jeremy Mackintosh (originally from Namibia) received deserved recognition at the Gold Pack banquet when he was named Packaging Achiever of the Year for 2012/13. Besides overseeing the development of the Polyoak group into one of the top rigid plastics packaging manufacturing operations in southern Africa, Jeremy has also been actively involved in industry services activities with Plastics|SA and the Plastics Convertors Association

\'&'*label for Fair Cape groups dairy and fruit juice containers. With its small amount of pre-applied pressure-sensitive adhesive with tight register, the ACF labels set a benchmark for the labelling of PET bottles

BEVERAGE CATEGORY

for plastics Cos

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BASF's Offi cial Distributor:Lake International Technologies Sherisha Ramruthan [email protected]: +27 11 409 5000 (switchboard)Fax: +27 11 388 6423 (direct )CALL CENTRE: 0860 99 00 11

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Fresh portfolio.Colour your world!

BASF South Africa (Pty) Ltd (Plastic Additives)

Charis Lewis Tel: +27 11 203 2596 Cell: +27 71 670 2407 Fax: +27 11 203 2602

E-mail: [email protected]


Afripack Consumer Flexibles took silver for its velvet touch packs for Nestls Heaven ice cream wrapper. The judges said this added to the consumption experience

Parmalat PrestoAstrapak Plastform won gold in the Perishable Food

category for its range of thermoformed

yoghurt container sixpacks for Parmalat Presto. The individual containers in the punnet are squeezable, which allows for the yoghurt to be consumed from the pack, which achieves brand

proposition and offers consumer convenience

Astrapaks leadership in the thin-wall packaging market was

emphasised with a judges special mention going to Astrapak Marcom Plastics for its injection moulded

oval tubs, with in-moulded labels from

Alex White, for Parmalat group. The Royalty range

designed for export to ZambiaAstrapak Peninsula

Q]the perishable food category

for its revolutionary introduction of the potato

bag that combines the best of netting with the best of

printing LDPE

Stadium lid The Dairypack Tubs division of Q]in the Perishable Food category with its range of Butro tubs for Clover. The new tubs feature a tilted lid and tub shape that is similar in appearance to the Green Point stadium. The solution has the advantage of making the lid label more visible, enhancing appeal

Miller Methods and Universal

Labels were

perishable food category for their caps for Enterprise polony. This

is a promotional item that has been well received by consumers

INDUSTRY NEWS

SILVER

Plastform won a second

medal, in this case

the bronze, in the Perishables

category for its range of thermoformed tubs

for Danone yoghurt, making it the big

winner in this important packaging market. The

label is a full-length sleeve that achieves maximum branding

and shelf impact

GOLD

PERISHABLE FOOD CATEGORY

BRONZE

Servo Klockner Rebuild

VICTOR MACHINERY

Tel: +27 11 824 3103 - Fax: +27 11 824 6018 email: [email protected] - www.sescc.co.za Unit 1, 16 Davidson Place, Wadeville, 1428

- passionate about the plastic industry.

Injection Moulding MachineGotty

Supplier of:


Consupaq, the Astrapak tubes manufacturing business in

Durban, took the bronze in the Health

& Beauty category for its Lucid jars and tubes for Annique. The application of foiling, particularly on the tubes, was assessed as very high standard by the judges

The African Closures business of Polyoak group won the gold in the Household category for its child-QQ#African Closures is one of the leaders in the local

closure development and production sectors, and here it again showed high levels of ingenuity. The

child-resistant closure is used for the effective sealing of potentially problematic liquids and combines both a visual and audible signal to the closures functionality. It is available in a variety of seal options

Q]/category for its range of shrink sleeve labels for Wynns Oil #$

that solves crushing and lifting issues with promotional banded packs as each pack is essentially shrunk in its own pocket creating a

Cinqplast and Winplas took the bronze in this category

for their range of eco superior

packs for Woolworths, in the process of which they also created a market for recycled material. The judges

commended the products on pack communication which will help drive recycling

Twelvepack Silver

in the Transit &

Secondary Packaging

category went to Q"

business Tropic Plastics of Durban for this pack

for two sixpacks, that allows for easy handling

throughout the supply chain

INDUSTRY NEWS

$Q50ml jars for Justine cosmetic products for Justine/Avon. These injection moulded twin-wall jars feature high standard foiling and

graphics and are produced in SAN

Gold in the Health & Beauty category went to Astrapak KZN Plastop and

Ferroprint for the Dawn range of cosmetic products for Unilever. The

structural and graphic designs have come together to uplift an affordable product, giving it the image of a luxurious brand. The production

quality of the shrink sleeve from Ferroprint, including the distortions and the visi-strip employed, lightweighting of the bottle, design and engineering of the closure plus the good collaboration between the brand owner and the convertors has resulted in a positive market response, the judges said

SILVER

GOLD

GOLD

BRONZE

BRONZE

HEALTH & BEAUTY

TRANSIT & SECONDARY PACKAGING

HOUSEHOLD

'Q\$range of Hoity Toity personal care products for Indigo Brands. This was a joint venture involving Evotec, Mpact Plastics and Tadbik, the latter being the supplier of the in-mould labels


THE three winners of the Food Science and Technology Category of the 2013 IPSA Student Gold Pack Awards all demonstrated insight into how packaging can be used as an eye-catching and user-friendly tool to promote products and attract consumers.

With its emphasis on the development of and education in food science, Nampak is the primary sponsor of this category of the awards. As part of the competition, Students of Stellenbosch University and Cape Peninsula University of Technology (CPUT) were given a brief to design *&&

[semester of the Food Science Product Development module.

Claire Kirkby of Stellenbosch University (middle), receiving her Nampak Gold Trophy for winning

the Food Science & Technology Category IPSA Student Gold Pack 2013, presented by Kirsten Tyler of Nampak Group Marketing and Johan

Visser of Nampak R&D. The Rosendale Labneh is a concentrated yoghurt product

"'#of Labneh was preserved and protected in an

individual PETG petal shaped shell, which extended shelf life to point of consumption. The

aesthetically appealing pack was made to look like petals in a

"

Jessica Kemp from Stellenbosch University won the silver award for her Bean Bites, a falafel style snack sold in party packs "'#$]'Qthe consumer to take the product straight from the freezer to the oven. The container can be added to the compost heap for decomposition after use.

The bronze award went to Zaharan Hussein +'?Atmosphere Packaging for fresh pom-arils. ?Q]the shelf life of arils from pomegranates adding convenience and preserving the fruits natural sensory attributes. The packaging was an ideal integration of lightweight, recyclable and compostable materials into a low cost preservation technology that relies on an integration of natural product respiration and package permeability to extend shelf life. The judges were particularly impressed with the extent of MAP research and level of technical detail presented in this project

INDUSTRY NEWS

www.nampak.com

Mpact Plastics Atlantis received a judges special mention recognition for consumer convenience in the ambient food category for its honey bottle for Woolworths

Nampak Flexible was a

Food category for its resealable packs for Cadbury chocolates. The feature is clearly communicated on the pack, which the judges liked

Polypet marinadeBraai time! Polypet

Ambient Food category

for its resealable PET packs for its range of

braai marinade sauces for South African

Breweries. Polypet is a division of Polyoak

group

AMBIENT FOOD CATEGORY

Nampak encourages next generationof packaging designers

Thermoformer Harrogatebuys assets of Kiley BakerHARROGATE Plastics of Benoni, a leading Johannesburg fabricator of point of sale and other thermoformed plastic items, has bought most of the assets of former rival Kiley Baker Products. Kiley, established by Messrs Kiley and Baker in 1969, was one of the oldest thermoforming businesses in Johannesburg, but the operation became uncompetitive and eventually closed in December last year. Enter the picture, Robert Rugheimber of Harrogate, who purchased the bulk of KBs equipment on auction. Former KB manager Peter Hawkins is now production manager at Harrogate.

Harrogate (established in 2004) manufactures point of sale items, dispensers, signage, name tags and other thermoformed sheet goods and is involved in digital printing as well as vacuum forming of fairly large plastic sheet items.

Robert Rugheimer of Harrogate at the companys premises in Johannesburg

BIC plant in DRC closesBIC South Africa is now the only the BIC plant operating in Africa following the closure recently of the global groups factory in Kinshasa. The plant in the Democratic Republic of Congo became unsustainable more as a result of the &&particularly regarding transporting product from the site, than due to any other factor.

The BIC group started in France in 1945. It is now an international operation manufacturing pens and other stationary items, lighters, shavers and promotional items.

The South Africa operation, which started in 1957, operates from Industria, Johannesburg, and manufactures only pens.


LOMOTEK Polymers, the compounding arm of the Lomold Group, has just celebrated its 10th year in operation a decade which has witnessed it becoming one of the top plastics compounding operations in Southern Africa.

Lomotek developed out of a requirement for the vertical integration of the Lomold Group. Entering the market in 1998 with its low-pressure injection moulding technology, a local market gap was &

&&Lomotek Polymers in Cape Town in early 2003.

Lomotek Polymers supplies customer-spec colouring for both milled and compounded LLDPE materials to the roto moulding sector. Due to the high quality of the roto materials and services, it started to rapidly expand both its services and comprehensive range of materials to accommodate all end users across the entire polymer market.

&

*

the groups acquisition of Plastamids compounding facility in Elsies River, Cape Town, in 2010, which created a platform for the group to increase capacity as well as develop and manufacture new and advanced materials. A fully specd lab service operated at the Elsies River plant, which became

&

[formulations for the powder, recycling and specialty grade sectors on demand.

In addition to its very wide range of products and services, Lomotek

&|_reinforced thermoplastics for use in the Lomold process as well as various other automotive applications. In total, the Lomold group processes an excess of 1500 tons per month.

ContinuityThe business suffered a major setback earlier this year when the group founder, Pieter du Toit, passed away. Du Toit was the motivator for the groups strategy and all of its primary initiatives, but thankfully in a rare incidence three of his sons remain employed within the group to carry the legacy forward.

Werner du Toit has succeeded his father as CEO, Wouter du Toit is now the sales and marketing director and Ruan du Toit heads up pallet sales for the Z&*

&accounts manager, Riekie Vorndran, are both sisters of Du Toit. So its truly a family business, with cousins and various other relatives all involved in making the business a success. Du Toit treated all of his employees as family, with it becoming a truly wonderful aspect of tenacity and perseverance within the group of companies.

Pieter provided us with the tools and many lessons in business, and our goal is to put these into practice and continue with the development of the businesses in the Lomold group, said Wouter du Toit.

Lomotek Polymers celebrates 10yrsLomold group processes over 1500 tons/ month

www.lomold.com

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The compounding business is a subsidiary of the Lomold group, which patented its Lomold technology for the production pallets

[email protected], [email protected] and [email protected] (Cape Town)[email protected] and [email protected] (Cape Town) www.exxonmobilchemical.com

UV TOOLING, one of the Capes most reputable toolmakers, recently celebrated 25 years in operation.

Gaining a good reputation is no easy matter for a toolroom in South Africa, such is the pressure on lead times, costs and expertise brought on particularly by toolrooms in China which have been offering local brand owners and product manufacturers exceptional deals. However, UV has managed to remain competitive through this challenging period.

The 25-year milestone is a happy occurrence for UV founder Uli Vogeli (UV), who got the show on the road in 1988. Originally from Switzerland, Vogeli completed a toolmaking apprenticeship there before he came out to Africa for a bit of holiday and fun.

He joined Drago Plastics, working for the successful Yugoslav proprietor, Drago Srdic. The company moulded television set housings and the manufacture of the comparatively large tools with extensive

=&experience.

Then, after what was effectively a further 12-year apprenticeship (as well as two extended global sailing trips, one on a yacht he built himself), Vogeli went on his own in 88, operating from the garage of his home. He was a one-man-band for just six months, however, as UV Tooling began to gather momentum. He was sought out for his toolmaking skills and made tools for a wide range of products, focussing on technically shaped parts like electrical and electronic housings.

Tool trials

tool trials, but production has become a mainstay of the business since.

The basis for the companys success to date is mainly due to good relationships built up with customers in respect of the quality of tools produced, lead times and low error level which Uli realized at the outset was most important.

Toolmakers in South Africa are positioned midway between Europe and

the Far East: costs for the manufacture of tools are comparatively high in the former and lower in the latter but the only way &

*&is to produce tools that function optimally and achieve production targets or better! UV Tooling has shown that it is able to make tools that match all these criteria and has as a result progressed steadily.

UV Tooling moved to its own dedicated premises in Killarney Gardens in 1995.

"year. It moved again in 2005 to larger premises in the same area, where it still operates from today.

Congratulations to Uli and the UV team!

www.uvtooling.co.za

INDUSTRY NEWS

Only perfect will do Uli Vogeli in the toolroom at UV Tooling in Killarney Gardens, where the companys toolmakers produce high standard tools for technical components

Karl Musik is the self-taught designer at UV Tooling who has excelled with development of complex tools

Andrew Bannatyne of Plastichem presented a gift to Uli on the occasion of the companys 25-year celebrations

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Tools for electrical and electronic housings are produced, and in some cases, UV handles the moulding as well

Produces tools that function optimally and achieve production targets or better

Tools for complex electrical and

irrigation parts are the norm

UV Tooling celebrates

25yrs

UV Tooling specialises in precision plastic injection and die casting mould making and production. The company has served the plastics industry in South Africa for the last 25 years.

"]#

We specialise in the manufacturing of plastic injection moulds using CAD/CAM and CNC machining to produce mould sizes of 546mm x 796mm and smaller. We also offer product design and mould design.

Our workmanship is based on international standards provided staff. We are recognised for our high precision manufacturing. We are also an accredited training facility for the practical training of apprentices in the industry and are a proud member of TASA (Toolmaking Association of South Africa).

We have over 20 production machines ranging from 12 tons to 250 tons. Our moulds are of the highest quality and are always ready to operate. Quality products need quality workmanship, so we use only the best.

22 Lauda Road, Killarney Gardens, Cape Town, South Africa, 7441P.O. Box 6406, Parow East, South Africa 7501Tel: +27(0)21 5560315, Fax: +27(0)21 5560316Email: [email protected]

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Design Manufacturing Production Contact

INDUSTRY NEWS

CAPE converter Alpine Injection Moulding has moved to far larger premises and added vacuum forming to its range of services.

The company moved earlier this year from premises it outgrew in Epping to a fully refurbished 4000m site in Parow Industria where it is able to accommodate its bank of injection

moulding machines as well as the new large-dimension vacuum work it has commenced. Alpine also conducts extensive assembly work on site, necessitating the extra space. The site was previously occupied by Macbean Plastics.

And Alpines Dave Roberts recent

&time appears to have been vindicated. The SML robot from Plasquip is being used for the injection moulding of a housing in polystyrene where the 29-second cycle times needed to be maintained (cycle times always need to be maintained!). Mouldings were previously removed manually, which on occasion caused interruptions to cycle &

&however, the machine maintained the 29-sec rate for a full 24-hour period and produced just a single scrap part, not bad for beginners!

Starts vacuum forming, and exports to China

www.alpinemouldings.co.za

Alpine grows

*'*new and neatly renovated factory in Parow Industria; the company has also recently ]Q?consistent cycle times


INDUSTRY NEWS


ECO POLYMERS, the polypropylene recycling operation in Alrode, Johannesburg, has succeeded in lifting tonnage turnover nicely since the business was established 18 months ago.

The company was set up by Victor Nash, Asheen Singh and one sleeping partner. The line, built around a 130mm extruder and wash plant, started as a turnkey operation in mid-2012.

PP has up till recently not been widely recycled, but thats not because it isnt popular: rPP is used in furniture, crates, household goods and a wide range of other applications. Use of a percentage of recycled material in the cores of mouldings or multi-layer structures offers a price advantage for PP converters.

The factor that has prevented rPPs more widespread reprocessing is the challenge of sourcing material from the post-consumer stream. Eco Polymers as a result started off right by having an expert within operational experience in this area, Victor Nash, together with a well-known material expert, Asheen Singh, to establish its collection system.

Much of the material is

&

requires coordination with both dedicated and informal collectors. Polypropylene mouldings can be hard to identify in the waste stream, since a wide variety of components are produced in PP and, unless prior sorting is conducted, these &

But it appears that recyclers are moving towards a solution: PP recycling rates have increased from an estimated 26 500 tons in 2005 to 47 000 tons in 2012, which is a major rise.

Nash, who was previously involved in PP yarn extrusion as well as bulk PP recycling, has carried those skills over at the Eco plant since relocating to Gauteng. He has succeeded in setting up a functioning system which has seen tonnages move up to the 140 tons a month range. Training of production and collection staff, as well as the incentivising of particularly the latter, has been an important part of the process. Production scrap from PP virgin convertors forms a

&=The demand for Eco Polymers material

outstrips supply pushing this newly founded company into the next stage of its plan, to further increase processed volumes to 180 tons and to develop new markets for the range of rPP polymers its supplying. Eco Polymers, phone 011 468 4871 /

082 880 5900

Eco Polymers ups PP recycling rate

Collected polyprop material contains an incredibly diverse range of products, from crates and buckets to furniture and toys, which in itself makes the collection process challenging. One of the plusses is that PP tends to have a high weight-to-mass ratio

Washed and granulated material including PP labels, containers and a variety of other common products tends to be mainly white with a sprinkling of other colours; here operator Lukas prepares granulated

Recycled PP from Eco Polymers is supplied in bulk bags

Victor Nash monitoring production of PP pellets from recycled material at the Eco Polymers plant in

Alrode, Johannesburg

SA recycling rates increase

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PackagingNon-

Packaging PackagingNon-

Packaging PackagingNon-

PackagingPE-LD/LLD 90 149 11 305 89 493 6 359 93 464 5 507PET 39 855 46 276 50 280PE-HD 27 907 11 825 27 108 11 871 36 316 9 633PP 20 869 17 744 21 549 18 734 21 716 25 365PVC 798 15 032 587 16 117 631 16 181PS & PS-E 2 038 1 218 1 636 1 578 1 621 1 774ABS 376 805 550 605 311 644Other 40 1 891 1 267 1 967 60 5 045Waste tonnages exported 7 696 1 358 8 294 1 464 12 532 2 212Total tons recovered 189 728 61 178 196 760 58 695 216 932 66 360

Total plastics

packaging 605 000 629 570 647 244Packaging

recovery rate 30.1% 29.9% 33.5%

Packaging and non-packaging tonnages recovered in South Africa from 2010 to 2012

2009 2010 2011 2012

Total tons converted 1 280 000 1 312 700 1 300 000 1 370 000

Total tons recycled 228 057 241 853 245 696 268 548

Recycling rate 17.8% 18.4% 18.9% 19.6%

Waste exported 5 575 9 054 9 758 14 744

Total tons diverted from 233 632 250 907 255 454 283 292

Recovery rate 18.3% 19.1% 19.7% 20.7%

Table 1: Plastics Recycling and Recovery rates for 2009 to 2012

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INDUSTRY NEWS

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have the tenacity and stamina to continue year

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Recyclers working out systems to meet

challenges


INDUSTRY NEWS

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INDUSTRY NEWS

AERONTEC, Cape-based composite materials supplier and distributor, recently completed a massive 300-ton contract of *[

Aerontec designed, manufactured and installed a special composite deck on one quay of the Cape Town container terminal to increase the height of a section of the concrete deck QJ

&*&ever been undertaken in the world, and I believe it was also the [Z&'

The Transnet National Ports Authority, through a local civil engineering company who was busy with the construction of a new section of the container terminal, approached Aerontec to

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The cable tray which houses the electricity cables for the large gantry cranes along an area of over 1200m and about 3m in width, were considered a serious trip-hazard to workers on the

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Blyth explained that the quay is a cantilever deck and the piles &\\[

&QJ*[[presented too many disadvantages: weighing in at about 1000 tons of concrete and rebar it was too heavy; too costly; too long to construct and too long to wait the prescribed 28 days for the concrete to cure, not ideal for a working quay with ships berthing

Realising an innovative resolution was urgently needed; the engineering company and civil engineers approached Aerontec &

_Q>solution had to be: light weight cost effective quick and easy to install able to allow waves to wash over the panels and allow water

to drain away quickly underneath the panels strong enough to endure loads of up to 40 tons in the event a

container was dropped or placed on the panels weather resistant safe and have a slip-proof coating fastened onto the existing deck surface without damaging the

surface or the rebar lattice such that damaged panels can be replaced

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The solutionAfter various designs, proposals and testing, a design was agreed on which made use of resin vacuum infused solid GFRP [[

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The solution! A gap was left between the panels adjacent to the rail and the panels at the waters edge where a Panzer belt had to be installed to cover the electric crane cables. The Panzer belt is lifted by a special belt lifter attached to each crane to withdraw the cable, and to nest the cables back into the hidden cable cavity as the crane passes down the rail system

Composite solution! 1161 GFRP panels weighing in at just 250 tons proved to be the ideal solution to the tricky problem of raising a

The problem! The cable tray which houses the electricity cables for the large gantry cranes along an area of over 1200m and about 3m in width, were considered a serious trip-hazard to workers on the quay

Biggest single composite job ever completed in South Africa

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Tooling / machine boards & tooling systems

ARALDITE epoxies & RENCAST polyurethanes Resins & adhesives

DIVINYCELL PVC and PET rigid structural foamsWe now stock DIAB Divinycell core materials, that we can cut to your thickness requirements from 2mm to 60mm

Supplier and distributor of composite materials and related technologies Epoxy Resin systems Vacuum bagging and infusion materials Fiberglass, carbon & Kevlar Tooling Systems Core materials Technical and Processing advice

TELEPHONE +27 (0) 21 671 2114 / +27 (0) 21 674 6325

FAX +27 (0) 21 674 6622 EMAIL [email protected]

Plastic HoneycombsNidaplast Honeycomb is a polypropylene honeycomb used as a core in structural sandwich panels


Z&||ZTechnology, specialists in infusion of large solid composite &

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INDUSTRY NEWS

Before work began to install a special composite deck on the quay to "

NICO van Wieringen joined Aerontec at

the beginning of September as the

import and purchasing manager. Nico has

extensive experience in the purchasing

and freighting arena, previously working for

more than 12 years for the Southern Wind

Shipyard in Cape Town which designs and

manufactures 100ft and larger composite yachts

for the European market.

www.aerontec.co.za www.mmstechnology.co.za

INDUSTRY NEWS

RIAAN Steyn is a man with a vision to alter the face of recycling in the Northern Cape and hes determined to make his vision a reality.

Currently there are only a handful of recycling companies operating out of the area, mainly from Kimberley and Upington, and these focus mostly on industry and retail outlets. However, Riaan believes the potential to grow the recycling industry achieved by involving the communities of surrounding smaller towns.

To help kickstart the ambitious project, Riaan and his son, Peter, recently hosted the two-day Green Kalahari Recycling Indaba in Upington. Major roleplayers in the recycling industry including Mpact,

_Z* were invited to spend the two days visiting Upington Recycling, which Riaan and Peter own, as well as smaller more informal recycling projects which Riaan hopes to incorporate into his vision.

A day was also dedicated to educating around 600 of the communities schoolchildren about recycling and the role they can play in helping to clean up their environment.

According to Riaan, the main challenges facing recycling in the Northern Cape are the long distances

between towns and the high cost of transport, as well as the lack of recycling infrastructure and knowledge of the potential of the Northern Cape.

The projectThere are 82 small towns in the greater Northern Cape area, with a population of about 1.1 million. Riaan has spent close on two years researching his vision which will concentrate on 40 of these towns, all of which will be new sources of recycling.

He estimates that the average monthly volumes of recycling currently generated by each of these towns to be: Box 5 tons PET 2.5 tons Plastics 2 tons HLI 2 tons (tin) Glass 15 tons

I realise this is very little. However, if multiplied by 40 towns another picture emerges which will grab the attention of Consol, Mpact and Extrupet, he adds.

Riaans vision is to establish a recycling buy-back centre in each of the 40 towns at businesses, like general stores, that are currently well run and accessible to the community. Individuals will then be encouraged to collect materials which can be recycled and take it to the buy-back centres where they will be paid cash determined by the

weight value of the recycling they deliver. Upington Recycling will implement a

system which, simply put, has a truck with a mobile baler travelling a logical circuit to each of the 40 towns where collected material will be baled and taken to Kimberley Recycling (also owned by the Steyns) or to Upington Recycling.

We will also provide ongoing guidance and advice to the buy-back centres to ensure that the project is sustainable, says Riaan.

Its going to be a costly start-up, but has the potential to be a long-term sustainable venture, he adds.

Need for recycling plan in smaller areas recognised#ZZ'of sustainability, says that industry tended to focus on recycling volumes and therefore on the bigger centres. However, he realized the need to extend the focus to the smaller areas.

Theres a real need for a good recycling plan for the smaller areas and I believe it could be a success if it has a champion like Riaan driving it, he added. The potential to build a culture of recycling exists here and this [

coming out of these smaller towns. Riaan Steyn, tel: 082 053 9741, email:

[email protected]

Huge potential to grow recycling industry in the area

Peter and Riaan Steyn outside their Upington Recycling depot which opened in February this year

Non-mechanised baling! Workers at the Raaswater Recycling Project, about 20kms from Upington, use muscle power to compact the PET recycling they collect. Q*sustainability, remarks on the effectiveness of their efforts

Q]explain the intricacies of PET recycling and the products that can be made from recycled PET to Upington schoolchildren

25 tons of material was processed by Upington Recycling in September, which opened in February. Here Riaan Steyn ?]'

Northern Cape recycling indaba

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NOW AVAILABLE IN SOUTH AFRICA

KAWAGUCHI injection moulding machines are well known for their reliability and longevity. This world-renowned brand is available in a variety of models.

KMB3 servo and hydraulic KMB4 servo and hydraulic KME full electric machines

All of these models use the KAWAGUCHI EZ8000 Hitachi controller with touch screen. For more information contact Dave Moore on 083 675 8325

CALL NOW FOR YOUR QUOTATION, PRICES ARE COMPETITIVE!

100 ton Servo

machine in stock

USABCO, local manufacturers of household icon ADDIS, is celebrating its centenary this year by reinvesting in the country, the company and the brand that has become part of the lives of generations of South Africans.

For one hundred years, USABCO has been manufacturing household products that make our lives easier from food and home storage containers, plastic kitchenware and laundry products, the most comprehensive and innovative range of home cleaning products, paint brushes and the ever present South African staple, the cooler box.

USABCO products have been available in virtually all of South Africas leading supermarkets and hypermarkets from the _Zmanufactures over 1000 product lines out of its world class plant in the Western Cape, supplying thousands of stores throughout South Africa and Africa.

Reaching the 100-year mark is a remarkable achievement for any company, but particularly so for a manufacturing company not just in South Africa, but anywhere in the world, in the face of ever changing threats of cheap =\hungry competitors.

_[its ability to retain employees through thick and thin, which adds a depth of experience and commitment to the company that is seldom seen in the manufacturing environment.

USABCO is proud to reach this remarkable milestone, which we could not have done without the constant and enduring support of our staff, our partners and our loyal customers and we cannot thank them enough, said USABCOs chief executive Errol Z_&our personnel, a culture of innovation, commitment to excellent service and world-class manufacturing.

If you invest in training and building

skills among staff at all levels, as we have, it is possible to create the capacity to be competitive on the global stage and not regard ones self as a South African company which de facto is limited in size and growth by the perceived constraints of a lack of world class expertise in a smaller market removed geographically from the world environment, added Stern.

USABCO is headquartered in Bellville in the Western Cape, operating out of a 40,000m state-of-the-art manufacturing plant which employs over 750 staff. _'of quality and innovation, it supports a product design and development industry in the Western Cape and is closely &*

As a sign of the companys commitment to the future, USABCO has ensured that the plant is equipped with the latest machinery, new products and moulds and a new state-of-the-art Enterprise Resource Planning (ERP) system from Oracle, which will streamline

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An enduring story lessons in manufacturing in South AfricaADDIS turns 100!

NCG CAM, a cutting edge computer-aided manufacturing (CAM) software system used in steel cutting and for the manufacture of moulds, is now available Z&_integrates readily with existing CAD and CAM systems.

_

NCG CAM Solutions of Witbank. NCG CAM is suitable for all types of forms, creating an optimised, smooth cutter

motion ideal for 3D HSM machining, which will help to extend tool life, minimise wear on the machine tool and produce \

&

NCG CAM has a user-friendly interface, with a typical learning curve of just a single day being required to machine a live job. It is ideal for the high-speed machining of moulds, dies, prototypes and precision surface machining.

Features include: several advanced 3D machining routines,

rest roughing and 3+2 capabilities for all tool paths (a simultaneous 5-axis add-on module is available);

&&including core roughing and adaptive clearance;

advanced drilling routines includes automatic hole detection and/or user

NCG CAM software system for manufacture of moulds now in SA

5 axis machining of (Picture courtesy of NCG CAM User: ORODJARSTVO Gorjak, Slovenia)

\\\?]'?

(Picture courtesy of NCG CAM User: LTH Castings, Slovenia)

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both its manufacturing and business processes._`Z

at the forefront of world class manufacturing, allowing us to optimize our processes, reduce &&&[to changing market conditions, said Stern.

_Z\future, and to bring awareness of its excellent products and brand and South African roots, the company has also embarked on a 360-degree marketing campaign, including television advertising, a new website and a national retail competition, which aims to stimulate the purchase of home-grown products.

Reaching the 100-year mark has &Z'ZAfrica, added Stern. It has re-energized us to ensure that we are not 100 years old, but rather a nimble company committed and focused on its future.

USABCOs is entering its next century as a [&

###[


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INDUSTRY NEWS

_Z"*manufacturer Makoro Bricks has opened a subsidiary operation, Makoro _*manufacturing roto moulded tanks _Bricks operation was previously the Botswana agent &$$_*Rudy Schuhardt, owner of the businesses, said they had decided in 2012 to commence with the production of tanks themselves.

|*_*

&&Reinhardt of India. Supplied by the well-known Dhanu Patell of Reinhardt, who managed the commissioning process, the machine is able to produce a 5000-litre tank in 26 minutes, which is an impressive cycle time.

_&&*|*offers tanks for industrial, chemical, and fertilizer storage solutions.

Makoro Tanks starts in Botswana

#]##

New tank maker =Q??]$]

]

all machining routines are fully gouge protected for both the cutter and the tool holder;

&minimise any air cutting;

available as both 32 and 64-bit versions (both are multi-threaded).

NCG CAMs latest release, Version 12, includes new features such as the ability to machine selected surfaces, the ability to generate ruled surfaces, thread milling, a tool size guide, core horizontal area passes, multi-\*`_

creator, as well as many enhancements. A demonstration version of NCG CAM v12

is available for download at http://www.ncgcam.co.za/request-a-demo.html

For more info, contact Nicole Geldenhuys on `}`}

\\?

(Picture courtesy of NCG CAM User: LTH Castings, Slovenia)

###[

A RECENT success story for Elastron thermoplastic elastomers was the approval received from Danish manufacturers to use Elastron thermoplastics to seal Stelton vacuum jugs for coffee and tea.

After a long and complicated testing and validation [Z&QJJ"

seal in the cap of the jug. Stelton is one of Denmarks *

&=

_;_=

'&|[ZZ=low fogging, low odour and excellent surface grade of G103.A63.B [&Z=

ZDH Polymers.

Contact Deon at 083 677 0852, [email protected]

CPE WEIFANGFLUORO ELASTOMERS CHENGUANGPER FLUORO ELASTOMERSTPE ,TPV AND TPR ELASTRON TURKEYEPS SHINHO ,TAITA, HYUNDAI ENGINEERING

PLASTICS (DONGBU) , SUSHOU CHANGLE(DONGBU Technology)

PS & HIPS HYUNDAI ENGINEERING PLASTICS (Dongbu)

LDPE & LLDPE HANWHAEVA

HDPE PIPE PE 80/100SILICON RUBBER Shanghai HongshenMAGNETITEENGINEERING POLYMERSREWORKED AND REPALETIZEDMATERIALS

POLYMERSPOLYMERS

DH POLYMERSCCContact: Deon

Cell: 083 677 0852Fax: 086 578 1830 Tel: 011 760 1089

[email protected]

THE largest production line for the #|at the Lanxess site of Sittard, Geleen, _"&

converted to the companys innovative ACE technology.

The German pioneer in synthetic [[12 million to convert the production line &["[[

The new line EPT 3 has a capacity of 95,000 tons per year. This is more than half of the total capacity at that plant. It is currently the worlds largest EPDM plant with an annual capacity of 180,000 tons.

The ACE process, using outstandingly [\[\

&[|#|free and with high degrees of purity. The process consumes less energy and produces no catalyst waste, which makes

Lanxess current range of EPDM

comprises seven _introduction of these grades from the _Yresult of an extensive technology and product validation including several test runs on one of the smaller production lines at the Geleen site, said Torsten Derr, head of Lanxess }~

#|[

automotive industry for door sealants or coolant hoses. According to Lanxess estimates, approximately 7kg of EPDM is used in every car. The product is also used construction and oil additives industries. Its properties include very low density, good resistance to heat, oxidation, chemicals and weathering as well as good electrical insulation properties.

_

&the production of the complete EPDM grade portfolio, including a wide range of

monomer compositions and molecular #[high ENB grades, for fast vulcanization, }\~[

weight grades, for excellent elastic properties.

Lanxess Changzhou plant in Jiangsu Province, China, starting up in 2015, will *

_will have a capacity of 160,000 tons per year and represents an investment of 235 million. \Z

Plastichem

New line has capacity of 95,000 tons per year


INDUSTRY NEWS

The largest production line for the Keltan-branded EPDM synthetic rubber at the Lanxess site of Sittard, Geleen, The Netherlands, has

been successfully converted to the companys innovative ACE technology (Photo: LANXESS AG)

www.lanxess.com

www.elastron.com

www.plastichem.co.za

Lanxess converts to ACE technology

The Stelton jug is known worldwide for its functional rocker stopper which opens automatically as coffee is poured. The Stelton vacuum jug has sold more than 10 million units to date

KIA use Elastrons new G103.A63.B grade in its "

INDUSTRY NEWS

MEDIA reports have abounded recently about the use of cash declining and individuals making more and more use of mobile and electronic payment methods. The big debate now is whether to introduce plastic banknotes to replace their paper equivalent.

Most recently the Bank of England

whether people would be ready to accept plastic banknotes. The recently appointed

governor of the Bank of England, Mark Carney, brought in polymer bank notes in his previous role as head of Canadas national bank, while Australia also has polymer notes in circulation.

Jan Visser, MD of Deter-A-Dye Security of Johannesburg, which uses technology to dye and track banknotes, said there are predictions that the use of cash will decline.

We see this with the advent of mobile payment features becoming available

on your mobile devices, such as a cell phone, and the use of credit cards, as well as the increased use of EFT payments, he adds.

The Bank of England said polymer banknotes would stay cleaner longer, would possess advanced security features making them harder to counterfeit and would last at least 2.5 times longer than existing paper notes.


DUPONT has honoured the innovative use of

gas, architectural and aviation industries with this years DuPont Plunkett Awards.

Flexitallic, Cleckheaton/UK, with its Flange Rescue Gaskets (FRG), providing an unsurpassed maintenance solution for the chemical and

Kunststoff GmbH, Ochtrup/Germany, with its new manufacturing technique for producing coloured ETFE

effect; and Draka Fileca, Sainte-Genevive/France, with its ultra-lightweight quad data cable with outstanding electrical properties, are the winners of the DuPont Plunkett Awards 2013 in Europe, Middle East and Africa (EMEA), which coincides with the 75th anniversary

Plunkett.

An international jury of experts met in September at the DuPont Geneva Innovation Centre in Meyrin, Switzerland, to select those entries that best met the judging criteria of degree of innovation, breadth of commercial application, sustainability and optimum use of the materials potential.

The Flange Rescue Gaskets (FRG) by Flexitallic, which won !"#

oil and gas industry to be replaced easily and cost-effectively. This patented system has a precision manufactured metal

body coated with expanded $%&'*

The high compressibility of the PTFE type used ensures that the FRG conforms even to highly corroded and damaged *

the need for any costly

*

Second prize went to

GmbH for its new proprietary extrusion technology for manufacturing coloured and structured ETFE architectural *+

impressed by the fact that

from 100% recycled material obtained from a proprietary recycling technology developed :"

overall environmental impact.

Draka Fileca received third prize for its newly developed, ultra-lightweight quad data cable for the aviation industry, which is 25% lighter than currently used quad cables, while still offering enhanced electrical properties.

environmental impact of aircraft and helicopters.

Once again we were positively surprised by the innovation potential of this 75 year old material, which became known

Sa plastics '013 12 for web

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