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Dubai’s World Expo may boost UAE 76 Pack-Ad-Vise starts operations 28 New MD for AAT Composites 44 OFFICIAL PUBLICATION OF THE PLASTICS CONVERTERS ASSOCIATION (PCA) & PLASTICS INSTITUTE OF SOUTHERN AFRICA (PISA) VOL 12 ISSUE 2 – APRIL / MAY 2014 www.saplastics.co.za Sleep easy! on ‘Space Base’: rPP bed base from Cycliq ‘Sharki’ repellent system WorldStar for Polyoak’s ‘Stadium Tub’ ALTECH UEC producing over half-a-million ‘set-top’ boxes a month Sustainability focus at Propak Packaging Innovations conference

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SA Plastics, Composites & Rubber is published six times a year in Feb, April, June, August, October and December and has a circulation list of over 2 400. Readers include individuals across the spectrum of the Southern African plastics industry – from equipment and material manufacturers and suppliers, their agents and principals; product manufacturers and plastics services and ancillaries suppliers. Our readers also include members of research and development facilities around the country. SA Plastics, Composites & Rubber is the official magazine of the Plastics Institute of Southern Africa and the Plastics Converters Association.

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  • Dubais World Expo may boost UAE

    76

    Pack-Ad-Vise starts operations

    28

    New MD for AAT Composites

    44

    OFFICIAL PUBLICATION OF THE PLASTICS CONVERTERS ASSOCIATION (PCA) & PLASTICS INSTITUTE OF SOUTHERN AFRICA (PISA)

    VOL 12 ISSUE 2 APRIL / MAY 2014 www.saplastics.co.za

    Sleep easy! onSpace Base:rPP bed basefrom Cycliq

    Sharki repellent system

    WorldStar for PolyoaksStadium Tub

    ALTECH UEC producing over half-a-millionset-top boxes a month

    Sustainability focus atPropak Packaging

    Innovations conference

  • Summit Publishing cct: +27 (21) 712 1408

    f: 086 519 6089c: +27 (82) 822 8115

    e: [email protected] Suite 42, Private Bag X16,

    Constantia 7848, Cape Town, South Africa70 Newton Drive, Meadowridge, Cape Town

    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])

    BY THE WAY . . .

    www.actioncoachsa.com

    plastic composites) from Croda reduces risk of water absorption for exterior panels (see page 93)

    New player SRF enters BOPP market

    scene of action lately, after years almost decades of inactivity. Unfortunately for FIMA, which for close to 30 years was South !"#!"$

    a challenging time: the company has been operating under business rescue terms since October last year. Its plight coincided almost

    %"&'*;!

  • Tailored engineering polymer compounds

    Composite Plastics ccp. +27 11 314 1035e. [email protected] | Craig: 083 680 9793 [email protected] | Allan: 082 886 6058

    Craig Paterson Allan Paterson

    Material compounds are exclusive to

    customers Formulations include colour, UV, impact or

    any other required additives Tailored solutions in consistently

    outstanding quality We offer polymer selection, mould design

    and mould trials on a proprietary and inclusive basis

    Polyamide, polythalamide, polyester

    and acetal compounds from of Spain;

    Polyamide, polythalamide and polyester compounds from of Germany;

    Compounded polycarbonates, acrylics and various polymeric alloys from of England;

    Heat dissipative and conductive

    compounds from of USA;

    APRIL / MAY 2014

    Contents

    ON THE COVER

    Find out more at www.saplastics.co.za

    kHq\{|}'|

    68

    64

    6

    8

    10

    16

    20

    24

    30

    52

    56

    58

    78

    84

    INDUSTRY NEWSAltech iUEC in major production rollout

    Cycliq commissions bed base plant

    Miracle Mould "~&

    WorldStar "~&!!

    ACD RotoFlo moves to new, larger premises

    photovoltaic pilot plant is in production

    PROPAK PACKAGING INNOVATIONS CONFERENCE

    Sustainability, !

    ASSOCIATION NEWSIOM3: Tyre, rubber imports place local industry

    under massive pressure

    !"Plastics welding inspection learning programme launched

    PISA: !;*"^

  • I BEHIND-THE-SCENES and unseen by almost all, interesting developments are taking place in the industry even in these challenging times.

    We have fortunately been privy to some of these projects lately and are happy to report about them here. Altech UEC at Mount Edgecombe in KZN is busy with a massive project to produce TV set-top boxes: it is manufacturing over 600,000 of the units a month in the rollout to supply subscribers across Africa, as the continent switches from analogue to digital television ;=;!";;sector contracts, where volumes are far higher: these are complicated devices that require both assembly and live testing. Volumes like this are impressive and testimony to good teamwork and planning.

    UEC has also made extensive use of automation systems such as robots in one of the largest rollouts in the industry since the switch to the new beer crates in the 1990s. Read about it on pages 6 and 7.

    Then we report about the new venture by Cycliq in Wadeville, where a completely new bed base is being manufactured in recycled PP. Although the business is at this stage far smaller than the Altech project, the partners at Cycliq have shown a lot of tenacity in getting the concept off ;!$!$~&

    has the potential to be a winner (p8).

    The reality is that it would be unwise to think manufacturers of rival products, in this case the wood bed base, are going to roll over and play dead. We always cheer material substitution, which for years has been in favour of !$!!#%=

    We report about a number of other cutting-edge projects #!";relevant.

    Some companies are reluctant to publicise their achievements, but we continue to work towards

    encouraging them to celebrate progress and initiative and inform the market and the public of these. There is a pervasive negative character in the media in general, ""$composites and rubber sectors.

    *""

    #;$certain that your competitors already know what equipment you have but what they have no control over is how you are going to make your machines work. Are your moulds going to achieve their claimed cycle times? Will your setters be able to keep the machines running optimally, 24/7? Will your night shift be suitably productive? Are you managing to contain your electricity account? There are other factors besides which only you and your production team can resolve. How you achieve that is what you need to keep $#!=

    &"#positive communication. All industries are under massive pressure, and it is creating a dangerously competitive market climate.

    We have also noticed that the Industrial Development Corporation (IDC) has lately been funding several new projects that are showing promise. It may be that the apparent political agenda pursued by the IDC previously is being toned down and funding rather extended to projects with clear business plans and programmes. Entrepreneurs need guts to undertake big projects, and your chances are much better if you have good partners!

    The current thinking is that most sectors of our market are reaching saturation point, and the next frontier is the wider $";;to need momentum to achieve in that area.

    COM

    MEN

    T Your chances are much better if you have good partners

    THIS ISSUE

    Several cutting-edge projects underway

    4 APRIL / MAY 2014

    sectors of our market

    Martin Wells, Publisher

    Altech UEC impresses Operator Brenda Williamson performing

    additional sub-assembly operations on set-top boxes at Altech UEC in

    Durban. The company has ramped up production and in February

    made 681,068 of the units, which require full assembly and live

    testing; it has produced 24 million of the boxes to date

    and radical projects underwayRecord breaking

  • e-mail: [email protected]

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  • ALTECH UEC in Durban is busy with one of the biggest product rollouts ever seen in the local plastics industry: the injection moulding and assembly of over half a million set-top boxes a month in a project to supply TV subscribers across Africa.

    The Mount Edgecombe-based Altech group business has had to make extensive use of high-output and automation solutions in order to ramp up output: it was until quite recently producing about 65,000 units a week, but has since the second half of 2013 been producing up to 170,000 of the decoder units weekly. The set-top boxes are

    for the DTT rollout across Africa, as the continent switches from analogue to digital television streaming.

    The volumes produced do not compare with thin-wall packaging mouldings such as tubs, where several companies in South Africa already possess high-output systems and are supplying major volume consumer contracts: the set-top boxes are technical and complex components using engineering materials where cycle times are in the 30 seconds-plus category. The project is comparable to the high-volume

    the 1990s, although in this case post-moulding assembly of several parts is required, extending the production cycle.

    Specialised equipment valued at over R50-million for the entire facility

    (including assembly, testing and packaging), has been installed, including a number of Toshiba

    electric injection moulding machines equipped with Sepro robots, in order

    to achieve the production targets. The pick-and-place robots enable cycle times

    Altech UECs decision to switch to

    Toshiba electric machines was based on the performance achieved by the Japanese manufacturers electric solution: the machines use less power and also run quietly. The Toshiba machines appear to be well suited to the production of thin-wall electronic components and housings, said Brendan Mayer, engineering manager at the plant.

    Weve had zero problems and the back-up from Toyota Tsusho Africa (the Toshiba supplier) has been very good, he added.

    The casings are produced in a tailored ABS from BASF group, which achieves with the necessary heat and impact resistance. Various ABS grades are used for other components in the decoder units.

    Durban manufacturer producing well over half-a-million set-top boxes a month

    INDUSTRY NEWS

    The latest models of the set-top boxes are smaller than

    the units supplied originally, and also need to accommodate additional cable ports,

    necessitating more complex moulds

    Altech UEC in major production rollout

    The Sepro robots have allowed for a reduction in cycle times of about 25%, reduced scrap rates and improved nightshift production quantities

    Brendan Mayer, engineering manager at Altech UEC, with the range of components produced at the injection plant. The Altech group company is also weighing up whether to have at least some of its moulds built locally

    6 APRIL / MAY 2014

  • Upswing in owner-occupied commercial property dealsAFRICAS largest lender by assets, Standard Bank, experienced 44% year-on-year growth in owner-occupied commercial property deals for the period 2012/13. One of the primary reasons for this is that more businesses have been looking to purchase buildings for their own use, rather than opting to rent their business premises.

    Standard Bank say the main reason for the increased owner-occupied commercial property deals is that businesses are seeking to shield themselves against annual rental increases which typically escalate at 8% per annum.

    The advantage of going the owner-occupied route is that you are not at the mercy of a landlords annual rental increases. Thats particularly relevant for businesses that have built up a goodwill with clients due to the location of their premises. Certain landlords can use that as leverage to negotiate a far higher rent when the lease expires, since they know that moving premises would erode a considerable amount of goodwill with clients or customers.

    Commercial property loans are typically granted over periods of 10 years, with

    of the propertys value. While the majority of owner-occupied commercial property transactions are from businesses looking to purchase an existing building, Standard !at building their own bespoke premises.

    Fire at Maritzburg rubber crumb plantENV&E Rubber, a manufacturer of rubber crumb and rubber reclaim in Maritzburg, "#$by husband-and-wife team Rosalie and Gareth Akerman, ENV&E was operating state-of-the-art butyl and tread rubber reclaim lines. The good news is that no one was injured in the calamity.

    Despite the huge setback, the Akermans are determined to rebuild and get back into action as soon as possible and have already embarked on a number of projects.

    All in the industry will join in wishing the '*+;' Phone 033 344 2679www.ENVandE.com

    JUST BRIEFLY

    www.uec.co.za

    APRIL / MAY 2014 7

    Altech UEC has installed a series of Toshiba electric injection machines at its plant: the machines operate quietly and are well suited to the 24/7 production of thin-wall components such as set-top box

    housings. The parts are produced in ABS

    Such has been the need to up output that UEC has had to enlist the services of other Durban injection moulding companies, with other manufacturers including Cooke & Sons and GAP Moulding currently producing parts too.

    The intensity of the project has also meant that there has been a demand for additional moulds and pressure for faster mould production turnaround times. Most of the moulds all of which are multi-cavity up till now have been produced in China, but Mayer said the reduced rate of the rand vs the dollar had made local production more feasible. As a result, some of Durbans mould makers

    are currently tendering for commissions. The tight schedule (its expected that the production contract will be mainly complete within two years) has meant that moulds have had to be air freighted out and that, together with the additional cost and time of mould trials in the Far East, has made it possible for local mould makers to be more competitive. Mayer says there are also obvious advantages in working with local toolmakers if, for

    !

  • CYCLIQ, a new injection moulding business, has commenced with the production of bed bases in plastic, a product which has the potential to create a new option in a product every single person knows very very well.

    The bed base market has traditionally offered wood as the material of choice, but Cycliq founders Graham Colman and Gianni Nosenzo saw an opportunity for change. Both veterans of the bed market, Colman and Nosenzo designed and developed the Space Base bed base system: besides the fact that the design is sturdy and well suited as a replacement for traditional wooden bases, the base and its modular support components are lighter than wood and collapse into a far smaller

    space than traditional wood beds, by a ratio of almost 4:1. The Cycliq partners believe the fact that the base kit will be easier to

    transport will be a big attraction. The base folds in two, saving space, with the full kit for a standard double bed weighing just 17kgs.

    Recycled polypropylene is being used for the mouldings.

    After several years in the bed market, Colman and Nosenzo began to see the logic of the plastic bed and potential opportunities. Their basic design involves a lightweight base with support structures that are similar to roof trusses, in this case simply inverted so as to transfer the weight on the bed to the centre below. The modular structure will also allow for the

  • Request For Proposals!"

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  • IT ALL started with a call to Brian Almanza of Miracle Mould International, from old friend and respected mould manufacturer, Dave Murgatroyd of Spec Tool & Die of Durban, who said that he had a customer in need of a suite of moulds.

    We made an appointment to meet and much to my surprise, when I arrived at the meeting I was greeted by Peter Lawson, also a friend and once a prominent pro surfer, said Almanza.

    Lawson presented Almanza with drawings of the Sharki, a shark repellent system which he had partly designed but which needed

    completing, as well as injection mould design and manufacture. When operational, the Sharki emits an

    and disorientation to any shark within close proximity to the surfer.

    A deal was cemented, an order placed and the completion of the design concept along with mould design and manufacture began.

    Almanza explained that the tooling for the Sharki consisted of: a threaded main body a threaded sonic disc holder a waterproof connector chassis an insert moulded TPU sucker for

    loosening and inserting the sonic disc

    SYNETICA, the South African supplier of a complete range of additives and processing aids for the polymer industry, agent and working partner for the entire range of polymer additives from global supplier Addivant. It will be supplying the range of Addivant materials across the Southern African region. The appointment took effect in March.

    The agreement includes all polymer additives which are sold under the trade names Anox, Alkanox, Lowinox, Lowilite, Naugard, NDB, Octamine, Polybond, Royaltuf, Ultranox and Weston.

    Charles Biddulph and Tim Cooper, the Synetica directors, said both companies will join their efforts to effectively serve the existing customer base and to provide a platform for growth and value creation by bringing new additive solutions to the local polymer industry.

    Addivant is a leading global supplier of antioxidants, intermediates and

  • THE production assets including extruders, bag makers and other equipment of Empower Plastics of Cape Town went under the hammer at the end of January, so ending a venture that promised much but ultimately failed to deliver. The business was set up, as its name suggested, to get empowerment contracts, particularly such as refuse bags, from government/municipal authorities.

    Started in about 2008, the operators may, however, have been unprepared for the intensity of the competition as well as tight price thresholds. Empower seemed to be constantly on the move, which would also have created challenges. The equipment most of which appeared neglected was sold off at very low prices on 30 January.

    DOW Chemical has rejected a proposal by hedge fund Third Point of New York that it spin off its petrochemical >$integration, scale, and shared technologies would be lost, while ?described as petrochemical and specialty chemical assets, would create no additional value, the global group said.

    Third Point, which has reportedly invested $1.3-billion in Dow, presented its position in a 21 January letter to investors that pointed to the companys poor operational track record across multiple business segments, a history of under-delivering relative to managements guidance and expectations, and the ill-timed acquisition of Rohm and Haas.

    ?X$it has taken to transition Dow from a commodity-based model into a vertically integrated science company focused on specialty materials, agriculture, and specialty plastics, is the right strategy to maximize value for all of our shareholders in the short and long term, it concluded.

    JUST BRIEFLY

    repellent system offers manufacture challenges

    holder into the main body sucker body and handle press tooling for the manufacture of

    the sucker components and sonic disc silicone mould for the moulding of a

    custom o-ringAlmanza said the manufacturing

    processes included some very interesting challenges and techniques.

    Sonic discFor the mounting of the pressed 304 stainless steel disc, Miracle Mould designed a locking ring that clipped the disc onto the sonic housing. This was done in a way that allowed the clip to return to a neutral state once assembled, minimising the locking ring post-assembly stress, he explained.

    Sonic disc logoThe Sharki logo was imprinted onto the 304 stainless steel disc using laser etching, resulting in an aesthetically pleasing and durable logo.

    TPU suckerThe TPU sucker was insert-moulded with the 304 stainless steel cam followers along with a 304 stainless steel pierced pressure disc.

    Waterproof connector chassisThis was redesigned to be sonically welded with the sonic holder cover in one operation.

    The sonic disc holder is screwed into the main body with the use of the sucker !holder. This is then used as leverage to insert the threaded sonic disc holder Z[nicer surprises, Almanza said. Who would have thought that two beach boys would end up working together on a world-class lifesaving device? Not

  • BLOWTECH of Pretoria went for the Zerma solution again when it chose another two of the Chinese-built granulators for the closed-loop reprocessing of material from its blow moulding operation. It now operates seven of the Zerma systems.

    The powerful Zerma granulators are reducing top and tails and reject 5 and 25-litre containers in a closed-loop process. A scrap conveyor transports the material directly from the machine to the infeed of the granulator. The operator is also able to manually place other material, such as reject containers, onto the conveyor. The chipped material is then transported back to the hopper and reprocessed.

    Blowtech has had a positive experience with Zerma over the years. For this application, the Zerma GSC series 3-blade rotors, V-cut technology and tangential infeed, which is ideal to handle 25-litre containers, tops/tails and purgings.

    Brothers Johann and Nardo Nel, who started the business

    together with Lida Bester, have a total of seven Zerma systems in the group so far and, according to Johann, plan to replace all our size-reduction equipment with Zerma as they are strong to the point of being over-engineered, reliable, easy to access to clean and maintain and simply dont give us any headaches.

    The GSC series granulators are also available without

  • Tel: +27 (0)11 466 1717Email: [email protected]: www.marimark.co.za

    ZERMA AND MARITIME MARKETING,YOUR PARTNERS IN PLASTIC SIZE REDUCTION

  • A NEW grinding system from Pallmann the Karakal enables

    $~$~$~

  • What was the logic and motivation behind the choice of the containers shape?

    As part of Clovers project to improve the spreadability of its Butro product and to provide a platform for line extensions, they wanted a new, innovative tub to create a better shelf presence. The tub also needed to be completely covered by the label which added to the challenge.

    Was the form borrowed direct from the shape of the Cape Town Stadium, or is the similarity coincidental?

    No coincidences here. The iconic design was inspired by the Green Point Stadium, regarded as one of Cape Towns most striking pieces of contemporary architecture. As a result, this tub is affectionately known as the Stadium >[$proposed to Clover, this striking design was immediately the preferred option.

    +6

    Pack differentiation and impactful shelf presence it looks great, is eye-catching but still functional.

    Do you know if this style of container has been used elsewhere?

    Polyoak has pioneered the design, a $all three dimensions, as recognised by the World Packaging Organisation with our recent WorldStar Award.

    The irregular form probably required and pressures in the mould, how was this resolved?

    Innovative mould design and use of technology by Dairypack Tubs made the manufacturing of this unique design possible. Polyoaks specialist design division, Design First, had to employ advanced injection mould design to ensure that the thin-wall sections were maintained for a lightweight, green pack.

    Patrick Ford explains: The changing curve on all three dimensions required careful consideration of the geometry of the plug-and clip-interface between |constantly changing curve to withstand high pressures was a mould design challenge that was only made possible with the latest mould design software.

    >$

    part was tested and before the mould was manufactured.

    Some admirers of the container

    86

    Display functionality is always important and was built into the design from the >$stable nesting feature for quick, easy and effective merchandising. In addition, the tub is tamper evident and provides a

    $

  • Tel: +27 (0)11 466 1717Email: [email protected]: www.marimark.co.za

  • What is the goal of the membership fee?The membership fee for the amount of R10 a ton has been introduced and is being paid by the material manufacturers and suppliers. R10 a ton equates currently to less than 0.1% of the average cost of polymer.

    At present the local polymer manufac-turers and most of the other suppliers are paying the membership fee, and we are very appreciative of this.

    Most of Plastics|SAs income about 55% is derived from our training division, but to expand our services overall and to make the model sustainable, the additional income is necessary. It will also give the polymer suppliers and importers an opportunity to be more involved in the funding of Plastics|SA and in the industry =membership fees will help it assist the

    industry grow. The goal is for the plastics and composites industry, which grew

    5.4% in 2012 (and 5.1% last year), to expand at a higher rate of 8%

  • Servo Klockner Rebuild

    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:

    VICTOR MACHINERYJIANGSU

  • ACD RotoFlo which suddenly and unexpectedly became South Africas main manufacturer of Rotational Moulding Powders earlier this year has achieved a minor miracle by upping capacity in an emergency operation which, thankfully, enabled it to continue supplying both its customers as well as several distress orders.

    Clive Robertson and the ACD RotoFlo team had been planning to move to larger premises in Kya Sands, Johannesburg, in February and March when they were pitched into a potential crisis by numerous additional orders for Roto Powders after the main rival supplier suddenly closed shop.

    ACD RotoFlo was inundated with requests for Powder the new orders started coming in just as the relocation of the extruders and mills was about to commence. The Colour Compounding and Milling of Roto Powders is a specialised operation and, with import lead times of eight weeks or more, there was a strong possibility that some Rotomoulding companies would have material supply cut off.

    ACD commenced business just two years ago, on 1 April 2012. This original operation, which ACD RotoFlo Managing Director Clive Robertson bought in February that year, was a distress business. From those meager beginnings, with just a handful of customers, Robertson and his team had sampled interested parties with a

    range of colours that were received with satisfaction in the market.

    belt, ACD RotoFlo started to expand ~back into the company, to improve productivity and conditions of the production staff. With the support of the Market and ACD RotoFlo staff, the company grew steadily during the rest of 2012. In 2013 Robertson was able to secure the services of Michael Bltau, who joined the company as Operations Manager. Bltau made an immediate impact with his knowledge of the transport industry: he set about improving logistics and enabled the company to supply long distance and cross-border clients as well lowering costs and improving delivery lead times. This provided impetus for ACD RotoFlo to expand further.

    By October last year ACD RotoFlo was bursting at the seams with orders exceeding capacity, but it somehow managed to keep up with its scheduled shipments.

    All orders were achieved with a smile, said Clive.

    Expansion projectThe latter part of 2013 saw ACD !

  • INDUSTRY NEWS

    time, ACD RotoFlo is now operating its full Phase 1 capacity with near on 600 tons/month capacity Phase 2 new capacity is currently being fast tracked with another potential 200t/m capacity at its new plant. Phase 3 will commence back in the old factory when new plant arrives in SA sometime mid-2014.

    Furthermore, ACD RotoFlo is currently evaluating the market requirements which may entail another full production line. But these kinds of expansions normally take three to four months to secure plant and equipment offshore. So ACD RotoFlo is back on the expansion drive and the market will

  • Nampak opens new plastic closures line in Lagos, Nigeria

    INDUSTRY NEWS

    Nampaks new plastics closures line in Lagos, Nigeria, will manufacture closures for still

    water and will be followed by carbonated soft drink closuresInitial product will be closures for still water

    NAMPAK has commissioned a new plastic closures line in Lagos, Nigeria. Nampak South Africa has a long-standing strategic partnership with Bericap, Germany who agreed to extend the manufacturing licence to include Nampak Nigeria.

    The initial product will be closures for still water and will be followed by carbonated soft drink closures.

    >

    Zinstallation of two Netstal 48 cavity Z**ZLagos state.

    >Z$capacity of 220 million closures that will Zand moulds are installed. This will increase the basket of goods Nampak Z

    Nampak Nigeria Lagos has been supplying quality metal packaging solutions since the early 1960s under

    the ownership of the Carnaud Metal !*Zstake in the company in 2002, and full ownership was obtained in 2011.

    Nampak Nigeria Lagos employs over 300 permanent and contract staff. A training school provides Nampak Nigeria staff with on-going training in health and safety, engineering, operational processes and systems.

    At this early stage the focus will be on the local Nigerian market, Coca Cola, Seven-Up, Nestle and SABMiller. In the future exports to Ghana and other neighbouring countries will be considered.

    Nampak Closures in South Africa, a division of Nampak Rigid Plastics, assisted Nampak Nigeria with technical assistance during the buy-off of the Zas well as training.

    Nampak Closures has world-class manufacturing facilities in Cape Town

    and Durban and strategically located >

    to leading brands in industries such

  • PHOTOVOLTAIC Technology Intellectual Property (PTiP) unveiled its pilot production line for the manufacture of CIGS# thin-JK

    Using engineering technology from Singulus Technologies of Germany, the PTiP plant is being used to demonstrate the ability to manufacture solar cells and modules. The CIGS (copper indium gallium selenide) thin-glass substrates on which a very thin photo-active layer with a thickness of approximately 1.5 to 2.5m is applied. This absorber layer consists of a compound semiconductor including the elements copper, gallium and indium with selenium and sulfur in a so-called chalcopyrite structure.

    The total thickness of the active just three microns, compared to the technology with a thickness of more

    PTiP, a spin-off from the University of Johannesburg (UJ), has been working on the development of CIGS solar modules for the past 20 years. The demonstration plant in the Techno Park near Stellenbosch was established on the back of the

    critical success demonstrated in the UJ research laboratories. This facility will serve as a state-of-the-art R+D facility for commercial-scale and market ready 1200mm x 600mm CIGS modules.

    An estimated R180-million has been invested in the project to date. The Industrial Development Corporation (IDC) is a strategic shareholder as is the Technology Innovation Agency (TIA), an initiative of Department of Science and Technology.

    With the new CIGS line, the development of modules can be improved the special demands of the African market.

    Professor Vivian Alberts, CEO of PTiP, ?opening of this CIGS pilot facility in #South African government to support and promote alternative and renewable energies, based on locally developed IP and skills.

    It is an important step for a successful energy policy in our country. The immediate goal is to set-up a commercially $#modules in South Africa in order to supply products with high local content to existing and future PV projects in South Africa, he added.

    The European Investment Bank already announced its support for the establishment of a PTiP production plant and the mass production of PV modules.

    With the core production equipment and support from our partner, Singulus, implement our developed process, added Alberts.

    The pilot plant, originally situated at the University of Johannesburg, started to produce semi-commercial products in

    PTiP " INDUSTRY NEWS

    Equipment from Singulus Technologies of Germany is being used at the pilot plant and will be used in the rollout. PTiP aims to provide the production technology for panel manufacturing plants across Africa

    The deposited layers applied in the panels are incredibly thin and high precision equipment is hence essential

    Professor Vivian Alberts, CEO of PTiP, with one of the panels produced at the

    plant in Techno Park, Stellenbosch

    Techno Park in Stellenbosch is the centre for new solar energy project

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    2006. Prof Alberts originally operated the UJ site. It was subsequently decided to move the research laboratories to Techno Park in Stellenbosch, in 2011. The park has been growing in popularity as an innovation hub in the Western |>|the world to licence the technology internationally. The processes and product characteristics are protected by worldwide patents in 17 countries.

    Stellenbosch is an environment that offers expertise for the commercialisation of the technology and present to the world, said Prof Alberts. The aim is now to establish $industry, train people and to stimulate job creation in the industry.

    Singulus had been working with the UJ scientists and $systems in 2011.

    Singulus CEO Dr-Ing Stefan Rinck said: With the vacuum coating, the selenization as well as two work steps in the wet-chemical area, in total we supplied four key process steps for a CIGS line. With our partner PTiP, we intend to continue to successfully implement the additional expansion stages as well.

    Opportunities for plastic moulders

    !

  • JOHANNESBURG-based Kahn & Kahn has achieved positive results over the past few years, one of the toughest eras ever for the plastics industry in South Africa.

    Part of the Damax Plastics & Packaging Group, Kahn & Kahn has been in existence for over four decades (established 1980) during which time it has built up a comprehensive range of products as well as comprehensive abilities, according to MD David Tromp.

    For the construction industry, Kahn & Kahn specialises in plastic sheeting for

  • mmm$YWhij$Ye$pW

    E D A N B : G H 9 > K > H > D C

    E _ _ ]] IE IEkhM_dd_d]

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    Offers packaging advice, audits, sourcing & project coordination

    AFTER 15 years in packaging, of which 11 years were served at Astrapak, Raymond Moussa has stepped out on his own and started up Pack-Ad-Vise a packaging consulting business, offering packaging advice, packaging Audits, packaging sourcing and project co-ordination.

    During Raymonds last three years with Astrapak he was group packaging development manager and headed up the sales for their moulding division.

    Pack-Ad-Vise opened its doors in Randburg in November. Raymond said inspiration to launch his own consulting business came after noticing that the market dynamics had changed in packaging over the past two years.

    Customers are constantly looking for improvements in their packaging that will deliver cost savings and performance improvements, said Raymond. Suppliers are often restricted to offering solutions relevant to their capabilities that only takes one item in the supply chain into consideration i.e. bottle or closure. This approach usually results in lost opportunities. I have found that by evaluating the entire value chain from source to post-consumer, substantial opportunities become more evident. This is the service PAV can offer.

    Raymond explained that Pack-Ad-Vise assesses packaging to establish if |!$alternatives but to withdraw as party to the MEIBC, said Pieterse, who added that problems included the fact that the PCA was not recognised by NUMSA as a legitimate party to the MEIBC; the PCA team had not been invited to attend MEIBC constitutional meeting; and the fact that $

    JUST BRIEFLY

  • 30 APRIL / MAY 2014

    Keynote speaker Louis Lindenberg, global design & sustainability director for Unilever, said it was important for the packaging industry to consider the latest {}~}~_=outcome of this is the notion of optimising systems rather than components, or the }~]'}*~

    Louis Lindenberg (Unilever), Milly Petzer (Extrupet), Lisa "["Q#X\[$"\"Q#X

    [$$\'_[=\presentations at the conference take '"["Q#X\

    =

    "(Extrupet) with Karl Lambrecht and Graham Haird, both from Polyoak Packaging

    SUSTAINABILITY was the main talking point at the inaugural Propak Packaging Innovations Conference at the Sandton Convention Centre in Johannesburg in February.

    Sponsored by USS Pactech, the CAMA Group and PETCO, the two-day conference attracted a number of South Africas leading packaging companies and food and drink brand owners and retailers, either as delegates, or presenting proudly South African examples of packaging innovation.

    With 18 presentations spread out over the two days, delegates were assured of a wide range of presentations covering a wealth of packaging issues, from its role in securing our future prosperity, infusing packaging with creativity, challenging convention in material selection, to what the DTIs Manufacturing Competitiveness Enhancement Programme (MCEP) offers South Africas packaging industry.

    Case studies were also presented by Distell, SAB, Parmalat, Sirane, Brandhouse Beverages, Mars Africa, Unilever SA, Nestle SA and Woolworths.

    Some of the more notable presentations included:Keynote speaker Louis Lindenberg, global design & sustainability

    director for Unilever, said sustainability was high up on the global agenda, and thus it was important for the packaging industry to ?][economies.

    Louis joined Unilever 1999 from LOreal. His initial portfolio was Southern Africa, but he quickly moved on to head up packaging for Africa/Middle East/Turkey. He then moved to Germany as global packaging director for the savoury category. After several successful packaging innovations, and a passion for structural design, he moved

    Sustainability, recyclability key focus at

    Propak Packaging Innovations conferenceTalk to the recyclers before you design your packaging!

    INDUSTRY NEWS

  • **$"*+#

    '

    #!

    "}"taking time out to digest the abundance of information presented by the wide array of speakers at the conference

    *]$*]~#Q"=~

    APRIL / MAY 2014 31

    to the UK to take up the position of global design & sustainability director.

    The main role of packaging is to answer the multiple needs of various products for every consumer, using as little as possible, but as much as necessary, said Louis.

    To achieve this it is essential that we talk to the recyclers before we design the packaging, he added.

    The sustainability of packaging across the value chain encompasses sourcing (sustainable P&B, bio-polymers, recycled content); reduction (concentration, re-use) and recyclability (lobby & advocacy, closed loop, energy recovery, anaerobic digestion and industrial composting). To secure the future prosperity of the packaging industry, it is essential that industry role-players look at circular economy.

    Louis explained that ][an industrial economy that is, by design or intention, restorative and in which material nutrients, designed to re-enter the biosphere safely, and technical nutrients, which are designed to circulate at high quality without entering the biosphere.

    The term encompasses more than the production and consumption of goods and services, including a shift from fossil fuels to the use of renewable energy, and the role of diversity as a characteristic of resilient and productive systems.

    Lindenberg also referred to Unilever CEO Paul Polman, who, since

    taking over as CEO of the group in 2009, has transformed the Anglo-Dutch multinational into one of the worlds most innovative corporations. In 2011 he launched an ambitious plan to double revenue by 2020 while halving the

    companys environmental impact!In an interview with the Harvard

    Business Review in 2012, Polman was ]business?

    He replied: I always turn that question around: How would you make the case that not doing this could help society and mankind? For proper long-term planning, youve got to take your externalities into account, in order to be closer to society. Its clear that if companies build this thinking into their business models and plan carefully, it will accelerate growth.

    $Q}~*

    ~]~

    how to aim packaging design towards different demographics, remaining consistent whilst battling for shelf distinction in new markets, and balancing cost and design in {Q~

    ][^"\

    Creating a look that delivers!

    The main role of packaging is to

    answer the multiple needs of various

    products for every consumer, using as

    little as possible, but as much as

    necessary

  • Y[=$\[\"#]^[=\interesting presentations

    #

    ['#\["_=_\

    Labelling to boost recyclingKiril Dimitrov, foods packaging manager for Woolworths, discussed the key elements of labelling to successfully boost recycling.

    He summarised Woolworths views on current and future packaging trends, which provided delegates with much to mull over, as follows: sustainability concerns will

    dominate packaging innovation agenda over cost factors;

    plastics and composite materials will continue to replace glass and metals;

    !replace rigid structures;

    light weight and cost-effectiveness will give way in importance to renewable and recyclable materials;

    design for local recyclability and increase use of recycled and renewable raw materials;

    plant-based renewable resins (PET, PE, PP); and

    regulations might start to play a more important role in packaging design in SA.Dimitrov explained that Woolworths

    sustainability agenda under its ][environmental packaging selection criteria (once the economic and safety and ethical aspects of sustainability are addressed) include: packaging weight down-gauging,

    right-sizing and eliminating unnecessary components;

    locally recyclable formats local collection & recycling rates, design for recyclability; and

    material selection preference towards post-consumer recycled content, as well as renewable materials with ][By reducing the packaging on its food

    products Woolworths has managed to

    eliminate over 80 tons of packaging annually, said Dimitrov.

    Woolworths involvement in

    participates in collection infrastructure at Engen stations with Nampak Recycling. Currently 52 of 120 planned locations are up and running. The organisation only uses technically recyclable (is recyclable, but not always in South Africa) materials in its packaging. Currently 98.3% of Woolworths food packaging is technically recyclable. The local recyclability content of Woolworths food packaging is currently around 52%. Woolworths also uses recycled material in its products and packaging, all of which have been designed with recyclability in mind.

    Dimitrov stressed that designing for recyclability was not just about the recyclability of the material, but more importantly, to do with access to local collection facilities, sorting infrastructure and the availability of mechanical recycling technology.

    In designing for recyclability, he emphasised the importance of taking into account the materials and components used (PET bottle is recyclable, but tray,

    cup, clamshell are not); colours (a clear bottle is widely recyclable vs brown which is considered a contaminant); additives (some are oxygen scavengers, oxo-biodegradable); labelling (sleeves, direct print, stickers, labels of incompatible materials); adhesives

    contaminants); and accurate labelling focused labelling and instruction) all of which, if poorly planned, could result in incompatibility with recycling streams.

    In South Africa there are many existing packaging recovery labels which are confusing to customers, designers and developers, inconsistent across material types, and applied to only certain packaging materials or package components, said Dimitrov.

    To address this issue, Woolworths started with the On-Pack Recycling Label (OPRL) packaging material information labelling in 2007.

    This labelling is not a recyclability claim but has been implemented mainly to assist waste collectors and separators, not just the consumer, Dimitrov explained.

    The OPRL has the following objectives in mind: help more consumers to recycle more

    packaging; be easily recognized by consumers

    and simple for them to understand; be able to drive positive action and

    provide clear advice to customers on how they can recycle in their local area;

    be easily adaptable to new packaging material types, formats and recovery systems;

    ensure the label text, colour and graphics are properly used on a package in already space-constrained packs;

    help local authorities and others to increase recycling rates for those materials that can be recycled, but >>

    +X_"'[X"'\

    is not a recyclability claim but has been implemented to assist consumers, waste collectors and separators

    32

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  • Tel: 011 762-5231 Fax: 011 762 5228 Mobile: 082 465 9491 [email protected] www.edmshop.co.za

    SERVO DRIVEN INJECTION MOULDING MACHINES

    90 320 Ton are normally EX-STOCK European B&R closed loop control system 36% Energy saving over Variable Displacement Pump Machines Piston Driven System has energy and mechanical advantages over gear pump and screw pump

    servo systems Reaction time of servo system is 40ms from rest to 1500rpm 0.3% weight deviation (82g product moulded on 190SE) ECO friendly Oil Filtration system Extremely competitive pricing

    to 2800 Ton

    from 90 Ton

  • At BASF, we create chemistry.Enquiries:BASF South AfricaDelyce [email protected] 011 203 2537www.basf.co.za

  • 36 APRIL / MAY 2014

    Materials to meet the challenge of microwave meals _#by is perfect for many foods, particularly seafood }~tasting _]=X#by'_packed discussion about materials to meet the challenge

    +~_

    Kuben Nair, marketing manager of strategy & innovation at =$ discussed #'~[Gold Pack award winner), and how the innovation happened without losing the impact of the iconic

    #

    ["=#=\[""\

    [$$\*[+\'_[=\

    ^

    *'["=\

    #*, franchise technical manager at #_#=, discussed next generation intelligent automation. He explained the concept of incorporating algorithms and analytics into automated production of packaging, as well as predictive maintenance to dramatically reduce line. www.cocacola.co.za

    , general manager for chemicals, mechanical and materials with the Y# ]|

  • TERLURAN GP35, one of Styrolutions most versatile ABS grades, has set worldwide standards for cost effectiveness and product quality.

    Its bright and consistent, intrinsic colour is ideally suited for self-colouring and the stable yellowness index allows a

    Retief Vorster of Realise Design & Manufacturing, a design Z|GP35, lower pressures are required during processing, $effectiveness, he added.

    Styrolutions global production footprint ensures not only the global availability of Terluran, but, as the only manufacturer world-wide, it can also offer identical products stemming from regional production sites. Terluran represents a range of general-purpose ABS products offered as standard natural and black materials around the world.

    '"|#accreditation in respect of its sales, manufacturing, installation, warehousing & distribution and project management of electrical heating systems.

    ~

  • Color and material combinationsthat make you say Wow!

    Introducing the Objet500 Connex3 from Stratasys, the worlds only full-color and multi-material 3D printer. Select from in-comparably brilliant and consistent colors, plus a full palette of transparent colors the only 3D printer to offer such a wide ar-ray. And its the only 3D printer that prints

    !$#-sys is the proven leader in multi-material X

    Objet500 !

    For whatever your mind can imagine, visit stratasys.com/Objet500 Connex3.

    TEL: +27 (0) 11 462 2990 FAX: +27 (0) 11 462 8229

    e-mail: [email protected] design into Reality faster than you can imagine

    TEL: +27 (0) 11 462 2990

    FAX: +27 (0) 11 462 8229

    e-mail: [email protected] (PTY) LTDOne total solution for Injection Moulding

  • IN virtually no other industry are the demands regarding the quality and diversity of surfaces as high as in the automotive industry. Carmakers are developing short production runs with numerous variants on the basis of high-volume base platforms. The focal point $production of components for the respective vehicle class.

    At K2013, Bayer MaterialScience presented a complete, polycarbonate-based material concept oriented on the future design of automotive interiors. The concept components were created in close collaboration with Gerhardi Kunststofftechnik in Ldenscheid, Germany. The processing specialist developed an innovative in which a diverse range of surfaces $produced. The comprehensive performance spectrum of modern Bayer polycarbonate materials enables a single mould frame to be used for a wide range of decorating options.

    These include matte and high-gloss structures, attractive shades with

  • MAKING A SPLASH. FOR ALL THE RIGHT REASONS.

    Polyvinyl chloride (PVC) is a cost-effective, versatile and safe material for use in our modern world. Its unique properties make it the material of choice in many applications. PVC pipe, in particular, has a life expectancy of 110 years and can form pipelines that provide communities with running water, without the need for frequent maintenance.

    We see the advantages of using PVC, which is why Sasol Polymers supplies polyvinyl chloride (PVC) resins needed to manufacture PVC products. This ensures that our country can keep reaping benets that, just like this durable plastic, can last a lifetime.

    Sasol Polymers +27 11 790 1111 | www.sasol.co.za

  • DPI Plastics has successfully supplied mPVC piping to a large irrigation project in Zambia. DPI Plastics |+supplied in standard 6m lengths to the Kapinga Irrigation Project in Zambia, >

  • SIAS van der Westhuizen, AAT Composites managing director since it started with production in 1998, will hand over the reins with effect from 1 April, to Dr Holger Friehmelt who will take over as MD.

    Van der Westhuizen has been a member of the Aerodyne team since 1987, and was intimately involved in the Groups early years. After more than 25 years in the composites industry, he said he looked forward to a completely new challenge.

    My career progressed from hard-core technical

  • APRIL / MAY 2014 45

    Sun Ace board appointments

    products and introducing them into the market. As the aviation

  • ADVENTURER Ray Chaplin, who completed the mammoth Orange River Riverboarding Project last year, selected the image on the left, of a pupil at Oranjekrag School during the clean-up at the Gariep Dam, as his favourite from the 8-month expedition.

    Ray started out on the riverboard project near Mount Aux Sources in the Berg on 9 April and reached Alexander Bay on the west coast on 10 December, covering 2400kms in what was the second longest river boarding expedition to date. Unfortunately, he encountered large volumes of litter, almost from the source of the river, but several positives emerged from the project: Ray gave motivational talks to schools, coordinated community clean-ups and, overall, generated as much exposure in each town as he progressed. He presented to over 9500

    learners along the river with over 5500 bags of litter being collected through clean-ups, with many more follow-up clean-up days already being coordinated by schools and communities.

    The young girl in his favourite photo took the task very seriously and returned with a bag full of collected plastic scrap. Some of the other pupils were less determined in their collection strategy, but all the pupils participated enthusiastically. The big positive to come out of the project was the interest created in the communities along the course of the river, which in many cases motivated young individuals, who otherwise might have not been informed of the problems of litter as well as, for that matter, of the many advantages derived from plastic products.

    The project was sponsored Nampak Rigid Plastics, Plastics|SA and Tuffy.

    AFTER a recent BNI Champions chapter

    you should be asking yourself is: What can I do about this?

    Do you shrug and say Thats life theres nothing that can be done? Or do you say, Lets look at ways to save power,

    whether you are a victor or a victim.

    Victors live their lives ABOVE the line. They take ownership or their lives; take responsibility for their actions and success. They hold themselves accountable for mistakes and failures. They ask themselves what can be learned from the experience to ensure improvement and success when they try again. They make things happen. They press the reset button on the situation and start again, from the new or changed reality.

    When you take ownership, accountability and responsibility you are a VICTOR because you are the architect of your success. Only you can get in the way of your achievements.

    Those who live below the line wallow in excuses. They blame other people and circumstances. They deny responsibility or

    accountability. We call this living BELOW the line.

    Victims live below the line. Victims allow things to happen to them. Victims dont make things happen for them or by them. Victims abdicate responsibility and ownership for their lives. They do not take control of their destiny, success or failure. They sit in the dungeon and wait for their white knight.

    Which would you rather be?Take action now!

    Are you a victor or a victim?

    Creating interest in schools was the big plus of Orange River Project

    www.actioncoachsa.co.za

    9500 learners informed about need for clean-ups, advantages of plastics

    Are you above or below the line?

    BY MARGARET FRY: ACTIONCOACH

    PEOPLE46

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  • SALES AND MARKETINGEastgate Office Park, Ground Floor, Block ASouth Boulevard, Bruma 2026, South Africa

    As we celebrate our golden anniversary, we remain committed to being a leading and innovative rubber company. We will continually strive to achieve customer service excellence and we thank you for sharing in our success.

    T +27 (0)11 601 1660F +27 (0)11 616 6651E [email protected]

    www.karbochem.co.za

    Celebrating 50 yearsof rubber productionin South Africa

    TRIOPLASTICS recently proved that plastics, in particular PVC, can be used everywhere even stage dcor! The opening night of Sweet Charity at the Mandela Theatre at the Johannesburg Peoples Theatre in February, exceeded all expectations of how beautiful PVC can be. The National School of the Arts approached Trioplastics to sponsor

    _"#be used as stage decor. Passionate about the arts and searching for a different community project to get involved in, the directors agreed to sponsor PVC for the Festival of Fame presented by the National School of the Arts. The National School of the Arts is South Africas leading arts high school and is recognized by the Department of Education as a centre of excellence for academics and the arts. The school

    policy is to accept children based on their "#was hung from the stage roof, dropping ]"#"#the stage and dcor another dimension.

    Trioplastics congratulate all the students and teachers of the National School of the Arts for their professional and creative performances, stage dcor and sound. It was an honour to be associated with such a professional institute.

    APRIL / MAY 2014 47

    www.trioplastics.com

    PVCs debut on stage

  • 48 APRIL / MAY 2014

    Dr Chris Woolard has returned to Nelson Mandela Metropolitan University in Port Elizabeth, where he has been appointed head of research. Much of the work is to be funded by REDISA, the tyre recycling group. Chris, who was originally a lecturer in the polymer chemistry department at NMMU, has over the past few years been involved in research at the Sasol Advanced Fuels Laboratory at UCT. He has been appointed an associate professor at NMMU.

    Ashin Tasdhary and Tony Dean have been appointed to RARE Groups board of directors. Ashin has been appointed as executive director to Rare Holdings Ltd

    and Tony as managing director of the Rare Plastics division.

    Before joining Rare as national sales manager in 2012,

    Tasdhary worked at DPI Plastics and Venture Plastics. He also served as MD of APS GP, a division of Amitech SA.

    Dean has more than 30 years experience in the plastic pipe and fittings industry. He held the positions of MD at Petzetakis Africa and CEO at Flo-Tek before joining Rare last year. He is a founding member of SAPPMA (South African Plastic Pipe Manufacturing Association).

    Tracy Sinclair has been appointed marketing manager at SAPY, based in Hammarsdale near Durban. Tracy has a BCom (Unisa) and has spent the past 12 years in the plastic card manufacturing business (credit, debit, loyalty etc); she moved from Harare to Durban two years ago and joined SAPY in October last year. She is now responsible for the marketing for SAPYs three divisions yarn manufacture, masterbatch division and Corehfil specialty fibres. With its yarns expertise, SAPY has succeeded in developing high-dispersion colour masterbatches that now account for a high portion of the companys turnover.

    The new market focus at SAPY caps a major redevelopment programme over the past few years, led by MD Majid Zarrebini, which has seen the company move to new premises and upgrade its entire production facilities. Work on the new high-tech visitor centre at the Hammarsdale plant is currently ongoing. This is where the new focus on branding welcome2colours will be showcased.

    Chris Richards has been appointed Gauteng area manager for SAPY. Chris attended school in Dubai, until he returned to South Africa to matriculate from Kearsney. From there, he worked for over six years in the concrete industry, gaining valuable experience in management and sales. Following SAPYs continuous expansion to a factory space of approximately 70,000m, Chris was

    $

  • PEOPLE

    APRIL / MAY 2014 49

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    Rawmac celebrates long-service and a new face

    Roman Painczyk, is currently working at Synchron as a market development consultant, helping to build the companys machinery, foil and stamps market in decorating and printing of graphics onto plastic products in the automobile, cosmetics and pharmaceutical industries.

    His company, Kalahari Tech & Consulting is alive and well and working on possible representation of specialised raw materials, product development and tooling problem solving.

    David Coetzee

  • DEMAPLASTECH held a successful series of in-house demonstrations of the Stratasys Objet 3D printers recently. Attendees were able to see both Polyjet and FDM printers in action during the rapid prototyping demonstration. DemaPlasTech MD Jacques Kleynhans (pictured back right corner), gave a presentation about the

    DemaPlasTech in-house demos

    www.demaplastech.co.za

    PREMA Charnock and Michelle Anne Clough have been appointed |$Pretoria region and the East Rand and Polokwane region respectively.

    ||ago in the internal sales department. In 2011 Prema was promoted to sales representative, responsible for the East Rand and Mpumalanga areas. After two years in which Prema gained much

    experience she has been promoted to the Pretoria area.

    Michelle recently joined the team based at the companys Edenvale head

  • Globalisation presents industries with both challenges and opportunities

    Stuart Patrick, chair of the IOM Polymer Society in the

    UK, gave a presentation, What we aim to achieve, in which he outlined how

    the Institute is trying to get young individuals involved

    in the industry

    ]X!#"[Y\#$[Q#\![\=#[Y\+_#[\

    ^#+and John Lithgow and Lukas X

    Tyre, rubber imports place local industry under massive pressureTHIS years Institute of Materials Foundation Lecture focused on a

  • 54 APRIL / MAY 2014

    BY DES ROYAPPEN

    ">'

    "#

  • PLANS for ARMSAs annual roto moulding conference and exhibition, Rotation 2014, are well underway: with a wide variety of interesting
  • PLASTICS|SA helped to make this years Cape Argus Pick n Pay Momentum Cycle Tour sustainable by coordinating a clean-up crew of 161 workers during Marchs cycle race.

    Covering the area from the Wynberg Hill in Constantia to Camps Bay, this dedicated team of waste pickers and collectors were employed from the nearby Ocean View and Masiphumelele townships near Kommetjie and were responsible for picking up all the litter strewn along the road and ensuring that

    the waste generated at the event is recycled.

    ?$loads with waste after this years race, which was predominantly made up of paper cups, and a fair amount of syrup sachets, said John Kieser, sustainability manager for Plastics|SA and coordinator of the cleaning crews.

    Because a large section of the 109km route actually takes place in a national park, Kieser stressed that any litter left to the elements could have a

    devastating effect on the wildlife. To this end, he complimented the race organisers on launching the Stash Your Trash campaign, which encouraged

    56 APRIL / MAY 2014

    Plastics|SA helps make popular cycling race sustainable

    8;

  • cyclists to throw their litter into designated areas that were created at refreshment stations.

    We saw a marked improvement in the amount of litter we were able to collect and the speed at which we could clean the route thanks to these chuck zones, Kieser said.

    Another improvement was the placing of the plastic litter bins along the route, brought in to replace the carton boxes that were easily blown away by the wind during previous years races.

    Kieser said that it is vitally important for event organizers to work together with service providers on developing an event greening strategy that is practical, well planned and executed effectively.

    ?strategies of collecting and recycling the litter at big events such as these, making sure they are socially and environmentally responsible. We will be increasing the amount of Chuck Zones during next years race and will also adopt this for other events. It has already been adopted by Amashova Durban Classic cycle race that will be taking place later this year.

    www.plasticsinfo.co.za

    "were easily blown away by the wind during

    ~

    (welds) is critical to the success of the pipeline.

    To this end, the Southern African Plastic Pipe Manufacturers Association (SAPPMA), through its Installation and Fabrication Plastics Pipe Association (IFPA) initiative, has welcomed and endorsed the development of the thermoplastic welding inspection programme.

    The training courses last three days. The pilot programme will be launched at Plastics|SAs training centre in Johannesburg from 8-10 April, after which the course will also be offered at the associations Cape Town and Durban branches, or presented in-house at a companys premises.

    The course fee is R4 218 (ex VAT) per learner for non-member companies, and

    R3 796.20 (ex VAT) per learner for member companies. For more information, email Renee.

    [email protected]

    =_

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

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

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    REGLOPLAS

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    WWWREGLOPLASCOMAPRIL / MAY 2014 57

    Q"=Xpost-cycle tour clean-up operations

  • These are individuals who do more than just rock up at work

    Outstanding Fellows: Work by PISA individuals acknowledgedA NUMBER of stalwart PISA members have received recognition in recent months for their work with both the Institute as well as their unstinting work in the industry.

    Among those recognised for their work are:

    Prof Eino Vuorinen of the National Metrology Institute; Mike Bullock, former director of the Plastics Convertors Association; Bob Bond of the Technical University of Tshwane; Claus Maurer of CBI Electric at Brits; and Dr Caroline Khoathane of the Technical University of Tshwane, all of who are members of the PISA Northern branch; and, in KZN, Gan Naicker of Idwala Sales & Distribution.

    Eino, a specialist in corrosion inhibitors who worked in research at Unisa, has actually retired since. Originally from Finland, Eino came to Africa in 1986 and capped his work at Unisa and the National Metrology Institute with a paper on How to analyse nano composites, which received international recognition.

    Hes now relaxing and pursuing his interest in horse riding and other leisure activities.

    Caroline has been lecturing polymer science and polymer technology students at TUT since 2000; she composites in 2013. She has published several papers on this topic and has also had an uplifting affect on the polymer technology students at TUT.

    Claus has been involved in cable production for over two decades (he was at Rosslyn Cables and ATC Telecom Cables) before joining CBI, during which time his attention to detail and standards has proved to be a good example to the younger generation servicing the plastics sector. He graduated with a diploma in polymer chemistry in Nuremburg, Germany, and came to Africa in 1987. He continued his studies with Unisa and gained a doctorate in 2012.

    Mike was involved in virtually all spheres of the industry prior to his retirement in 2012: he was involved

    $cans and then plastics) in Zimbabwe in the 1970s and then in KZN in the 80s before moving to material supply with the Sentrachem group. He was later involved with the Plastics Industry Training Board (PITB) which revitalized training in our industry in the 90s, and he then ended his career with a decade-long stint as director of the Plastics Convertors Association.

    Gan has been a truly committed member of the KZN branch. Here is a man whos a worker and not a talker, according to KZN ex-chairman Garth Taylor. Ask Gan to carry out a duty and consider the task done! Gans been involved in the industry for 35 years, mainly in material supply at Idwala Sales & Distribution. He says he learned a lot from the main manne at |#Zand learned valuable lessons from these people, and encourages young people joining the industry and the institute today to do the same.

    58

    AP

    RIL

    / M

    AY

    201

    4ASSOCIATION NEWS

    Eino Vuorinen Bob Bond Dr Caroline Khoathane Mike Bullock Claus Maurer Gan Naicker

    Time for golf!KZNThe KZN event is to take place at Royal Durban on Friday 27 June.The KZN event appears to have become the most popular PISA golf day, ever: last year it attracted a massive #the popularity of the Durban Contact Garth Taylor,

    084 924 4551, [email protected]

    WESTERN CAPEMeanwhile, over in Slaapstad, the locals are still thinking about whether they should get in a bit of practise, but the date has been set: the event will be held at Durbanville on Thursday 12 June.

  • THE PISA Northern team has again come up with a challenging but creative objective for this years PISA Design Awards competition: to design a product made from 100% recycled material.

    Given the experience of making any product that sells well, even with 100% virgin material, readers will be aware

    $>University of Technology (TUT) students who have participated in the PISA design programme over the past few years have unerringly come up with creative and unusual solutions and designed products that have exhibited considerable market potential which, dare one say it, have largely not attracted much interest from the local market.

    In 2012 the students were asked to design a vehicle for the transportation of recycled materials in urban and rural environments, and last year they were tasked to design a bottle crusher for plastic containers. On both occasions the students came up with varied and insightful solutions, !

    Fairly substantial prizes are on offer for the winners!The entries will be exhibited at Afrimold at the Sandton

    $

    {|#Plastics|SA: [email protected], phone 078 460 0044

    APRIL / MAY 2014 59

    Entries in last years PISA student design competition, when the quest was to design a bottle crusher for domestic use. The students came up with novel and practical solutions

    PISA student design competition: design a product made entirely from recycled material

    Students have come up with creative and

    unusual solutions and designed products with considerable

    market potential

  • 60 APRIL / MAY 2014

    ASSO

    CIAT

    ION

    NEW

    S

    THE Polystyrene Council (PSPC) is driving a dynamic marketing and awareness campaign of its

    various charity projects to schools across Gauteng. According to PSPC director, Adri Spangenberg, 20 new

    schools committed themselves during March to collecting breadtags and other products made from high impact polystyrene, such as polystyrene take-away trays and containers, casings used to protect appliances and products

    Polystyrene council starts collection

    THE Southern African Vinyls Association (SAVA) will host the 2014 convention of the Global Vinyls Council (GVC) from the 21-23 October at the Hilton Hotel in Sandton, Johannesburg.

    ?>#the opportunity to host international PVC experts from more than 11 countries, and we are very excited about the opportunity to introduce them to our beautiful country, while at the same time creating the opportunity for networking and learning more about international best practices, said SAVA CEO, Delanie Bezuidenhout.

    The GVC meets bi-annually to share pertinent information with industry partners all over the world, and to distribute this information to its members. Their objectives include:

    PVC/vinyl products bring to society Correcting misinformation about the health

    and safety of vinyl production and use

    legislation about PVC and vinyl products Defending the industry and its products

    from unwarranted attacks Strengthening bonds between the vinyl

    industry and its customer companies and trade associations.

    International conferenceSAVA has been a member of the GVC since 2011, allowing them to be part of an international network of experts that encourage knowledge transfer and international cooperation. Although the Council meeting on 21 October will be a closed meeting, Delanie said the GVC members have kindly agreed to participate in a full-day, international conference with their South African counterparts on Wednesday, 22 October 2014. This PVC industry and will be open to all industry players and interested parties.

    Being part of a successful industry implies accepting a responsibility towards others in that industry, to join forces, to share ideas and to turn ideas into action, Delanie said. David Cook of The Natural Step (Stockholm) has already been

  • THE Toolmaking Association of South Africa (TASA) Gauteng convened in Midrand in February for its AGM where newly re-elected chairman, Vusi Mkhize, highlighted the revitalisation of the training capability for toolmakers as possibly the biggest single success story in South Africas training history over the past decade.

    Addressing the AGM, Mkhize said that more than R200

    $and managed seven-year artisan training programme for the tooling industry. The TDM Powered training programme is based on international standards set by the National Institute for Metalworking Standards (NIMS) in Washington DC.

    In April, 109 toolmaker artisans will graduate in Gauteng, while another 48 will qualify as machinists. Eighty Foundation Level and 290 Level 1 students will start their training this year, !launched Master Toolmaker Programme.

    Our strategy is to bring jobs back from the East and other parts of the world where tooling, that can be produced in South Africa, is currently being imported from, said Mkhize.

    He emphasised that in terms of the new paradigm for the revitalisation of the tooling industry, South Africa will have to focus strongly on inward investment to establish a premium tooling sector as well as clustering in the medium technology toolmaking sector to alleviate the pressure from Asian and East European tools.

    Mkhize went on to point out that the new toolmaking rules aimed at making South Africa globally competitive will require a revolution in productivity, production depth or specialisation

    >investments in production facilities, technology, recapitalisation of local tooling entities and co-operation and clustering infrastructure.

    According to Mkhize, enterprise development will be a key building block in the revitalisation of the local tooling industry. To this end, TASA Gauteng has already developed and implemented a pilot project aimed at developing a methodology to run a tool shop as a tool factory. A tool shop management programme based on Lean Production and Visual Management has also been developed and documented. In addition, value chain specialisation and specialised clustering are also promoted by TASA Gauteng.

    made from HIPS, such as plastic cutlery, yoghurt tubs, and the outer casings of BIC ballpoint pens for the Wheelchairs Project and the Tutu Desk Project.

    As part of the schools project, the PSPC has provided branded wheelie bins to the schools free of charge, explaining the charity project and the recycling process with fun and colourful graphics. The PSPC also helped to put them into contact with the local waste collectors in their area, such as WastePlan or Tolblik, making sure these schools are given the necessary support and infrastructure.

    Toolmaker training one of SAs great success stories

    points at schools

    ==[==\Gauteng

    South Africa must focus on inward investment to establish a premium tooling sector

    ==^$*=

    ^_#^

    $![\'=*$$

    unable to attend.

    APRIL / MAY 2014 61

    www.tasagauteng.co.za

  • 62 APRIL / MAY 2014

    ONE of the issues currently facing the plastic recycling industry is the lack of

    demand, according to Annab Pretorius, convenor of SAPRO (the Southern African Plastics Recyclers Organisation).

    The increased demand for recycled material has led to an increase in demand for the recovery of post-consumer material. However, these materials tend to be dirtier than production scrap or material received from closed loop cycles and this has in turn turned the focus on to the need for the washing of material prior to reprocessing.

    If we want to grow this industry, we need to grow wash plant capacity, said Annab.

    SAPRO presented a seminar on exactly this topic in Midrand in February.

    Topics under the spotlight included:: What are the basic differences

    between an LDPE and an HDPE wash line;

    What are the critical components of a PE wash line;

    What do you need to have in place for a wash line, in terms of water supply, waste water treatment, power

  • WITH a new production base of 5000m and use of fully automatic
  • SABIC introduced two new pharmaceutical grades of polypropylene intended for syringes and other medical dosing application devices at this years Pharapack Europe in Paris in February.

    The two grades, SABIC PP PCGR40 and a lubricated $

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  • THE new stacking station for Kiefels KMD 78 SPEED pressure forming machine has recently attracted a lot of interest. This innovative stacking concept has enthralled technical experts and made a persuasive case for substantial gains in productivity in the production of moulded parts.

    The stacking system is innovative and new. It already integrates the horizontal stacking step, making it $>are delivered at an ergonomic removal height via the conveyor belt,: said Erwin Wabnig, in charge of the packaging division at Kiefel in Germany.

    This results in a continuous removal

    stack, which is already oriented ~tip stacking system can be used for a wide range of different moulded parts. Retooling is easy and quick to achieve.

    For now, Kiefel will only be offering the tip stacking system for the KMD 64 SPEED and KMD 78 SPEED. Represented in South Africa by

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    66 APRIL / MAY 2014

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    WITTMANN Battenfelds all-electric MicroPower is specially designed for injection moulding small and micro parts, ideal for medical technology

    where the minutest of components are needed. Pictured here is an example of an opto-electronic application where a barrel holder made of POM was produced by a MicroPower 15/10. The component is a focusing device used in cameras to hold the lenses in place or to focus them, and in medical measuring devices. The internal thread of the component is produced with the help of a threaded core operated directly via the ejector of the injection moulding machine. This means that the threaded core is unscrewed directly

    inside the mould before it is removed by a Wittmann

    W8VS2 robot. It is then presented to a

    camera integrated in the production line and the machines control system

    deposited in a collecting box separated according to cavities. Another special feature is the production process under clean-room conditions achieved by means of a Laminar FlowBox inside the machine. This innovative two-step injection unit, consisting of a screw and a plunger, with a shot volume ranging from 0.05 to 4cm, injects thermally homogeneous melt. The machines clean room-compatible design and the clean-room module, which provides clean air class 6 according to ISO 14644-1, are ideal for medical applications. Represented in South Africa by

    Mouldplas Marketing

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    WIttmann Battenfeld at Compamed

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  • WHEN Closed Loop London began producing food contact grade HDPE from transparent bottle material back in 2008 it was B+B Anlagenbau GmbH and Erema Engineering Recycling Maschinen und Anlagen GmbH who provided the technical solution for this pioneer work. The successful collaboration has now been continued through the expansion of the existing plant capacity to 4,800 kg/h in total.

    The processing steps include dry

  • BENECKE Changshun Auto Trim, a joint venture between Benecke-Kaliko in Hanover and Chinese specialist dealer for automotive plastics Jiangsu Changshun Group, based in Zhangjiagang in eastern China, have put a new production line for interior >|

    This new production capacity is being added in response to the steady growth in demand in the Chinese automotive >|

    $

    |line, Benecke Changshun Auto Trim has practically built its own new factory, complete with production hall, numerous ancillary rooms and a warehouse at a cost of around 7million, according to sources within

    !||implemented all of the material supply

    Z

    $|$|+|!result, the regrind conveyor had to be equipped with special process controls and plant technology that was adapted

    >!

  • ILLIG will present an IC-RDM 54K automatic roll-fed machine, state-of-the-art in thermoforming at ChinaPlas this year. With a forming area of 520mm x 300mm, 54,000 APET cups are manufactured per hour using an 18-cavity mould at a speed of 50 cycles per minute.

    RDM-K machines are designed cups in various shapes and sizes from thermoplastic material. Equipped with the new IC operating concept (Illig Intelligent Control concept), the this servo-driven thermoformer much more easily and reliably and also to the full extent. The IC concept includes several compatible modules: Illig ThermoLineControl, dynamic process optimization of the machine, compensation of environmental

  • A PATENTED single-screw, single-barrel equipment package from Nordson XALOY provides the cost savings and versatility of two-component moulding while requiring substantially less investment than more complex co-injection moulding systems that use separate injection units.The Twinshot system replaces a standard screw and barrel with counterparts designed to produce a two-component part in a single moulding cycle with a single screw, single shot and single recovery. It is available as an option on new Zinstalled in one or two days. The Twinshot system is limited to simple A-B-A sandwich structures and cannot be used for hot-runner moulding or on equipment with L/D ratios less than 20:1. Within these limitations it can process a wide range of resin and colour combinations and can readily be switched back to single-material moulding, according to the USA manufacturers.While resin typically accounts for well over half of the cost of producing a part, two-component moulding makes it possible to optimize the tradeoff between material function and cost by using two different resins instead of one, said Anton Hagen, global product manager for screws and multi-material moulding.The advantages of Twinshot two-component moulding include:

    general-purpose material in the core using recycled or wide-spec material in the

    core combining a structural core with a cosmetic

    exterior adding new product value by, e.g. combining

    a soft-touch TPE skin with a rigid core

    (reduction in weight and moulded-in stress and elimination of warpage and sink marks)

    !$$Twinshot system, Hagen cited the case of an automotive mirror housing that entailed costs of $5.00 for material and $1.00 for energy. With co-injection, a 15% savings in material costs is easily obtainable, reducing the resin cost per part by $0.75 and cutting the total cost per part by 12.5%.

    How Twinshot system worksThe Twinshot system includes a screw with two independent melting zones and a barrel with two feed ports. The skin material

    $feeder. The core material enters via the second port and is metered into the system by an auger feeder with speed control. Other components are a dual-purpose non-return valve and an Eliminator nozzle tip. Layer thicknesses are controlled by the speeds of the primary screw and the auger screw.

    >$>sequential injection of the two materials through the same gate (or gates), with some amount of simultaneous injection. The skin material cools against the mould walls as the molten >

  • Thank you.

    Heres to the heroes, the champions of change, the concerned companies whove realised their responsibility. Theyve joined POLYCO,

    6J67:6*

    &

    (;"6+,E,*26

    newest members who are leading the charge. KJJ(7J(7*

    LN"O"

    P A C K A G I N GBOXMORE

    !8=**;[email protected]+BMK8***;

  • BY DR NIALL MARSHALL

    BUILD and theyll come. This is the core idea behind Dubais dramatic growth from

    transport hub in just 40 years. Airports, mega