Dubais World Expo may boost UAE

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Pack-Ad-Vise starts operations

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New MD for AAT Composites

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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: saplastics@iafrica.comPostnet 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: lowrieplasticsmedia@absamail.co.za

KZN Lynne Askew

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

e: lynne@leafpublishing.co.za

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(martin@summitpub.co.za)

Editor: Tessa OHara(tessa@summitpub.co.za)

Editorial assistant: Heather Peplow(heather@summitpub.co.za)

Financial manager: Lisa Mulligan(lisa@summitpub.co.za)

Designer: Jeanette Erasmus Graphic Design (jeanette.erasmus@lateraldynamics.co.za)

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. craig@compositeplastics.co.za | Craig: 083 680 9793 allan@compositeplastics.co.za | 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\{|}'|

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64

6

8

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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: nickie.s@hestico.co.za

For all your plastic and packaging needs

SERVING THE PLASTIC AND PACKAGINGINDUSTRY FOR MORE THAN 50 YEARS

SINCE 1962

For all your plastic and packaging needs

Mould temperaturecontrollers,chillers,

granulators

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: sales@marimark.co.zaWeb: 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: sales@marimark.co.zaWeb: 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: sales@sescc.co.za - 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

AP

RIL / M

AY

2014 25

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

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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

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"(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

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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.

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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~

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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

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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

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Tel: 011 762-5231 Fax: 011 762 5228 Mobile: 082 465 9491 steve@edmshop.co.za 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 Ririedelyce.ririe@basf.comTel 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

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#*, 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: jacques@demaplastech.co.zaTurning design into Reality faster than you can imagine

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FAX: +27 (0) 11 462 8229

e-mail: jacques@demaplastech.co.zaSOLUTIONMACHINERY (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

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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 kbcinfo@karbochem.co.za

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

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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\+_#[\

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

54 APRIL / MAY 2014

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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.

McLean@plasticssa.co.za

=_

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

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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.

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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, garthtaylor42@gmail.com

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: jacques.lightfoot@plasticssa.co.za, 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

==^$*=

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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

Ferrostaal Equipment Solutions.

Tip stacking: A real thermoforming innovation from Kiefel

EQUIPMENT

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

High-tech micro injection moulding

Trays stacked

An economical alternative to robotic stacking

WIttmann Battenfeld at Compamed

The Kiefel tip stacking stacking unit

Lens focusing device for medical measuring

instruments

The MicroPower ideally suited for production under clean-room conditions

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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=**;M8NQ+?R?@.B-SS+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