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SA Plastics, Composites & Rubber is published six times a year. 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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t: +27 (21) 712 1408
f: 086 519 6089
c: +27 (82) 822 8115
Postnet Suite 42, Private Bag X16,
Constantia 7848, Cape Town, South Africa
70 Newton Drive, Meadowridge, Cape Town
www.saplastics.co.za
GAUTENG
Lowrie Sharp
t: (011) 793 4691
f: (011) 791 0544
c: 082 344 7870
KZN
Lynne Askew
t: (031) 764 2494
f: (031) 764 0676
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 9863581/23
VAT 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
Editor: Tessa O’Hara
Editorial assistant: Heather Peplow
Financial manager: Lisa Mulligan
Designer: Jeanette Erasmus Graphic Design
Bronwen Moys Blinc Design
BY THE WAY . . .
Will lower oil prices translate to the
industry? – With crude oil prices
coming down over the last few
months, many have been optimistic
that we would soon see lower
polymer prices. And that indeed has
been the case, but just as quickly
as prices have fallen they’ve started
nudging up again. At the same time,
all the polymer manufacturers and suppliers have reduced stock holdings,
being apprehensive about the market volatility. Our Middle East columnist,
Niall Marshall, reports about the background to this scenario on page 32.
Setback for small business developmentA GLIMPSE at a map of Africa, and just a little bit of knowledge about the continent’s history, should be enough for most people to understand why Somalians are good traders. They have been handling trade around the Horn of Africa for a few thousand years. Their little dhows have been bobbing on the winds along the east coast of Africa since before the time of the prophets, moving spices, fabrics, jewelry, precious metals and stones … and just about anything of value. And they’re still at, as revealed by their more recent ventures into high seas piracy.
It was just a matter of time before the Somali traders reached South Africa, and over the past decade or so they’ve developed a niche here, operating small stores across the country, even in small platteland dorpies. They have been supplying goods to people in townships across the country in a sustainable manner.
The attacks on the Somali-run shops in the last few weeks are regrettable, but it’s even more regrettable that the country’s Minister of Small Business Development should argue that the Somalis should ‘share their secrets with us’.
It’s a sad day for us if people in important positions in government are going to react as the Business Development department has done. For the Somali traders, it’s not just a job – it’s a life. These people understand the value of money and how to handle cash and trade arrangements responsibly. And they spend long days at their small businesses, supplying what the people seek. They have been supplying a service where there was virtually no service before. We suggest that, rather than criticize, the small business development authorities rather study how the model works and then develop local individuals to reach for that standard.
Bob’s leopard work continuesBOB Boden, the ex-Coextruded Film Technologies man who has
been involved in leopard conservation since retiring in 2011, has had
to be tough to persevere with his new work, battling the problems of
snaring and poaching.
In June last year Northwest Biodiversity and Conservation
of these leopards, named Brandy, was immediately released into
the Magaliesberg and was doing extremely well, only to be caught
in a snare in September. The leopard was airlifted to Joburg Zoo
for urgent treatment, and it was discovered she was pregnant. The
female has since been released again into her home range and
camera trap footage suggests she
may have given birth.
… IF YOU HAVE SOMETHING
TO SAY
Look at the bright side: if you
have some gem of wisdom to
impart, please write to us at
2-3.indd 2 2015/02/17 4:16 PM
Contents
… for large injection moulds,
extruders, rollers, autoclaves and
other processing equipment
set-point and actual value
indicating elements
heating contactor
made of non-rusting materials, hence
long service-life
REGLOPLAS
High-performance
temperature control units
Type 90 Smart
Temperature control units for water up to 90°C
JENOWILL SERVICES
Type 150 Smart
Temperature control units for oil up to 150°C
FEBRUARY / MARCH 2015
Contents
www.milliken.com
ON THE COVER
Find out more at www.saplastics.co.za
VOLUME 13 NR 1
56
6
8
12
16
18
20
22
26
28
34
40
48
50
53
56
76
78
INDUSTRY NEWSExtrupet ramps up Phoenix rPET output
Unilever partners with global suppliers
BASF celebrates 150th anniversary
Plastamid
Maritime acquires Liansu agency
New rPET producer SAFrePET
up and running
Building moulds in China:
How to overcome potential hazards
Dias & Sons builds huge mould
Tega Industries overhauls factory to meet
global standards
DESIGNAutomotive innovation at its best
ASSOCIATION NEWSSAPPMA: Deadline looms for
heavy metal-free pipes ruling
Plastics|SA wins environmental award
POLYCO:
recycling projects around SA
MATERIALS & EQUIPMENTMould and Die Solutions & Tirad: Super-sized
high precision custom mould bases from
SABIC & AMPA Group: Chemistry for a
sustainable synergy
WORLD NEWSPlastics play part in architectural illusion
First panorama roof with infrared absorption
36
10
67
69
40
At UTECH in Amsterdam from 14-16 April, Milliken
will showcase its unique fully reactive polymeric
additive technologies focused on enhancing
performance, improving visual appearance and
preserving the long-term quality of polyurethane
(PU) systems – all without contributing to VOC or
during manufacturing, they avoid migration and
loss of properties over time, and help to address
the major issues of degradation and discoloration
of PU articles due to light and heat sensitivity.
2-3.indd 3 2015/02/17 4:29 PM
OUR main story this issue is about the
expansion of Extrupet’s PhoenixPET
plant in Johannesburg. Extrupet is in the
process of tripling its food-grade rPET capacity,
and will in the near future be producing about
1750 tons a month of the material.
That is a substantial quantity of material, and a
response to demand from a number of the brand groups
to include recycled grade material in their packaging.
PET, undoubtedly, offers one of the most direct routes for
the generation of ‘r’ grade material, as its relatively easy
to recognise PET containers and the collected material
usually contains little colour additive. But after that it gets
complicated: the technology involved is more complex than
impressive achievement on pages 6-7.
At the same time, SAFrePET in Cape Town has also
entered the rPET market, via a different route, however,
with a system that it constructed itself (page 20). Here we
look at another example of how businessmen can achieve
their goals – with ingenuity, determination and, probably
most importantly, experience. Well done guys!
Is it safe to speak up, yet?Professor Ben Turok, the retired ANC MP, castigated the
audience at Plastics|SA’s AGM late last year in a good-
natured manner, but when he accused the audience of
being ‘supine’ he may have struck a nerve. For those not
familiar with this seldom used term, supine essentially
means to offer very little resistance – in fact, no resistance.
Turok was referring to the industry’s reluctance to engage
with government, and suggested that it was no surprise
that the government often promulgated legislation with little
consultation with the industry. He suggested that we were
really to blame for the situation (12-13).
We know the stakes are high, and also that the industry
does have several very capable and well-informed
solution, somehow, and urgently.
Elsewhere, in a related context, we run a summary of
the Department of Environmental Affairs’ proposed waste
management charges, in its draft regulations released in
February (page 31). This is essentially a lengthy document
outlining the structures that DEA may apply in order to
incentivise re-use, recycling or recovery of waste. Economic
opportunities may also be created in the process, which is
very necessary if we are to achieve a ‘win win’ result.
The well-researched draft document does invite members
opportunity to engage creatively with
government. We had 60 days as at
early February in which to do so.
It’s hardly incumbent on individual
businessmen to participate, although
some may, but many will look at the
industry’s professional associations
to take responsibility here and
engage with the DEA fully on the
topic. We hope POLYCO, PETCO,
SAPPMA, SAVA and others can achieve a good result for
the industry.
We have a substantial amount of news from the
associations this issue too, about their many and varied
programmes and activities (pages 40-51).
What’s coming up in 2015We end with a larger than normal DIARY section, which
– if you are planning to travel this year – may help you
plan. Our industry has been built up by taking strategies
from elsewhere in the world and
redeveloping them for local use, so
here’s your opportunity.
May the year ahead be good for
you and your businesses … it has
to be!
CO
MM
ENT
opportunity to engage
THIS ISSUE
4 FEBRUARY / MARCH 2015
Martin Wells, Publisher
Made in space – Given the
rapid rate of technology
development over the past
few centuries, and not least
over the last decade or two,
the progress of 3-D printing
has been nothing short of
astounding. In some applications,
particularly for short-run products,
the process even rivals injection
moulding … and now, you guessed
it, they’re even doing 3-D printing in
space – see the NASA article, page 68
Food-grade recycled material is what the brand companies want
Unexpected growth of rPET demand
4.indd 4 2015/02/17 4:29 PM
BEFORE its recent plant upgrade, rPET manufacturer Extrupet was reprocessing about 1 million PET bottles a day into its ‘food grade’ rPet product, PhoenixPET… and
a startling 2 million bottles a day in the short period since the summer holidays.
That’s the nett result of the Wadeville recycler’s commissioning of a Starlinger recoSTAR PET iV system at the tail end of 2014.
Extrupet had been producing about 550 tons of its food grade PhoenixPET a month for a number of years, and that
following the installation of the new line. The recoSTAR system can process up to 1200 tons/month, giving Extrupet a theoretical total current capacity of 1750 tons/month,
January it was producing at a rate of about 30 tons a day, close to the targeted 40 tons/day. The output rate is collection related, since the increased volumes are dependent on quantities of PET containers collected.
At the same time, Extrupet also continues
woven and woven bag markets. The new food grade potential gives the SA company the opportunity to direct cleaner collected bales into its Phoenix rPET stream, where
Unitemp enters partnership with Thermon of USABrand name will continue and its business as usual for SA heating specialist
IN ORDER to pursue substantial growth opportunities, particularly on larger heating projects in Africa, Unitemp has entered into an agreement to become
a global leader in the industrial heating market and a channel partner of Unitemp for many years.
“We are excited about this new development. We believe the combined company will enable us to strengthen our
product ranges, expand our services and assist us in becoming a stronger partner to our valued customers, distributors and suppliers,” said Unitemp CEO Hans Hitzeroth.
The acquisition will be completed by a newly formed entity called Thermon South Africa, which is currently in the process of being formally registered in South Africa.
“Other than a change in company name, we do not foresee any material
changes to our business from the way it is conducted today. We anticipate that the brand name Unitemp will continue to be used for many of the products we sell in South Africa. Our management team and staff will remain in place following the closing of the transaction and we will continue to offer the same product ranges and services going forward,” added Hitzeroth.
Through its global network, Thermon provides highly engineered thermal solutions,
It’s in the bag – Extrupet has also introduced new woven bags to clearly identify its Phoenix rPET, building the image of the material as it grows in popularity with the brand companies
New Starlinger line enables Jhb recycler to increase volumes substantially
Extrupet rampsup PhoenixrPET output
NEW
S
FEBRUARY / MARCH 2015 7
BRIEFS
known as heat tracing, for process industries, including energy, chemical processing and power generation. Thermon’s products provide an external heat source to pipes, vessels and instruments for the purposes of freeze protection, temperature maintenance, environmental monitoring and surface snow and ice melting.
Thermon is headquartered in San Marcos, Texas. It generated annual revenue of $277-million in its most
around the globe.
www.extrupet.com
www.unitemp.co.za
ity is essential, and utilize other material for
initially shipped out to an associate business in Nigeria. But since its big move into the
ness and keep abreast of what has become a runaway market success story. The core of the phenomenon is that several brand owners and retailers have detected a very positive consumer reaction to the inclusion
and household detergent products, spurring the unexpected growth in the reprocessed material in a market in which virgin material was used exclusively before.
In what must rate as one of the biggest single capex projects in the industry in South
team have had to keep their wits about them in order to not lose existing customers during the plant installation and yet, with the
being produced, offer all the right specs and participate in the development of new con-
that coming through the new line.One of the goals at present is the
and water bottles including a percentage of
recoSTAR PET iV – The solid state polycon-densation unit of the recoSTAR line at Extru-
about 40 tons of material a day
Mpact celebrates as global food safety standard achieved
manufacturing operations have achieved the sought-after Food Safety
putting these factories at the highest global level in meeting food safety standards.
is a major achievement. “This standard is fundamentally about food safety and us being able to offer customers a very high level of assurance about the qual-ity of our process and the safety that is built in to the way we work.”
ance standard involved a team of
months.“It also great dedication and buy-in
from staff. It was also remarkable to see the amount of research, training and continuous monitoring of all pro-cesses to ensure practice meets the written standards and policies,” added Naidoo.
Boxmore buys more Astra companies
an agreement to purchase the Hilfort Plastics operations in Bloemfontein and Upington from Astrapak.
Astrapak stated that the disposal
manufacturing operations was in line with its strategic objectives of focusing on operations of scale.
“The plastic packaging market remains highly competitive; the funda-mentals continue changing rapidly and, to remain sustainable, the single most important factor is operational scale”
The purchase consideration of
Astrapak’s current debt. The net assets value of the businesses is approxi-mately R28-million and the annual net
Moore added that the Astrapak was progressing well with its efforts to reposition the group for the future and that this was one further step in the right direction.
www.mpact.co.za
8 FEBRUARY / MARCH 2015
ANGLO-Dutch FMCG multinational Uni-lever has agreed new partnerships with several global packaging suppliers, bring-ing global capabilities and investment to South Africa. The partnerships will enable Unilever to acceler-ate the introduction of product innovations with world-class quality and create new jobs.
This forms part of the company’s goal to deliver world class capabilities in Africa to accelerate innovations that drive growth and continuous improvement in quality and service for consumers.
According to Unilever chief supply chain
ships will be a key element of Unilever’s investment strategy in South Africa. The investments, which include the Anderboldt and Midrand factories, will facilitate the manufacture of home care and ice cream products of popular brands such as Omo, Skip, Handy Andy, Ola and Magnum.
Speaking during a visit to Unilever South Africa, Sigismondi said: “Consum-ers expect the best quality from Unilever. They look to us for exciting new product innovations to market. Our partnerships will ensure that we can grow our business over the long term through great product
Unilever partners with global suppliers
NEW
S
www.unilever.com
to drive quality Will accelerate world-class product innovations, create new jobs
quality and service. This kind of collabora-tion will also provide a much needed skills transfer and technological capability in South Africa.”
Sigismondi also described the partner-ships as a demon-stration of Unilever’s commitment to South Africa, saying the multinational has made investments of close to R3-billion in the last
four years and had worked closely with partners such as the Department of Trade and Industry (DTI) to bring the invest-ments to life.
“With 57% of our sales coming from the emerging markets in 2013 and South Africa being key in the Africa business, we will continue to seek ways to gener-ate sustainable growth in this country. Our investments in South Africa form
our business whilst reducing our envi-ronmental footprint and increasing our positive social impact. The investments will allow us to better serve South African consumers with green technology innova-tion, such as rainwater harvesting, as well as improve service levels to our retail customers,” explained Sigismondi.
‘Unilever has made investments in SA of close to R3-billion in
the last 4yrs’
for SA consumers
BRIEFS
SARS inspects incoming containersSOUTH African Revenue Services inspectors have been intercepting containers carrying polymer material arriving at Durban port and inspecting the contacts. This is the result of the introduction of two new tariff sub-headings, 3901.20.90 and 3903.19.90, leading SARS inspectors to automatically intervene on all transactions with these headings. The sub-headings
differentiate between virgin and recycled material (it’s surprising that such a distinction was not made before), but the net effect is that shipping companies are charging an additional R4000 per container, which has to be paid by the importer. Besides the cost, there is also the problem of the delays caused.
The need to inspect was apparently a result of a request from a ‘recycling association,’ but it appears that few if any irregularities have been detected by the SARS inspectors. The material dealers are hence hopeful that the interruptions and extra costs will soon be terminated.
Get your legally required employee related posters from the PCA
are legally required to display a set
information for employees on their premises.
Basic Conditions of Employment Act;Employment Equity Act; Machinery Regulations, Occupational Health & Safety Act;Skills Development Act; andSafety Regulations.
Convertors Association of SA
factually incorrect posters are doing the rounds. To ensure you have the correct set of posters, you can buy
Contact: Carol Klomfass on
tel 011 314 0019.
3138_Safripol_Advance_Ad_PRINT.indd 13138_Safripol_Advance_Ad_PRINT.indd 13138_Safripol_Advance_Ad_PRINT.indd 13138_Safripol_Advance_Ad_PRINT.indd 13138_Safripol_Advance_Ad_PRINT.indd 1 2014/07/24 2:28 PM2014/07/24 2:28 PM2014/07/24 2:28 PM2014/07/24 2:28 PM2014/07/24 2:28 PM2014/07/24 2:28 PM2014/07/24 2:28 PM
10 FEBRUARY / MARCH 2015
THE Performance Colour Systems team has done it again by combining resources with global market leader in Black Masterbatch – Hubron International Ltd, which is based in Manchester, England. The new partnership becomes effective January 2015. Keith Simms, Managing Director of Hubron visited South Africa in January to meet with the Performance team and explore growth opportunities.
The Performance Colour Systems team hosted technical presentations in Johannesburg, Durban and Cape Town, announcing the partnership between these two Masterbatch giants. Keith led the countywide visit with in-depth discussions about Black Masterbatch and related technologies.
Hubron has a black masterbatch manufacturing capacity of 35,000 tons per annum and has been supplying the South African market since 1997. The link with Performance will further ensure that our customers have additional stock locally available throughout South Africa, combined with excellent technical support.
Hubron and Performance Colour Systems
- a new force in Africa
NEW
S
Hubron has an extensive range based upon many different polymer carriers, which are suitable for a wide variety of applications and processes, including
and injection moulding.Chad Francis, who heads up the
PCS organisation mentioned just how important it is to stay ahead of the technology frontier and keep on learning.
“Our suppliers, and the partnerships we create through these relationships are the ultimate differentiator”. Chad goes on to say that new ways of making quality material are a must for PCS to remain leaders in their industry.
The Hubron/Performance partnership is an exciting one, which could be a game changer in the Africa plastics market. The manufacture of granular Masterbatch is a challenging technology and these kinds of relationships are welcomed, and most certainly needed in South Africa.
www.hubron.com
www.coloursystems.co.za
Hubron manufactures over 100 types of black master-
batch for a wide range of industries, the main
sectors being cable, compounding, conductive
bre/tape, mould-ing, pipe extru-sion, sheet extrusion and
Keith Simms of Hubron (centre in white shirt) was hosted on his recent tour by the Performance Colour Systems team. A reception was held in the ‘lapa’ at the Performance plant in Meadowdale. Here we see Keith with Shaun Bouwer of Performance, Henri Pretorius (Gundle API) and Riccardo di Blasio, Lurika van Staden and Glenn Roppa (all of Performance group)
BRIEFS
DTI offers subsidy for composites companiesTHE Department of Trade and Industry has invited composites companies to apply for subsidies to participate in the CAMX show in Dallas, Texas, from 27-29 October. CAMX (Composite and Advanced Material Expo) is one of the top global composites events.
air travel assistance; daily subsistence allowance; freight forwarding of display material and exhibition space and booth rental costs. The deal is offered to SMMEs and BOEs
More information is available at
BUSA electricity surveyBUSINESS Unity South Africa is con-ducting a survey in which businesses are given the opportunity to explain what effect load shedding is having on their activities. Eskom apparently needs 3 000 MW lower demand to allow it to catch up on its maintenance back log, which has resulted in a situation where there is cur-rently 11 000 MW of unplanned outages – which has put the electricity system under pressure. If you have not heard of the survey or not yet participated, com-pleting the survey questionnaire should be a positive step.
The BUSA survey is being handled in cooperation with Plastics|SA.
Download the survey from
China bans import of mixed scrapCHINA’S customs department has banned the importation of mixed plastic scrap (that’s bulk mingled material that is unsorted and unwashed). A statement by the country’s Ministry of Commerce said contracts approved before 31 Dec 2014 had to be completed by 30 June 2015.
The deduction from this appears to be that China presently has an excess of bulk mingled scrap.
Substantial quantities of recycled plastic material have been exported from South Africa to China in recent years, mainly washed and sorted – in fact, much of SA’s best quality material has been ex-ported, due to the fact that both collectors and recyclers are getting better prices from the Chinese merchants.
We hear too that shipping of mate-rial too China is subject to lower fees as huge numbers of containers need to be returned to the East.
www.thedti.gov.za
www.busa.org.za
JOHANNESBURG
GLENN ROPPA: 082 416 8352
LURIKA VAN STADEN: 083 555 2001
PETER LOWRIE: 082 377 6133
JACQUES PRINSLOO: 083 339 3234
DURBAN
GREG WIBLIN: 082 264 3635
COLIN GOUNDER: 071 363 1829
CAPE TOWN
JARED KHOURY: 071 775 5747
BARRY SHAW: 083 408 9226
BRETT POLLARD: 082 691 3758
EAST LONDON
DAVID BOATWRIGHT
083 893 4131
“Everyday do
something that
will inch you
closer to a better
tomorrow.”
Doug Firebaugh
BASF celebrates its 150th
anniversary this year! From its beginnings in Germany in 1865 with the development and production of dyes, then the production of ammonia to make fertilizer, to plastics – BASF’s portfolio has continuously developed and evolved and today its product range covers a vast spectrum of industries.
It’s a great achievement for any company to remain successful for so many years. For BASF this number speaks to the creativity and determination of its employees – in the past and the present.
As a science and research-based com-pany, a prerequisite for the 150th anniver-sary celebration, locally and globally, was to connect to the company strategy and
corporate purpose - “We create chemistry for a sustainable future.” This statement expresses what has made, and continues to make, BASF successful. Over the years this winning recipe has not changed: BASF recognize societal trends and the needs of people; and with research and develop-
meet these challenges, again and again.“Today’s requirements and the expecta-
tions of society are much more complex. But our focus is still on improving people’s quality of life,” explained Laurent Tainturier, senior vice president for the EUE region, including CIS-Middle East-Africa. “This, however, should not come at the expense of the next generations. When we conduct research today, we keep one guiding principle in mind: sustainability. We treat re-sources with care and respect and strive to
strike a balance between all three dimensions: economy, environment and society.”
“It is critical that a company such as BASF addresses the challenges facing our planet, including those of energy and food resources, as well as urban living,” said Tainturier.
Collaboration to innovateBASF continues to work closely with univer-sity researchers, scientists and chemists on research, considering solutions together with customers and scientists.
“We see our anniversary as an opportunity to open up in ways that go beyond these prov-en collaborations,” said Joan-Maria Garcia-Girona, vice president and head of BASF in South Africa and Sub-Sahara. “We want to ini-tiate something new with our anniversary and try out new ways of working together over the next year – both within BASF and with people
Industry doesn’t offer resistance to State policies … seems to offer NONESpeaker says private sector is too quiet
YOU are supine! That was the message from the seemingly mild mannered Professor Ben Turok when he addressed the Plastics|SA annual general meeting in Midrand in October.
Turok, an ANC MP and director of the Institute for African Alternatives, was commenting about the industry’s lack of opposition to government policies.
“The private sector is far too quiet,” said Turok. He suggested that, since
most businessmen seem to want to avoid dealing with government ministers and departments, the government can’t be blamed for not taking business seriously.
Turok said he wished to foster a “serious debate about the serious state
in currently”.In discussion with some of the
delegates, prior to the commencement of the AGM, he inquired about the situation
in the local plastic converting industry. He said he was aware that one of the reasons why local convertors have been out-competed by Chinese manufacturers was due to state subsidies which Chinese convertors received from their government. By comparison, the South African government has over the past two decades virtually rushed to remove subsidies and import protection tariffs and duties.
That was particularly the case during the
NEW
S
Focus topics: energy, food and urban living
BASF celebrates
anniversary150th
FEBRUARY / MARCH 2015 13
1990s, when globalisation was the talk of the town. So open was the SA economy that many local businesses were virtually
More recently, however, the government
“So there are cases where government
Ben Turok was thanked for his presentation by Thobela Tapula, corporate affairs manager at Plastics|SA
Space™ virtual laboratory programme as
our target groups. Our three anniversary
The South African anniversary pro-gramme for the year will see a number of highly interactive events being
ing scientists, customers, business
focus will be on the three strategic
urban living. Events will range from
will challenge staff across all levels to come up with innovative solutions to societal issues, to participation
Speakers at BASF’s 150 year an-niversary launch in South Africa (from left to right): Petra Be-zuidenhout (head of corporate communications, governmental relations and advocacy, BASF Holdings), Joan-Maria Garcia-Gi-rona (BASF vice president, head of BASF Business Centre South Africa & Sub-Sahara); Professor Mamokgethi Phakeng (vice principal: research & innovation, University of South Africa), Dr Christo Marais (chief director, Department of Environmental Af-fairs), Laurent Tainturier (BASF senior vice president EUE–CIS, Middle East and Africa), Hanli Prinsloo (founder of the “I am Water” Foundation), His Excel-lency, Dr Horst Freitag (ambas-sador of the Federal Republic of Germany to South Africa)
A big ‘thumbs up’ for BASF
– Joan-Maria Garcia-Girona (BASF vice president, head of BASF Business Centre South Africa & Sub-Sahara) and Laurent Tainturier (BASF senior vice president EUE–CIS, Middle East and Africa) celebrating BASF’s 150th anniversary
Safripol CEO, Joaquin Schoch (centre), toasts BASF’s longevity with SA Plastics magazine’s Lowrie Sharp and Martin Wells
Investment of up to €500 million in production capacities worldwide
www.basf.co.za
www.basf.com
BASF plans major investment inpioneering superabsorbent technology
investment in a pioneering superabsorbent technology platform of its hygiene business.
over the next two to three years
existing plants.Superabsorbent polymers are
relative to their own mass. They are
will launch a new generation of highly innovative superabsorbent
SAVIVATM. The launch is
particles with micro-pores, SAVIVA
mechanism, making it a highly
global footprint for a reliable, global supply.
www.basf.com
Piovan of Italy and Eder Design of South Africa have established
Piovan South Africa
Contact us for your requirements
Johann Eder, Managing Director of Piovan South Africa,
tel: 012 253 1025 | email: [email protected]
The new generation Quantum
Gravimetric Blender – the fi rst gravimetric
batch blender that is mechanically and
electronically isolated from vibrations.
This is a fi rst for a global auxiliary supplier!
Piovan South Africa will focus on its core business of
material handling systems for plastic granules and
powders, ensuring signifi cantly improved turnaround
times and service to customers.
Piovan South Africa offers customers complete
turn-key solutions:
Piovan is also a leader in low energy consumption PET
drying solutions and the recycling of post-production
PET scrap. Piovan offers dedusting and crystallization
solutions for PET.
Rapid GranulatorsOur customers have always stressed
how happy they are with the reliability,
superior design and build quality of
their Rapid granulators. Our service &
support facilities are in place to help
our customers get the best from their
machinery.
Rapid’s Open-Hearted technology
offers uniquely fast access to machine
interior for cleaning and maintenance.
Further, we’re offering a complete
range of auxillary equipments includ-
ing dust separation systems, metal
detection/separation and much more.
EDER DESIGN, based in South
Africa, have been appointed Rapid’s
exclusive distributor for South Africa
and Sub-Sahara Africa.
EDER DESIGN/RAPID provides
granulators in widths up to 1500 mm,
with throughput capacities up to 4
tonnes/hour.
www.rapidgranulator.com
Rapid Granulator AB
Phone: +46 (0)370 86500
E-mail: [email protected]
Tel: +27 82 651 3315
E-mail: [email protected]
600_eder_A4.indd 1 2014-11-13 11.13
Tel: 012 253 1025E-mail: [email protected]
16 FEBRUARY / MARCH 2015
NEW
S
Cape team –
Dave Cowan, Tania Smit and Johan van Wyk
Johannesburg
team – Sherisha Ramruthan (seated),
the new Plastamid manager, with
Renee Brennan, Tania Postlethwaite, Nthabiseng Mdikwa
and Aneshri Padayachy
Plastamid customer
ment includes Tshipane Nkwe,
achee and Latasha Pillay
ness Unit Manager. Sherisha was previ-ously at Lake International Technologies,
also an AECI Group company.
Ryan Harrison.
supplier of choice for customers in the markets we serve,” said Harrison.
Plastamid is now supplying compounded engineering poly-mer material and grades from an international compounder.
material that was previously manufactured locally,” added Harrison.
“With the diversity of polymers, pig-ments and additives, Plastamid aims to increase its presence in the plastics industry and to diversify into different market sectors, including packaging.
“With our history of excellent technical support and customer service, we look forward to this new opportunities,” said Harrison.
AECI has made some strategic changes
its product range. Besides the range of polymers it has supplied for over four decades (the com-
Plastamid is now also supplying a full range of additives and pig-ments to the plastics market, as well as to the coatings industry.
under the new management of Sherisha
Durban
team –
Uresha
beer and ChristoJordt
FORD debuted its newest GT supercar at the North American International Auto Show in January, a car that will come with a carbon
development project with Dow Chemical’s DowAksa joint venture to develop lower cost,
the growing needs for lightweight materials in
Turkey’s Aksa Akrilik Kimya Sanayii AS, builds on a 2012 project with the same companies
companies will also look at ways to recycle
The last GT, in 2005, used carbon
an interior panel within the hood, where it was not
one, set to go into production this year, has carbon
passenger cell
along with aluminium front and rear sub frames, which are encapsulated in
Ryan Harrison
The Plastamid Team can be reached on:
phone +27 (0)11 922 1780/1973/1954;
phone +27 (0)21 914 9042;
phone: +27 (0)31 762 3445;
18
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15 MARITIME Marketing has acquired the
agency for Liansu Extrusion Machinery, one of the largest and most respected extruder manufacturers in China.
the industry have rejoined Maritime: Andy Woods has joined the team as extrusion product manager. He has a phenomenal 45 years’ experience in the plastics industry and will expand Maritime’s
and sheet extrusion sector.Paul Ferreira makes a welcome
return to Maritime Marketing, as ancillary product manager. Paul has over 30 years’ experience in the industry and is a familiar face to most – welcome back ‘Mr Shini’.
Maritime acquires Liansu agency
NEWS
www.marimark.co.za
www.nisseiasb.co.jp
Paul Ferreira makes
a welcome return to
Maritime as ancillary
product manager
Andy Woods has joined
the Maritime Market-
ing team as extrusion
product manager
Nissei ASB
in Kenya
reach across the sub-Saharan continent.“We decided to open the Kenyan
with our existing and potential new customers,” said Corné Pretorius, GM of the Japanese machine manufacturer’s
“It also allows us to work more closely with our customers on their projects and shorten timelines,” he added. “We understand the importance of customer service and support and would like to grow Africa together with our customers.”
PC Gokhale, who has a lot of experience
Safripol rated Top Employer for 7th year in succession
SAFRIPOL has been awarded the Top Employ-er South Africa 2014 for the seventh consecutive year. This comes as reward for the company’s continued efforts to improve employee satisfac-tion at all levels.
As the country’s sole high-density polyeth-ylene manufacturer, and one of only two local producers of polypropylene, Safripol prides itself on an excellent portfolio of products, supplied to an elite selection of customers in all areas of plastic conversion.
Recognised as one of South Africa’s top em-ployers for the past seven years in succession, Safripol is very aware that employee satisfaction is one of the most important building blocks of business success, sustainability and the ultimate bottom line. Employees are encouraged to im-prove their knowledge and skills through work-related training and education to keep abreast of the newest trends, modern technical advances
and innovative opportunities for growth. Employees are given more responsibility for their own environment, participating in
and taking charge of safety in the manufac-turing plant.
Through its employees, the company is focused on the continual improvement of its products and performance, and on develop-ing new products. The most successful of these developments have been the world-class PE100 pipe resin, iMPACT100® which has excellent processing characteristics, as well as high clarity PP random copolymers in the ADVANCE series, which give prod-
times and saving energy.
Employees are given more responsibility for their own environment
www.safripol.co.za
Safripol HR manager Victor Matsoso had the honour of receiving the Top Employer Award on stage at the Top Employers Institute
in the ISBM (injection stretch blow moulding) area.
Nissei ASB South Africa will provide technical and spares support
technical support in the very near future.
to service the West Africa market; reporting to
PC Gokhale who heads up Nissei
20 FEBRUARY / MARCH 2015
Ingenuity applied: existing equipment used to keep set-up costs down
NEW
S
www.safrepet.com
New rPET producer SAFrePETup and running
Steve Newby and Johan Grové, two of the partners in the new venture, at the SAFrePET plant in Parow Industria, with chipped, sorted and washed PET material. At present SAFrePET is processing approximately 60 tons of rPET a month and selling it into the
High quality chipped rPET
+27 (0)31 765 5720
0086 151 685 69018
+27 (0)82 821 4775
How to overcome potential hazards
NEWS
Miracle Mould man says production in Far East continues to offer many advantages
22 FEBRUARY / MARCH 2015
Building moulds in China:
THE enticement and perceived advantages of having moulds built in China is immense, but does the result always justify this?
Up until quite recently, a large portion of injection moulds in operation in South Africa have been built in China, with the Chinese mould makers offering both ex-ceptional prices and turnaround times that local toolmakers have often not been able to match.
That situation has been revised more recently with the decline in the rand-dollar exchange rate, which resulted virtually overnight in moulds ex-China costing about
creasing as the rand has further weakened against the dollar). This switch has made prices offered by the South African mould makers more competitive.
But Chinese moulds still have a lot to offer, and one of the men who is most in-volved in this area is Brian Almanza of Mir-acle Mould International (MMI) of Durban.
Miracle runs mould shops in both Durban and China, although the circumstances in these two centres differ fundamentally: the trend in China is for several mould shops with different but complimentary expertise to cooperate and work on complicated and/or large moulds jointly, which is gener-ally not the case in South Africa.
The biggest stumbling block in working with Chinese mould makers was previous-ly the language barrier. Although the prob-lem has improved, since many of China’s top mould makers now employ young individuals who speak both English (and well too), clear understanding remains a challenge. This is particularly the case when it’s necessary to explain complex mould designs and alterations.
Almanza, however, appears to have semi-perfected the process. MMI has been building moulds as well as press tools (which MMI also specialises in) for the past 31 years.
Following in the footsteps of the late John Algate, a South African designer who
carved a niche for himself in the Far East, designing and building moulds in China for South African clients, Almanza speaks Man-darin. He has been working with a cluster of designers and mould makers in China.
We asked Brian about his experience in the East to date:
in China?About 15 years ago my ISO 2000 injection moulding and mould making company could not cope with the demands of the company’s injection mould manufacturing requirements, and the local lead times were unsuitable. This forced me to look offshore for options.
getting my moulds made in China were short lead times and very competitive pricing. China is growing at a staggering rate and, with this growth there are many changes such as
FEBRUARY / MARCH 2015 23
to follow when manufacturing tooling in China:
Rule number 1: People do what you inspect and not what you expect
Rule number 2: Make sure you thoroughly know who you are dealing with
Rule number 3: Physical inspection is always better than written reports or verbal assurances
Rule number 4: Formulate a 100% material
Rule number 5: Transact honourably, keep your word and respect your suppliers, and you will make good friends and gain respect.
higher wage demands by the labour force and shorter working weeks.
What do you believe are the main advan-tages of running a mould shop in China?Despite the rapidly changing landscape, there are still major advantages to be obtained by designing and making produc-tion tooling in China. The lead times are still unbeatable in most instances. Pricing on an apples-for-apples basis is currently unbeat-able, despite the changes.
What are the chief challenges and problems when working with Chinese mould-makers?Sourcing moulds successfully requires an in depth understanding of many cultural differ-ences. These have been learnt by constant interaction. A lot can also be learnt by the reading of many very interesting books on the subject. It is also hugely important to remember that, like many other parts of the world, people do what is inspected and not
what is expected.Every project that MMI takes on is
designed by me, with a team of mould design engineers in design review
encouraged from all participants. Once started the project has to be micro-managed, and every step of the project managed and inspected to minimise the chance of defects. These defects are caused by numerous factors, including but not limited to, human error, material
tions, incorrect machining and, most commonly, design deviation.
The choice of remedial and manage-ment strategies cannot be the same as one would use locally, as these would most certainly result in an undesirable outcome and most likely worsen the problem. The ability to communicate in Mandarin and have an intimate knowl-edge of the culture, Confucianism and Chinese way certainly go a long way to resolving any snags and managing
The ability to speak Mandarin has been a big aid for Brian Almanza when doing business in China, but the man’s huge interest in injection mould technology has been the main factor behind Miracle Mould International’s success. MMI operates out of Durban, but Almanza is frequently in China
SOME USEFUL RULES
NEWS
24 FEBRUARY / MARCH 2015
a project successfully. Like any other business environment, a loyal, local, personal assistant is also invaluable and goes a long way during complex cross-cultural negotiations.
Quality controlPeople do what you inspect not what you expect. With the requirements that the position dictates, it is impossible for me to be present every minute of the mould manufacturing process, as the moulds are built on a 24-hour six-days-a-week schedule, provided there is not a compel-ling reason to work a 24/7 schedule.
Despite this understandable limitation, before a mould is shipped, every piece of the mould is inspected in a strip-and-rebuild conducted by MMI personnel. If a fault is found, it is immediately reported to the client and a course of action decided on.What has been your most successful
www.miraclemould.com
mould built/success story in China?The most challenging of moulds manufac-tured in China was a door hanger runner. The mould was successfully manufactured without the use of a hot runner, despite the dimension being 1.3 metres long and only about 60mm wide, with an undercut over the whole length The design review team could not agree on the mould design, given the fact that warpage had to be avoided.
tests were done, there was no conclusive answer. In times like this, someone has to
the component in the end of the 1.3m part without a hot runner system.
Although it was an educated guess, I got
The end result was a near perfect part,
the client, and a saving to the client of R650,000!
a 4-cavity sequential gated tappet cover mould, a somewhat complex undertaking
‘No consumer health risk from Bisphenol A exposure’
www.plasticseurope.org
www.bisphenol-a-europe.org
THE European Food Safety Authority
opinion on the safety of Bisphenol A (BPA) on 21 January. It combines the authority´s assessment of both exposure and health aspects and considers comments received from national authorities and stakeholders following extensive engagement and consultation. The new assessment covers exposure from food sources along with exposure from a range of other potential sources, and considers all age groups of the population.
Exposure from all sources is very low and well below the new safe limit for all age groups – BPA-based products safe for consumers Applying a comprehensive weight-of-evidence approach to all relevant studies
set a lifetime safe intake level, known as the tolerable daily intake (TDI). Notably, the safe level conservatively takes into account remaining uncertainties about potential health effects of BPA.
Considering all sources of exposure together, the expert panel concluded: ‘BPA poses no health risk to consumers of any age group’.
It is anticipated that EFSA will revisit the TDI, which is currently designated as temporary, to incorporate the results of ongoing US governmental studies, which were designed to resolve remaining uncertainties about the safety of BPA.
Transparent and open process strengthens the conclusion The PC/BPA Group and Epoxy Resin Committee of PlasticsEurope appreciate the transparent and open stakeholder engagement of EFSA during the public consultation. This process ensured
and information were considered and
assessments of government bodies around the world The EFSA conclusion is consistent with
the safety of BPA in food contact
materials from the US Food and Drug Administration (FDA). Many other government bodies, for example Health Canada, have also evaluated the
similar conclusions.
In light of EFSA’s conclusions, the French restriction on BPA is disproportionate and should be withdrawn“The fact that any realistic exposure to BPA is well below even the conservative safety threshold established by EFSA shows that blanket restrictions being applied at national level, in particular in
withdrawn,” says Jasmin Bird of the PC/BPA-group. “This EFSA conclusion on BPA should be used as the basis for consistent and harmonised European food safety regulation, and should be respected by all EU member states.”
PhoenixPET is proud to announce the opening of its new state of the art
Bottle-2-Bottle recycling facility capable of producing the highest
quality recycled PET on record in South Africa. This giant leap in recycling
means for the first time recycled PET can be used for bottles of carbonated
soft drinks, bottled water and all other forms of PET packaging.
With a new plant, we’re helping industry turn over a new leaf.
www.extrupet.com
E-mail [email protected]
Website www.phoenixpet.co.za
Contact 011 865 8380
“Some people said it was not possible for the tool to be made in this country and
Dias of the Westville-based mould and die manufacturer.
Dias & Sons has been in operation since
his sons and the team now operates from a well-equipped toolroom with all the latest
moulded in polyprop locally. It is aimed at
this case is for the rural areas.
A lot of Dias & Sons’ work has been for a sanitary ware and plumb-
“We have been
small moulds as well as
We have built up a close relationship with a sanitary ware supplier and have basically made a plan to help them out
machine and the customer was very happy
Did your company design the mould as well?“We weren’t involved in any of the develop-ment of the actual product. There were too
NEWS
Durban toolroom competes successfully with Far Eastern competitors
Dias & Sonsbuilds huge mould
26 FEBRUARY / MARCH 2015
The hydraulic core pulling unit, in itself a large item, is vital for the cone shaped
moulding, with undercuts, and allows the mould to open/close
Mould mounted in the injection machine, with the core pulling system installed
What are the particular features of the mould?
the mould has four hydraulic
tions which have to work in
How were you able to fend off competition from China?
on the mould. We were more expensive than
they would consider us. We wanted to take on
We brought our price in line with
the overseas competitors and we were given the go-ahead
SALES AND MARKETING
Eastgate Office Park, Ground Floor, Block ASouth Boulevard, Bruma 2026, South Africa
Locally manufactured, globally sought aftersynthetic rubberssince 1964
T +27 (0)11 601 1660F +27 (0)11 616 6651E [email protected]
FEBRUARY / MARCH 2015 27
overseas competitors and we were given the go-ahead. We had managed to source a lot of the material needed for the project
for costing and availability in South Africa.“Having to compete with the time lines
quoted by our Chinese competitors – which was a 12-week lead time for the completion of the project – was obviously a challenge. Some of the tool steel pieces weighed about 1000kgs, so we would have been in dire straits if we hadn’t been able to get the steel material locally, as importing would have taken weeks. The exchange rate did play into our favour, along with the three-week shipping period (that the Far Eastern manufacturer would
Dias & Sons is able to cut steel up to 1300mm x 900mm, which made it possible for it to manufacture the large mould
have had to factor in), which gave us more time to complete the mould. Have the mould trials proceeded well?“We have run the mould twice and it has run smoothly on both occasions. We are cur-rently adding a few webs onto the product to strengthen it. The mould will be ready to run at the end of January as the company has orders it needs to start getting out.
“The customer has now commissioned an even bigger tool with the same sort of concept.”
Open view of the one half of
the pan mould
28 FEBRUARY / MARCH 2015
TEGA Industries South Africa has com-pletely overhauled its manufacturing plant to TÜV Rheinland ISO 9001 standards in order to supply markets in Africa and glob-ally with its unique rubber and engineered products.
The company invested millions of Rands in its new plant in Vulcania, Brak-pan to put itself in a position to grow the business to its full potential and integrate fully into the vast supply chain of the global Tega Industries Limited group. The investment in an extra-large facility, as well as trained technical and production staff, enables the company to supply locally manufactured goods to any one of the company’s operations in more than 72 countries worldwide.
According to Tega Industries SA quality manager, Siya Rala, all the necessary
factory to meet global standardsMillions of rand invested in new factory
processes, procedures, equipment and staff have been put in place and these have been subjected to a thorough audit from the TÜV Rheinland team.
International supply chain“By obtaining ISO 9001 accreditation through this internationally recognized au-thority we are able to establish our creden-tials upfront and allow our global operations to pick and place order from our facility with
“Likewise our customers in Africa and further abroad also have the assurance that they are dealing with a company that is able to meet the world’s highest quality require-ments in terms of design, manufacture, supply and service of products in mineral
“By implementing such a system we have
The investment in an extra-large
facility, as well as trained technical
and production staff, enables the company
to supply locally manufactured goods
to any one of the company’s operations
in more than 72 countries worldwide
NEW
S
aligned ourselves with our global outlets and manufacturing plants in Australia, Brazil, Chile, India and other manufactur-
Top to bottom approach
new equipment and laid out according to
methods possible. Tega Industries have also built a new lab with world-class facilities to enable it to undertake its own product testing, as well as in-process and
“Everything has been improved and standardized, right up to our packaging materials and methods so that our prod-ucts can be shipped easily and delivered undamaged to any destination in Africa or
www.tegaindustries.comTega Industries’ SA factory has been built and equipped to produce world-class mining, rubber and engineered products. Here, a worker supervises one of the large rubber presses
One of the well-used moulds on the company’s small rubber press line
Tega Industries SA quality
manager, Siya Rala,
says all the necessary
processes, procedures,
equipment and staff
have been put in place
and these have been
subjected to a thorough
audit from the TÜV
Rheinland team
Tega Industries overhauls
AUTOMOTIVE companies and suppliers
are working hard on autonomous driving
technologies and expect to come up with a
solution in the foreseeable future. A concept
car called XchangE, has been developed
by Rinspeed, Swiss developer, and
presented a vehicle in running order at the
2014 Geneva Motor Show, but also showed
that the new technology will change the
interior of a car completely.
One of the advantages of autonomous
driving is all the time freed up – on
average, two weeks per year! That is
more than 20,000 minutes the ‘driver’ can
use to relax, for entertainment or to work.
Car manufacturers want to create an
atmosphere conducive to using this extra
time to its best effect. Evonik Industries’
acrylic Plexiglas plays a vital part in
achieving this by offering designers creative
scope in terms of forming, and making it
possible to integrate a number of different
functions.
Plexiglas LED for edge lighting is used
in the car head liners as well as cross
car beam. The transparent, light-diffusing
Plexiglas creates an attractive interplay of
colours that can be changed according to
the desired mood.
Plexiglas has proven itself time and again
in the automotive market. It is weather
and age resistant and can be coloured as
desired, making painting and laminating
redundant. It can also be found in the
XchangE’s high-gloss covers, the cover
of the centre column, the rear spoilers,
the rear lamps covers, as well as in the
headlamp lenses.
CAN a professor working out of a modest
laboratory in a teachers’ college crack one
of the biggest technical challenges facing
plastics recyclers? Hong Kong Institute of
Education chemistry professor Stephen
Chow hopes so.
Chow’s research was spurred by a
growing problem – what to do with the six
million metric tons of solid waste Hong
Kong’s seven million people generate
each year. Hong Kong residents haven’t
caught the frugal bug like other Asian
powerhouses – per capita domestic waste
in 2011 was a hefty 1.36kg every day,
compared to 0.95kg in Seoul and 0.77kg in
Tokyo, according to the city’s Environment
Bureau.
At current rates, the city’s three
are expected to be full by the end of the
decade. And land is at a premium: Hong
Kong comprises a dinky 1014km².
Chow’s research focuses on ‘cracking’
or breaking down, polyethylene,
polypropylene, PVC and polystyrene,
and he believes these polymers can be
BRYAN Priestman of Intaplastics of
Durban, a man who knew the plastic
sheet market inside out, passed away
suddenly in June. He was just 59.
Bryan spent virtually his entire career
FBR Plastics and then Modek, the
manufacturer of roof sheeting and
merged with Ampaglas, the leader in the
SA sheet market, Bryan managed the
Ampaglas branch in Durban. He later
joined the breakaway EBF Plastics, but
Torch Plastics was established.
Torch Plastics was involved in the
sale of plastic sheet to a variety of
markets, much of its product was
imported, but Bryan and his team
specialised in sourcing the right product
for any application.
Bryan was a larger than life
character who had a joke for just
about everything. He was active too:
he played water polo for over 40
years, competed in seven SA water
polo masters championships, did the
Midmar Mile many times and was still
playing water polo actively last year.
Torch was purchased by Intamarket
group in September 2013, and now
operates as Intaplastics out of New
Germany in Durban. The company is
now being run by Ryan Easton, who
worked with Bryan for several years at
Torch and before that.
www.evonik.comwww.intamarket.co.za
Plexiglas offers designers creative scope in forming, making it
possible to integrate different functions
Claims to be working on a catalyst that takes just 10 minutes to crack the polymer
Autonomous driving in a pleasant setting: Rudolf Blass (left) from Evonik and Frank
Rinderknecht also have the Feelgood factor when driving in mind
Novel car concept uses
Plexiglas
Can Hong Kong researcher ‘crack’ waste plastics?
Torch Plastics man
knew sheet market
inside out (1955-2014)
Bryan Priestman in Hong Kong in 2010: like
many in the industry in South Africa, and
globally, Bryan sourced material from China,
with Hong Kong being the main transit point
30
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Industry news 30-31.indd 30 2015/02/17 4:14 PM
THE National Pricing Strategy for Waste Management Charges
has been gazetted, and the implications of the legislation could
be a ‘game changer’ for the industry.
The document was signed by the Minister of Environmental Affairs
Edith Molewa on 2 February, and members of the public (and notably
individuals involved in the processing of plastic, composites and
rubber materials as well as recycled materials) have 60 days in
which to make representations or objections to the Minister.
The strategy outlined was addressed at a joint meeting
involving the Department of Environmental Affairs (DEA) and
the Waste Management Forum on 13 February, with some
interesting strategies and opportunities being outlined.
The aim of the National Pricing Strategy for Waste Management
(NPSWM) is to provide the basis and guiding methodology for
setting of waste management charges in South Africa.
The ‘Waste Act’ allows for the targeting of economic instruments
encourage a change in behavior towards the generation of waste
and waste management by all sectors of society”. The Waste
Act, as amended in section 13B, calls for an Act of Parliament
to give effect to the pricing strategy, including details on 13B(b)
determination of waste management charges and the review of
these waste management charges from time to time. Section
13B(c) includes procedures for collection of charges through the
use, recycling or recovery of waste and the ‘polluter pays principle’.
practices
implementation of approved guidelines, norms and standards
management of the disbursements of incentives
monitoring of the impacts of incentives and disincentives
including in previously disadvantaged communities
The Waste Act directly allows for the implementation of
economic instruments through what it refers to as ‘priority waste;’
The objectives include reducing the generation of waste;
recycling and recovery; and supporting the growth of a Southern
African (regional) secondary resources economy from waste.
South Africa is estimated to generate 108 million tonnes of waste
a year (as at 2011), of which 98 million tonnes (or 90%) is disposed
secondary resources are mostly lost to the South African economy.
than 20% for tyres, plastic and WEEE (waste electrical and
By international standards, certain waste streams generated in
South Africa have achieved encouraging levels of recycling through
voluntary programmes, while other waste streams are lagging
behind that of other developed and developing countries.
outlines the ‘potential economic instruments’ for solid waste
Downstream instruments:
Upstream instruments:
Subsidy-based instruments:
based instruments are not elaborated on further in the document.
downstream recycling and recovery markets,” the statement said.
The draft regulations, listed under ‘Documents for Comment,’
can be accessed at
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Dept of Environment Affairs proposes system to incentivize reuse, recycling and recovery
The build-up of plastic scrap in Hong Kong, particularly
along its coastline, may be a thing of the past if Professor
Stephen Chow cracks the code and manages to reduce
polymers back to organic fuel
Draft regulations make provision for waste charges
Can Hong Kong researcher ‘crack’ waste plastics?
reduced back to organic fuel. Cracking
polymers requires a combination of heat
and pressure — pyrolysis, and sometimes,
a catalyst. The problem is generating those
high temperatures and pressure — always
recycling. Chow claims to be working on
a catalyst that takes a scant 10 minutes to
crack the polymer. The catalyst works at
low pressure and temperature, resulting in
and rings that make up plastics can take
from 20 minutes to an hour. Doing this
eliminates the need to bury the scrap in
greenhouse gas.
spray and dish detergent. His research is
On the output side, he’s still unsure
acid. And he’s testing the emissions
carcenogenic particulate matter.
He readily acknowledged that work
hasn’t begun on the hard part of scaling up
his technique to handle the 1,100 metric
tons of plastics Hong Kong throws away
every day.
www.plasticsnews.com
www.PlasticsNews.com
www.sawic.environment.gov.za
Industry news 30-31.indd 31 2015/02/17 4:14 PM
BY DR NIALL MARSHALL
THE second most common question I
have been asked recently is ‘what effect
will the drop in oil prices have on the
polymer producers in the Middle East?’
A good question. A tough question. A
question that I don’t have an answer
for, but a question that has been much
debated over the last few months by
everyone from consultants to suppliers,
engineering contractors to customers,
and of course the polymer producers
themselves. And the consensus is… well,
there is no consensus!
The reason why there is no consensus is
because it is complicated. Complicated in
terms of the products that are co-produced
from a ‘barrel of oil’,
complicated in terms of
the costs of producing
petrochemicals,
including polymers, and
complicated in terms
of the links between
costs and price. To
understand why (in
the space of a single
week, predictions are
made by analysts that the oil price will
drop below $40/barrel, while the CEO
of an Italian oil company is warning of
prices over $200/barrel) it is necessary to
through the chemistry and economics of
petrochemicals because the answer will
depend on which of a number of competing
the price of oil at any time.
Chemistry plays an important part
First the chemistry: Petrochemicals
are chemicals consisting mostly of
carbon and hydrogen (hydrocarbons)
usually separated out from crude oil
or natural gas or products synthesized
using chemicals found in oil and gas.
Products used for energy, whether as
transportation fuels, in heating or power
generation, are not considered to be
petrochemicals, even though more than
90% of the products produced from crude
oil or natural gas are fuels.
Natural gas contains molecules made
up of one to four carbon atoms including
methane (C1 meaning it is made up of
one carbon atom), ethane (C2 containing
two carbon atoms), propane (C3) and
butane (C4). Natural gas is usually used
as a fuel for heating and
cooking (most city gas
distributed through pipelines
is methane, propane is
supplied in cylinders for
gas braais, butane is used
in lighters, and LPG is
a mixture of butane and
propane) but they can
also be used as ‘building
blocks’ for other chemicals,
for example ethane and propane can
be converted to ethylene and propylene
respectively which are the raw materials
for polyethylene and polypropylene.
Crude oil mostly consists of molecules
containing 5 to 50+ carbon atoms
although it may also contain smaller
molecules (referred to as ‘associated
and separate it into different fractions
based on the size of the molecules. The
most important fractions in crude oil
are the C5-C10 ‘light distillates’ used to
make petrol and the C10-C18 ‘middle
distillates’ used for kerosene, diesel and
jet fuel. Less important ‘heavy distillates’
(C18-C25) are used for lubricants and
fuel oils while the heavier residual
fractions (C25-C50+) include greases,
waxes and asphalt.
fractionate the crude oil, to separate
out the components that can be used
directly and to send the other fractions for
further processing – and this is where the
economics start to becomes important.
All these hydrocarbon molecules can
be transformed into other molecules:
naphtha can be used in fuel or converted
into ethylene and propylene to be used to
make polymers.
Not all crude oil the same
Another important point to consider is that
not all crude oil is the same. A ‘light crude’
contains more light- and middle-distillates
than a ‘heavy crude’ which contains
more of the heavy distillates and residual
fractions which need to be broken down to
the economically more useful molecules.
As the most important fractions are those
used to produce transportation fuels
(petrol, diesel and jet fuel) the value of a
they contain more of the light and middle
distillates and there is less need for further
processing. An oil with relatively more
light-distillates than medium-distillates will
produce less diesel than one with more
medium-distillates. Heavier crude oils
Large quantities of low cost oil is found in the Middle East – even at $25/barrel
many of these
32 FEBRUARY / MARCH 2015
Low oil prices not a cause for gloom & doomfor Middle East polymer producers
May increase importance of polymers to the Middle East economies as a way
to increase value of exports
MIDDLE EAST feature.indd 32 2015/02/17 9:25 AM
FEATURE
Big quantities of low cost oil in Middle
East
Overall optimism in the regional oil and
gas industry
really
NIALL CAN BE REACHED AT: [email protected]
FEBRUARY / MARCH 2015 33
MIDDLE EAST feature.indd 33 2015/02/17 9:25 AM
THE Automotive Division of the Society of Plastics Engineers’ (SPE®) celebrated its 44th-annual Automotive Innovation Awards Competition at the end of 2014, the oldest and largest recognition event in the automotive and plastics industries.
The Safety category winner also was the event’s Grand Award winner selected by a panel of Blue Ribbon judges as the year’s Most Innovative use Plastics. Dozens of teams made up of OEMs, tier suppliers, and polymer producers submit nominations describing their part, system, or complete vehicle module and why it merits the claim as ‘Year’s Most Innovative Use of Plastics’.
This annual event typically draws 600-700 OEM engineers, automotive and plastics industry executives, consultants, and media.
DESIGN
34 FEBRUARY / MARCH 2015
Most innovative use of plastics
Grand Award Winner & winner in the Safety category
Active glove boxFord Motor Co, 2015 Ford Mustang sports car
System supplier: Faurecia Automotive System
Material processor: Faurecia Interior Systems
Material suppliers: Mitsubishi Chemical Corp / Advanced Composites, Inc.
Resins: TP850N, ADX5028 & ADX5017 TPO
Tooling/equipment supplier: Extol, Inc.
airbag is integrated with the glove-box door, reducing weight 65% and space
woven textile airbag, a special bladder is hot-plate welded to the door and then
hermetic seal. This saves $5-10 USD/car while providing consumers with more
Panoramic sunroof frameHyundai Motor Group, 2015
Kia Sorento CUV
System supplier: Inalfa Roof Systems Korea
Material processor: Inalfa Roof Systems, Korea
Material supplier: GS Caltex
Resin: Hiprene ALC12B Polyamide 6
Tooling/equipment supplier: Hyundai Motor Group
This large but very light panoramic
reinforced thermoplastic, which has been optimised for density, mechanical properties, and reasonable cost. This
thermoplastic application in a sunroof frame. It allowed 33 steel parts to be integrated into just four reinforced plastic ones.
GRAND
WINNER
Automotive innovation
Body Exterior
at its bestBody Interior
Second-row seat backFord Motor Co, 2015 Ford
Mustang sports car
System supplier: Continental Structural Plastics Inc.
Material processor: Continental Structural Plastics Inc.
Material supplier: Hanwha L&C
Resin: GMT 45% GF unidirectional
Tooling/equipment supplier: Century Tool & Gage
This second-row seat back successfully meets the extremely challenging ECE luggage-retention load case through the use of unidirectional glass-reinforced GMT composite rather than typical steel. The compression-moulded design, which required over 100 iterations of FEA
eliminates
from the earlier steel design and saves 3.1 kg/car in a thinner construction that also is easier to install.
Chassis/Hardware
Co-ex thermoplastic coolant tubeRenault Group, 2015 Renault Twingo city car
System supplier: Tristone Flowtech
Material processor: Tristone Flowtech
Material supplier: DuPont Automotive
Resin: Zytel LC6200 PA612
This co-extruded coolant tube with patented bellows design replaced aluminium tubing and rubber hose while meeting all the high-temperature and high-pressure demands of the coolant system. The co-ex tube uses functionalized high temperature PP with hydrolysis-resistant PA 6/12 to withstand internal temperatures to 125 C and external temperatures to 150 C.
formability vs. previous technology.
Hall of Fame
General Motors Co, 1984 E/K Platform
System supplier: Nexteer Automotive
Material processor: ABC Group Inc.
Material supplier: DuPont Automotive
Resin: Hytrel TPC-EC
(TPE) constant velocity joint (CVJ) half-shaft drive-axle boot seal used on 1984 MY E/K platform produced by then General Motors Corp. was selected as the 2014 Hall of Fame winner. This application was a far more robust CVJ sealing solution that also was lighter, more durable, and less costly than the injection-moulded rubber boots it replaced. It has been in continuous use on GM cars and trucks for 30 years, and 85% of front-axle CVJ boot seals on light-duty vehicles worldwide now use TPE in this application.
Thermoplastic CV/J boot seal
FEBRUARY / MARCH 2015 35
Process/Assembly/Enabling Technologies
Single-collimator moulded LED lensFord Motor Co, 2015 Ford F-150 pickup
System supplier: Ventra Plastics Div. of Ventra, Group Inc. /Flex-N-Gate Corp.
Material processor:
Material supplier: Bayer MaterialScience
Resin: Makrolon LED 22.4.5 PC
Tooling/equipment supplier:
DESIGN
Materials
Metallic appearance finish panelsFord Motor Co, 2015 Ford
Mondeo sedan
System supplier: International Automotive Components
Material processor: Key Plastics Löhne GmbH
Material supplier: Samsung Chemical
Resin: Luminous LX-1098 PC/ABS
Tooling/equipment supplier: Michael Tool & Mold Ltd
36 FEBRUARY / MARCH 2015
Cellulose fibre composite console armrestFord Motor Co, 2013 Lincoln MKX luxury CUV
System supplier: Johnson Controls, Inc.
Material processor: Johnson Controls, Inc.
Material supplier: Weyerhaeuser NR Co.
Resin: Thrive 20DX235 PP
Environmental
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MACHINERY (PTY) LTD“One total solution for Injection Moulding”
Untitled-1 1 2014/03/26 8:33 PM
Powertrain
Crankshaft cover with integrated oil sealVolkswagen AG, 2014 MDB
engine platform
System supplier: Kaco GmbH + Co. KG
Material processor: Engel Austria GmbH
Material supplier: DSM Engineering Plastics B.V.
Resin: EcoPaXX Q-HG10 PA 4/10
Tooling/equipment supplier: Elmet GmbH
DESIGN
38 FEBRUARY / MARCH 2015
German university revolutionises electric
car design, production methods
www.stratasys.com
A StreetScooterC16 is expected to typically weigh 450kg excluding battery, has a range of 100km and delivers a top speed of 100km/h, making it an ideal city vehicle
3D printedstreet scooter
Deadline loomsfor heavy metal-free pipes ruling
MANUFACTURERS of PVC pipes in South Africa have only a couple of months left to ensure that their products are compliant with the Southern African Bureau of Standards’ (SABS) ruling that all locally manufactured pipes be free of heavy metals by July 2015.
This ruling was announced by
Sibongile Dhlamini, General Manager
October 2013, following an amendment
of a series of standards by the technical
committee of the SABS Standard
Division.
The Southern African Plastics Pipe
Manufacturers Association (SAPPMA),
representing more than 80% of the
country’s pipe manufacturers, welcomed
the announcement.
SAPPMA members started process as
early as 2006
“SAPPMA’s aim is to support the industry
in promoting quality products. To this
end, we work closely with the SABS in
matters of standards and quality through
implementing various quality-assurance
measures and initiatives, as well as
demanding additional good practice
measures from our members,” explains
SAPPMA chairman, Jan Venter.
According to Venter, SAPPMA
members had already embarked on
a voluntary removal of heavy metal
stabilizers from their PVC pipes as
early as 2006. The policy was fully
implemented by SAPPMA in July 2009
and applied to drinking water systems as
well as sewer, drainage and mine pipes.
Although lead does not leach from
the plastic pipes and does not pose
any danger to people once installed,
SAPPMA felt compelled to create a
safer environment for the manufacturers
where lead poisoning does pose a
risk for their workers. As a result, all
PVC pipe manufactured by SAPPMA
members are lead-free and are stabilised
with environmentally friendly materials
such as Calcium Zinc or organics-based
stabilisers instead.
Supports SAPPMA’s life cycle
thinking
“Removing heavy metals from their pipes
PVC pipes was done at considerable
cost to our members, but was wholly
supported because it was in line
with SAPPMA’s life cycle thinking,
took into account end-of-life issues,
waste management options and was
based on health and environmental
considerations,” Venter said.
“Adherence to the policy has been a
requirement for SAPPMA membership
over the past eight years, and as such
has formed part of the regular SAPPMA
factory audits”, he added.
The SABS gave local manufacturers
window period
of 24 months to
get their house
in order and to
comply with the
new relevant
standard
requirements. However, this grace
period ends on the 31st of July 2015,
after which companies found to be non-
compliant could see steps taken against
them by the Standards Bureau. Pipes
bearing the SABS mark of quality will
also have to be re-submitted for testing
in order to be issued with new permits.
“In the interest of the consumer and
good business practice, the SABS
strongly promotes the highest possible
product quality standards as well as
environmentally friendly manufacturing
processes and materials. We urge
companies to ensure they comply and
that all heavy metals are removed from
their manufacturing process in time for
the deadline,” said Venter.
PVC pipe manufacturers needing
assistance with the process can
contact SAPPMA on (011) 314-4021 or
via email at [email protected]
For more information about the new
standard, visit https://www.sabs.
co.za/Business_Units/Standards_SA/
Controls/Published_Standards/
PS138H.PDF
PVC pipe manufactures have until July to ensure compliance
www.sappma.co.za
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40 FEBRUARY / MARCH 2015
According to
SAPPMA chairman,
Jan Venter, SAPPMA
members had already
embarked on a
voluntary removal
of heavy metal
stabilizers from their
PVC pipes as early as
2006. The policy was
fully implemented
by SAPPMA in July
2009 and applied
to drinking water
systems as well as
sewer, drainage and
mine pipes
ASSOC NEWS - SAPPMA-1.indd 40 2015/02/17 10:37 AM
CONTACT US
P.O. Box 1070, Kempton Park, 1620
Johannesburg, South Africa
Tel : +27(11) 552 6200
Fax : +27(11) 552 6499
Email : [email protected]
SUN ACE South Africa (Pty) Ltd
12 Innes Road, Jet Park 1459,
East Rand
Johannesburg
GPS: S26° 09.957’
E028° 12.610’
The World’s leading
producers of PVC additives
and metallic stearates
www.sunace.co.za
SA Plastic SunAce FP Dec-Jan FA.indd 1 2013/11/15 10:37 AM
THE Southern African Plastic Pipe Manufacturers Association
(SAPPMA) used the occasion of its 10th Annual General
Meeting to announce exciting changes to the Association’s
Board of Directors and announce the winners of the
Association’s 2014 Merit Awards.
Commenting on SAPPMA’s successes and highlights of
the past year, Venter said they had seen evidence that the
association’s hard work to ensure quality standards are being
adhered to, is paying off. “Our recent rounds of pipe quality
surveys have all shown a positive downward trend, indicating
that we are seeing fewer incidences of non-conformance in
the pipe production,” he said.
New board of directors
The SAPPMA Board consists of six or seven nominated
members of the industry who are tasked with providing
assistance to the Association’s direction, strategy,
Chairman Jan Venter welcomed the following new directors
for 2015: Gerhard Kotzee (DPI Plastics/Dawn Infrastructural
division), Hein Momberg (Fiberpipe), Ronnie Kruger (Marley
Pipe Systems), Tony Dean (Rare Plastics), David Mokomela
(Sasol) and Bernhard Mahl (Safripol).
Merit Award winners
The winners of the 2014 Merit Awards were also announced,
based on their contribution to SAPPMA and frequency of
attending meetings. The winners of this year’s awards were
Renier Snyman of DPI Plastics, Ian Venter of Marley Pipe
Systems, Ralph Mosikidi Marley Pipe Systems and George
Diliyannis of Safripol.
manufacturing environment, our members have managed to
not only to hang on to their businesses, but in some instances
even grow their operations. We are proud to represent more
than 80% of the plastic pipe market that is building a name
and a reputation for being strong, resilient and tenacious. We
are looking forward to 2015 and will meet every challenge and
opportunity that comes across our path with the same can-do
attitude that has come to exemplify
our industry,” said Jan.
ENTRIES are open for the South African Plastics Pipe
Manufacturers’ Association (SAPPMA)’s 6th annual golf day,
which takes place on Friday, 27 March at the Blue Valley
Golf and Country Estate in Midrand.
Named for the blue skies and open country of its
surroundings, this Gary Player designed Blue Valley is a
perfect blend of hospitality, sport and nature. It is situated
conveniently between northern Johannesburg and Pretoria,
and offers a location second to none in the Gauteng area.
The entry fee for fourballs has remained unchanged from
previous years at R3 500. Various sponsorship opportunities
are available for companies in the plastic pipe industry to
promote their corporate brands on the day, including:
Tee/Hole at R4 000
Halfway House at R4 000
Caps/Shirts at R6 000 (logo)
Corporates are also welcome to sponsor team prizes
(4 items of your choice)
“The SAPPMA golf day is a hugely popular event and a
day on the industry calendar that nobody wants to miss,”
said SAPPMA CEO Jan Venter. “Last year’s event saw 80
course tested every aspect of the players’ game and provided
even the longest hitters with a challenge. We are looking
forward to an equally exciting course and hosting a day that
is punctuated with a sense of camaraderie and fun”.
A prize giving will conclude the day’s activities. For more
information or entry forms, visit the SAPPMA website or contact
Louise Muller on email on [email protected]
SAPPMA announces
new board of directors at AGM
SAPPMA golf day on 27 March
www.sappma.co.za42 FEBRUARY / MARCH 2015
Jan Venter with the winners of this year’s awards, Renier Snyman of
DPI Plastics, Ralph Mosikidi of Marley Pipe Systems, Ian Venter of
Marley Pipe Systems. Absent: George Diliyannis of Safripol
ASSOCIATION NEWS
ASSOC NEWS - SAPPMA-1.indd 42 2015/02/17 10:37 AM
To be held at the
CATHEDRAL PEAK HOTEL
THE DRAKENSBURG
KWAZULU NATAL, SOUTH AFRICA
Thursday 18 Juneto Sunday 21 June 2015
Programme
Thursday 18 June 2015:
Delegates arrive
Friday 19 June 2015:
Conference commences
Saturday 20 June 2015:
Conference continues
Sunday 21 June 2015:
Delegates depart
For more information on this event visit
www.iom3.co.za
Contact
Wendy Knott Craig
The PR Junction
Email: [email protected]
Mobile +27 (0)73 201 8699
BOOKINGS CLOSE WEDNESDAY 13 MAY 2015
22nd National RubberConference
You are invited to attend the IOM3 Southern Africa
We look forward to welcoming you at the 2015 Conference
PVC recycling in SAto be placed under the spotlight
THE Southern African Vinyls
Association (SAVA) has tasked Annabé
Pretorius of Plastix 911 to conduct its
and size of PVC recycling currently
According to the South African
40 recyclers around South Africa that
all focus on building and construction
but it has to be seen in the context of
Companies who want to ensure
they are part of the survey, or
who have any queries, should
contact Annabé at email: annabe@
absamail.co.za
Approximately 40 recyclers in South Africa recycle PVC products
Delanie Bezuidenthout (SAVA CEO) and Annabé Pretorius of Plastix 911. SAVA has tasked Annabé
ASSOCIATION NEWS
www.savinyls.co.za
FEBRUARY / MARCH 2015 43
ASSOC NEWS-POLYCO+IOM-1.indd 43 2015/02/17 10:37 AM
PETCO’S ‘Legacy Project,’ through which the
PET recycling business is assisting challenged
introduction of a range of quilts manufactured from
recycled PET fabric and rPET batting.
The fabric and batting are made from ‘repurposed’
PET bottles that were collected and processed in
South Africa, together with project partners Propet and
Romatex. The quilts can be folded into a pillow with a
limited living spaces and even homeless individuals.
to organisations that run ‘swop shops’ in the Western
Cape in December.
hundreds of women and children in disadvantaged
communities, who bring recyclables – mainly PET bottles – in
exchange for tokens that can be used at the swop shops to
‘buy’ essentials,” said Lisa Parkes, marketing manager of
PETCO.
In due course the quilts will also be made available to swop
shops and other similar channels in other parts of the country.
PETCO last year celebrated its 10th anniversary, and
the Legacy Project honours the decade of achievement,
highlighting the value of PET and its end markets, and
acknowledges PETCO’s role as part of a larger community.
“We want to contribute in a tangible way to show that
we care about our communities. The project represents
caring combined with conscience,” said Parkes. “We are
demonstrating that recycling and repurposing of recycled
materials has far-reaching implications. Not only does
recycling protect natural resources and address some of the
are in themselves valuable – and in a case like this, can put a
smile on the face of a needy child.”
A number of Swop Shops are now operating in the Western
Cape, in Hermanus as well as at two
informal settlements in Cape Town.
THE Association of Rotational
Moulders of Southern Africa
(ARMSA) will be holding its Annual Conference
Rotation 2015 on 20 and 21 May at The Blades
Conference Centre in Pretoria, Gauteng.
The theme for Rotation 2015 will be ‘The Good the
Bad and the Ugly of Rotational Moulding’ focussing
on aspects of moulds, machines, outsourcing,
production management and control, material, energy
consumption and other exciting relevant topics ...
Rotation 2015 promises to be enlightening, with
both international and local speakers, including
comprehensive presentations from local moulders.
Furthermore, the ARMSA committee welcomes
any form of sponsorship from players in the industry.
Should you be interested in sponsorship, kindly please
also contact Petro Geldenhuys at [email protected]
44
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Collectors obtain tokens which can then be
used at ‘Swop Shops’
www.petco.co.za
www.armsa.co.za [email protected]
ASSOCIATION NEWS
Legacy Project reaches out a comforting hand to the needy
Cheri Scholtz (PETCO), Maria Van der Westhuizen (Recycle Swop Shop),
Helmut Höck (Romatex) and Jorge Fonseca (Propet) with one of the quilts
made from rPET that were introduced to the market in December
The Good, the Bad & the Ugly of Rotational
Moulding at ROTATION
2015
ASSOC NEWS-PETCO+PCA+ARMSA-1.indd 44 2015/02/17 10:32 AM
CHOOSE THE NUMBER ONE.
Self-service. Redefined.
INTAREMAThe new system generation from EREMA.
Reaching perfect pellet quality at the press of a button: the new INTAREMA®
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Relloy S.A. (Pty) Ltd / 27 Mopedi Road
Sebenza / Evendale, 1609 / Gauteng
Tel: +27 11 452 3724 / [email protected]
www.relloy.co.za
PLASTIC convertors in SA are legally required to
Get your legally required
employee related posters
from the PCA
Leonie Coulson and Christo Steenkamp, both from Sebor, and
Belinda Ford and Belinda Geffen, both from Reinforce Hosing
Margot Viana
of Vee Plastics,
Carol Klomfass
of PCA and
Linda Lyons of
Pro-Viro
Vincent Keesenberg of Transpaco Bronkhorstspruit Maria Wilson, PCA legal advisor, Davel Kirsten and Hannes Smit of Trogtek
FE
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/ MA
RC
H 2
01
5 4
5
ASSOC NEWS-PETCO+PCA+ARMSA-1.indd 45 2015/02/17 10:32 AM
Will service approximately 3,000 households
Vaalpark recycling separation- at-source project launched
AFTER three years of planning,
preparation and resource mobilisation,
the Vaalpark recycling separation-at-
source project has been launched in
Vaalpark in northern Free State. The
project focuses on collecting recyclables
from approximately 3 000 households
around the Vaalpark residential area.
The Ikageng Ditamating Co-
operative, waste pickers that previously
responsible for collecting the recyclables
from households once a week. The
22-member co-operative sorts materials
at their site and then bales it before it is
sold to recyclers.
The Vaalpark recycling project has been
made possible through the contributions
of many sponsors and role-players. These
include all the Recovery Action Group
(RAG) members; Collect-a-Can, the Glass
Recycling Company, Plastics|SA, Tetra
Pak, Polyco, PRASA, PETCO and the
Polystyrene Packaging Council.
PISA KZN entered a team in the Chatsworth Drug Rehabilitation
Golf Forum annual golf day. The team was sponsored by
GPS Plastics and comprised Anan Govender, PISA national
chairman Garth Taylor, GPS director Kevin Govender and
national Springbok selector Ian McIntosh. The team came 5th
and if it was not for the intermittent rain the day would have been
a great success. GPS through Kevin Govender does a great deal for
different charities in KZN and has supported the Drug Forum for the
past 12 years
Delanie Bezuidenhout (CEO of the Southern African Vinyls
Association), Belinda Booker (PETCO project manager) and
Duart Hugo (DESTEA deputy director) celebrate the launch of the
Vaalpark recycling separation at source project
The Ikageng Ditamating Co-operative comprises waste pickers that previously
materials at their site and then bales it before it is sold to recyclers
46 FEBRUARY / MARCH 2015
www.petco.co.za
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AMOGELANG Secondary School in Soshanguve, Pretoria was
crowned the winner of the 2014 PEN-Schools Recycling competition.
PEN-Schools is a joint venture project between the PET Recycling
Company (PETCO), the Wildlife and Environment Society of South
Africa (WESSA) and Nampak and aims to promote waste reduction
activities at schools and their respective local communities.
Throughout the year, participating schools were encouraged to
collect as much recyclable material as possible. Efforts culminated
in September with the collection of 22 tons of recyclables of which
close on 4 tons of PET bottles
Soshanguve learners win
2014 PEN-Schools Recycling
PISA KZN enjoys Chatsworth
Drug Rehabilitation Golf day
ASSOC-PISA+PETCO-1.indd 46 2015/02/17 10:33 AM
separation- at-source project launched
“This has been a long
journey and the efforts of all the
contributors cannot be taken for
granted,” said Belinda Booker,
PETCO’s category B projects
manager.
PETCO has been instrumental in
training the co-operative members
and also providing equipment
support. PETCO sponsored eight
cages for recyclable collection
which will be placed at shopping
centres and schools. The cages will
be collected once they are full and
Co-operative. According to Booker,
“PETCO is committed to offering
ongoing support to ensure that the
project becomes a success.”
Government involvement
collection for recycling project in
which all spheres of government
are involved. The National
Tourism and Environmental
fully support the project.
great example of a successful
public-private partnership model
and we are very proud to be part
that more local residents will
of recycling for both the local
economy and the environment.”
PETCO sponsored eight of the cages for recyclable
collection which will be placed at shopping centres
and schools. The cages will be collected once they are
of the compactor
Judd Lombard (UJ)
Manhole cover
FEBRUARY / MARCH 2015 47
www.petco.co.za
ASSOC-PISA+PETCO-1.indd 47 2015/02/17 10:33 AM
48 FEBRUARY / MARCH 2015
PLASTIC associations globally are
Plastics|SA is a signatory to the
4-6 June
waterways.
www.plasticsinfo.co.za
185 separate projects to combat plastic marine debris
Renewedcommitment
The 5 Gyres Institute recently released new
research that estimates some 5.25 trillion
plastic particles weighing about 269,000 tons
All stakeholders in the area were
which has considerable recycling
www.polystyrenepackaging.co.za
ASSOC-PLASTICS SA-1.indd 48 2015/02/17 10:36 AM
CONTACT US: Tel/fax: 032 944 2860 | www.quadplastic.co.zaByron Nunes: 082 778 8713 ([email protected]) | Neville Lategan: 082 498 2198 ([email protected])
Quality machinery and componentsccpQUAD
lastics
THE Sustainability Division of Plastics|SA was honoured
for the commitment it has shown over the past 18 years
to rid the environment of plastic litter by being awarded
the Corporate External Award at the Ezemvelo KZN
Wildlife/Old Mutual Excellency Awards for 2014.
“Forming partnerships is an indispensable
component of Emzemvelo KZN Wildlife’s responsibility
to protect the biodiversity in our province. Since 1996,
Plastics|SA has partnered with us in helping deal with
the problem of marine litter,” said Dr Bandile Mkhize,
CEO of Ezemvelo KZN Wildlife.
“We are particularly grateful for their support,
which now amounts to some 18 years of sustained
assistance. Their generous contribution has
included providing more than 400 000 clean-
up bags for KZN beach clean-ups, a monetary
turtle research and sponsoring a boat for clean-ups
in the Durban Mangroves,” he added.
Receiving the award on behalf of Plastics|SA,
Sustainability Director Douw Steyn emphasized
that sustainability is one of the six core functions of
Plastics|SA, the mouthpiece of the entire plastics
industry.
“The plastics sector is uniquely placed to meet
the needs of a sustainable society and to deliver
solutions to many challenges, such as climate
change, water scarcity, resource usage and energy
recovery,” Steyn said.
“Looking after the environment is a key driving
take. We have been mandated to ensure a vibrant
and sustainable plastics industry in South Africa, and
take this task very seriously. We are relentless in
our efforts as we educate people that “Plastics don’t
litter. People do.” Plastic litter doesn’t belong in the
be recycled to create new useful products without
adding strain on our natural resources,” he explained.
Steyn concluded that they are very proud of
receiving the award and appreciated the recognition
Ezemvelo KZN Wildlife has shown to the association.
“We look forward to building an even stronger
partnership in the years to come as we are united in
our mutual passion to protect the biodiversity in the
province and therefore support each other
in every way we can”.
ASSOCIATION NEWS
Receiving the
award on behalf
of Plastics|SA,
Sustainability
Director Douw Steyn
emphasized that
sustainability is one of
the six core functions
of Plastics|SA,
the mouthpiece of
the entire plastics
industry
FEBRUARY / MARCH 2015 49
www.plasticsinfo.co.za
Plastics|SA winsprestigious environmental award
ASSOC-PLASTICS SA-1.indd 49 2015/02/17 10:36 AM
Myplas
Italian Plastic Technologies
Mountain View Plastics
Polymark Recycling
EMET
Moiware t/a Coastal Recycling
POLYCO announces names of successful applicants for second round of proposals
Mandy Naudé, chief executive
with successful applicants from
four of the six companies that will
receive total investment loans of
R7 million over the next six months
recycling operations. From left: Riaan
Brenkman of Mountain View Plastics,
Eban and Miri Moses of EMET, Cris
and Vavi Vassarotti of Italian Plastics
Technologies, Mandy Naudé and Rudi
50 FEBRUARY / MARCH 2015
R7 million
www.polyco.co.za
POLYCO’s goal is to achieve a recycling rate of 35% (or 239
000 tons)recycled out of a total
market share of an estimated 680 000
tons by 2020.
ASSOC NEWS-POLYCO+IOM-1.indd 50 2015/02/17 10:42 AM
374C2726C 279C 116C 368C
637C
716C
214C
52 FEBRUARY / MARCH 2015
NEW CASTLE, U.S.A. – A high-rate
plasticizing unit incorporating an
innovative screw design produces
enhanced-quality melt at rates that
make possible shorter cycles in
injection moulding of high-speed,
thin-wall packaging, says Nordson
Corporation of the United States.
The Nordson Xaloy Quantum™
plasticizing system includes a barrier
screw designed to increase the rate of
plastication for unmelted material while
minimizing shear forces on polymer that
is already in a molten state. Along with
the innovative screw, Nordson supplies
a custom-designed poppet-style
channels prevent polymer degradation
and whose rapid shut-off ensures shot-
to-shot consistency.
“The Quantum system delivers
optimum melt quality at a rate that
reduces actual screw recovery time
by 10 to 15% in comparison with
existing high-performance plasticizing
units, enabling it to keep pace with
the exceedingly short cooling times
in high-volume production of thin-wall
parts,” said Tony Genova, engineering
supervisor for screw manufacture.
“Moulders who use the Quantum
processing system are often able
to reduce cycle times, increasing
on investment.”
A barrier screw has a middle section
designed to separate solids from molten
polymer so that the heat and shear
forces applied to the solids can be
maximized, increasing the plastication
rate.
“In the screw for the Quantum
system, we strive for a mass balance
throughout the length of the screw,
accommodating the differential between
the bulk density of the pellets being fed
into the system and the density of the
molten polymer,” said Mr Genova.
Nordson custom designs each screw
for the Nordson Xaloy plasticizing
requirements.
Nordson Corporation engineers,
manufactures and markets differentiated
products and systems used for the
precision dispensing of adhesives,
coatings, sealants, biomaterials,
polymers, plastics and other materials,
UV curing and plasma surface treatment,
all supported by application expertise and
direct global sales and service. Nordson
serves a wide variety of consumer non-
durable, durable and technology end
markets including packaging, nonwovens,
electronics, medical, appliances, energy,
transportation, construction, and general
in 1954 and headquartered in Westlake,
Ohio, the company has operations and
RJ CORPS, the biggest franchisee of PepsiCo
line from Reifenhäuser Kiefel Extrusion at the plant
of Varun Beverages located in Alwar, Rajasthan.
for packaging of Pepsi bottles and water bottles
Reifenhäuser Kiefel Extrusion has equipped
the line with state-of-the-art Evolution Ultra Range
extruders and Ultra Cool technology for high output
systems, with an output of up to 700kg/h with
Varun’s recipes.
The line is also provided with an Evolution WP
winder of the newest generation ensuring fast
winding and multi up rolls. The industry leading
Evolution C automation system developed by
Reifenhäuser Kiefel features an intuitive user interface and
24“ touch screen panel that enables Varun Beverages’
employees to get familiar with the operation of the line, rapidly
and without problem.
New plasticizing unit
boosts thin-wall packaging output
Ultra Cool technology for high output
Nordson Xaloy plasticizing system reduces screw recovery time by 10-15%
EQUIPMENTNew screw –
EQUIP-NORDSON+REIFENHAUSER.indd 52 2015/02/17 10:20 AM
MOULD & Die Solutions (MDS) have a new alliance with yet another prestigious Milacron group company, Tirad. Together with their association with DME, this allows Mould & Die Solutions to offer a unique service to the toolmaking industry in South Africa.
Tirad is a specialist, high precision Czech manufacturer of custom mould bases, specialising in large size, multi-cavity mould bases. Whilst Tirad do not produce complete injection moulds, their mould bases are supplied to toolrooms for
complete the mould or tool. Internationally this trend is adopted by the toolmaking industry to shorten the lead time in the mould manufacturing process.
Tirad’s services include:Complete production of custom mould bases, including plates, frames and various other components for injection mouldsHot runner manifold plates produced to manufacturers’
Specialist CNC machining, up to 10,000 x 3,500mm with a maximum weight of 20 tonsGun drilling with NC-dumper axis Mould base assembly complete with componentsDie casting and press tools
Mould production accounts for 92% of Tirad’s turnover – of which 100% is exported throughout Europe, as well as the USA, Canada and Ireland. Current market sectors serviced are medical and pharmaceutical, food and beverage packaging and
FEBRUARY / MARCH 2015 53www.tirad.cz www.m-d-s.co.za
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PET preforms.Quality is critical to
Tirad’s business – with EN ISO
their specialist CNC machining division), Tirad leave nothing to chance. Finish machining is done in a controlled air-conditioned environment and a 3D measured report is supplied with each work piece.
Mould base machining capacities available are:2,300 x 1,600 x 1,000mm maximum plate size12 ton plate weightGun drilling up to a depth of 1,500mm from one side, in diameters ranging from 4.0 to 44.45mmPositioning accuracies of +/-0.01mm/1000mm and diameters and pockets of +/-0.005mm
Tirad’s monthly capacity is in excess of 300 plates for multi-cavity injection moulds and eight large work pieces up to 20 tons per month, dependent on their complexity.
For more information or a quote, contact:Radek Dvorak – Tirad International Sales Manager, [email protected] Carter - Mould and Die Solutions, [email protected]
Tirad’s monthly capacity in excess of 300 plates for multi-cavity injection moulds
Tirad is a specialist, high precision Czech manufacturer of custom
mould bases, specialising in large size, multi-cavity mould bases
Super-sized high precision custom mould bases from Mould and Die Solutions & Tirad
High-quality pelletising of post-
EQUIPMENT
Provides plastic resin equivalent to virgin material for manufacture of high quality products
Virgin material is not entirely without defects – A high molecular polymer matrix out of PE with an MFI of 8 (on the left) embeds a gel with a very much lower MFI. The photo on the right shows a polymer defect in virgin material which found its way to the outer layer of a
Failure in fi lms –
impurities within the polymer matrix during the manufacturing process can become is displayed in these images: the left photo shows a hole in the
led to the damage. In this instance, a particle of poorly dissolved additive
A hole at the edge of an
of starch introduced into the polymer stream by a contami-nated silo transporter
54
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The S:GRAN recycling machine from NGR
High quality resin from production waste
The basic design of a modern shredder-feeder-extruder combination for the pelletizing of
provide excellent results, with the best systems
level of automation into account
Inserat_SAPlastics_2015_210x140mm_5mm.indd 1
Big enough to innovate,small enough to cooperate!
It takes sophisticated technology to make plastics recycling
sustainable and more efficient and to continuously improve pellet quality.
And it takes commitment to really be successful.
SIMPLY ONE STEP AHEAD
Next Generation Recyclingmaschinen GmbH
www.ngr.at
Visit us @ Austria Showcase
Plastic Industry in South Africa ^ March 09 - 13, 2015
www.technimac.co.za
Inserat_SAPlastics_2015_210x140mm_5mm.indd 1 28.01.2015 16:13:57
FEBRUARY / MARCH 2015 55
takes place in the temperature controlled extruder by applying as little shear as possible. Melt temperature as well as melt pressure should be maintained at the lowest possible level.
Besides keeping temperature and pressure settings under control, there are several other design aspects to consider:
plastic mass can accumulate;
and maintenance of any machine part
which comes into contact with the material;
molten plastic to minimise the shear applied to the material.
Filtration of the molten mass
to the level of contamination of the waste material versus the desired purity of the recycled pellets. In all plastic
impurities and separates them from the
demands, combinations of various different meshes are arranged to provide
plastics recycling.
www.ngr.at
If polymers with different melting points are accidentally mixed, it can result in a
on the right provides the cross-section view. The gel consists of HDPE which is included in a PP matrix
A classic ‘black spot,’ which is thermally damaged, cracked polymer. Black spots appear in the material because of
molten plastic mass
mer matrix. These particles are usually brought into the polymer stream by
using improper machine cleaning cloth and due to ineffective maintenance
design of machines
TAKE a global leader in providing
innovative engineering thermoplastic
solutions across the world and match
it with a South African organisation
that has an acclaimed track record
for importing, manufacturing and
distributing quality plastics for a range of
formula for a synergistic partnership.
January 2015 brought an exciting
dimension to the business of Ampa
Group (Pty) Ltd, with its appointment as
the sole distributor for SABIC Innovative
Plastics’ Lexan polycarbonate sheet
For Ampa Group, the distributorship
is a solid endorsement of its long
held commitment to innovation and
continuous improvement.
People power = business power
A key Ampa Group philosophy is
rooted in the belief that strategic
knowledge and cutting edge skills are
the cornerstones on which successful
businesses are built. To this end there
is relentless focus on hiring the right
people for the job and augmenting
their capabilities at every level with
continuous training and development.
Lexan is no stranger to the South
African market. For the past 32 years its
products have been used extensively
with great success. In a similar way,
Dean Treges and Victoria Majoni are
no strangers to Lexan products. As a
result, it made perfect sense for the
Ampa Group to bring them onboard. In
conjunction with their comprehensive
experience in dealing with Lexan
of the plastics industry will add
considerable value to the operations of
the Group and its respective customers.
The world’s most innovative portfolio
Particularly exciting is SABIC’s Lexan
Thermoclear polycarbonate sheet
multipurpose sheeting is available in
a variety of structures, colours and
Each lightweight sheet combines
ease of installation with excellent
thermal insulation alongside UV and
the product’s high desirability amongst
architects, builders and roofers is its
The availability of the sheeting in an
array of colours that includes clear, opal
white, solar control, blue, bronze, grey
and green makes it ideally suited for
residential, greenhouse and commercial
roof glazing, building facades
and claddings in addition to
skylights and walkways.
Lexan Thermoclear sheets
are obtainable with a range
of speciality coatings such
as Easy Clean which is a
innovation. With UV
protection on both sides
and a hydrophobic coating
on the outer surface, it
causes large droplets of
water to form which then
wash away dirt.
Thermoclear SunXP sheets are
ultra UV resistant and serve to lower
radiation, yellowing and loss of light
transmission. As an added bonus
they come with a 15 year guarantee.
Thermoclear Dripguard sheets
have a specially developed coating
on the inner surface that reduces
condensation droplets.
Ampa Group will also be distributing
9030 and WLS sheeting, both of
which have become something
of a necessity in South African
construction today. Combining high
impact resistance with excellent
optical clarity, the sheeting delivers
superior protection against intrusion.
Marguard sheeting has all the
properties of polycarbonate material
with an additional proprietary hard
surface coating on either one or both
sides. As a result it is highly resistant
to abrasion and damage caused by
weather conditions.
FEAT
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SABIC& AMPA Group
– chemistry for a sustainable synergyAn equation that works
A new monorail seating
solution for Bombardier Transportation, using injection-
moulding rather
plastic and traditional thermoset processing
methods, uses the high performance Lexan FST
3403 resin, suitable for its high impact resistance, malleability to develop visually attractive designs and its light weight
AMPA GROUP.indd 56 2015/02/17 10:19 AM
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Lexan sheet products that are directly extruded from
advantages over many other glazing materials, especially
when it comes to design freedom and thermal insulation.
The fact that they are lightweight makes for ease of handling
performance test.
Alongside the various types of sheeting, Ampa will also
leading market warranties and full support from their Head
Two separate organisations with a similar mindset
to adapt swiftly to the ever changing requirements of its
to improving quality of life in the environments in which
lives around the world on a daily basis, Ampa replicates
this on a smaller scale in sectors that include the printing,
packaging, automotive, fabrication, construction and
engineering industries; as well as professional disciplines
such as architecture, interior and exterior design and quantity
surveying.
also set its sights on expanding its existing footprint on the
African continent.
At present it has distributorships in Namibia, Zimbabwe,
However, given the business opportunities it has recognized
their chemistry gels and the economic alliance they have
established has all the criteria for a sustainable, mutually
SABIC’S Lexan Thermoclear PC
sport stadium, Arena do Grêmio,
AMPA GROUP.indd 58 2015/02/17 10:19 AM
IF ANY of the 3,200 bumpers moulded each day
for the Golf 6, Golf GTI and Golf Plus models at
Volkswagen’s plant in Wolfsburg, Germany, does
not pass the strict 100% visual inspection, it can
be directly recycled to provide high quality regrind.
Rapid Granulator has installed a custom tailored
area of the Volkswagen plant. While meeting the
automotive manufacturer’s high safety standards,
the granulation equipment also had to be
integrated in an existing production hall without
Jannis Piep, from the plastics business unit
‘Bumper Planning’ at Volkswagen and responsible
for the new granulator project, is pleased with the
implemented solution. “Rapid mastered the big
challenge we had come up with and supplied a
granulator tailored to our needs at a perfect price/
performance ratio,” she said.
design a granulator that would
be capable of being fed with
up to three scrap bumpers at
one time and grinding them in
one step into low-dust regrind
demands, Rapid selected a
model of its new 600 Series
providing a cutterhouse opening of 1,200 x 800mm.
The granulator has a rotor diameter of 600mm and
a rotor length of 1,200 mm. Maximum throughput is
1,000kg/hr.
“Of course we don’t operate the machine at
this capacity,” said Piep, “but we need its large
A characteristic feature of the Rapid granulator
series is its ‘open-hearted’ design. The cutterhouse
maintenance and cleaning work to be performed
by one single operator. “The ease of handling
saves us time and money,” explained Piep. Thanks
to its double scissors cutting action, the machine
will grind even large parts at relatively low forces,
As to the constructional circumstances on-site,
the granulator had to be perfectly integrated into
the building. At the same time it needed to comply
of occupational safety, i.e. maintain escape ways,
potential risk of injury.
“Rapid met all these requirements and
team work,” said Piep.
Rapid Granulator is represented in South Africa by
Eder Design, tel: 012 253 1025
60 FEBRUARY / MARCH 2015 www.rapidgranulator.com
Rapid Granulator has installed a custom tailored granulator in
inspection area of the Volkswagen plant. While meeting the automotive manufacturer’s high safety standards, the granulation equipment also had to be integrated in an existing production hall without any constructional
The regrind from the Rapid 600-120 granulator is separated from dust and any metals before being packaged in bags
EQUIPMENT
Bumpers rejected by quality control are easily recycled in the Rapid 600-120 granulator
Volkswagen chooses Rapid open-hearted 600-120 granulator
EQUIP-RAPID.indd 60 2015/02/17 10:18 AM
MATERIALS
A VERSATILE series of TPEs developed by Teknor Apex Company for consumer electronics provides the enhanced functionality, pleasing tactile properties, vivid colour, and durability that are particularly valuable for constant-use personal devices like in-ear headphones,
watches. The consumer electronics series of
compounds is part of the Monprene® family of TPEs. All products in the series exhibit resistance to skin oil, stains, household chemicals, and UV and are free of latex, phthalates, BPA and heavy metals. Grades for over-moulding show excellent adhesion to polycarbonate, ABS, and PC/ABS. Custom formulation by Teknor Apex makes possible a wide choice of surface properties – from plastic-like to rubbery, from silky smooth to ‘grippy’ and from glossy to matte. The compounds can be supplied in light, natural-coloured pellets or custom-coloured to match any requirement.
Besides custom-formulating any of the
Versatile TPEs for personal electronic devicesProvides enhanced functionality, pleasing tactile properties, vivid colour, durability
Monprene compounds to meet customer requirements, Teknor Apex can provide engineering support for application development and can supply identical formulations around the world.
Monprene OM-13255 and OM-13265 over-moulding compounds for wearable devices provide a silky smooth feel, with low surface friction in uses like wristbands. Their light natural colour allows for excellent colourability. The
compounds have excellent resistance to abrasion, skin oil, water, and weathering.
Monprene OM-16277 over-moulding 75 Shore A compound provides a
of 0.910. The compound is naturally translucent and can be used as-is or custom-coloured.
Recommended applications for Monprene®
MOULD BASE SADave Moore: 083 675 8325Danni: 074 589 3357Email: [email protected]
Dave Moore: 083 675 8325 | Fax: 086 540 0908 | www.mouldbasesa.co.za
Energy saving servo system
Proportional back pressure adjustment
6 tube water battery
Mould Clamp set
T Slot Platens
Hopper Slide
2 core pull circuits
2 Air Jet circuits
Double cylinders for carriage movement
Liquid grease lube system for toggles
Taiwanese Mirle Controller
Roller mounted rear covers for easy access
STANDARD FEATURES FOR SA MACHINES
FEBRUARY / MARCH 2015 61
EQUIPMENT
Hybrid manufacturing solutions the best of both worlds
New methodsfor process-oriented design of additive components
KR PLASTICS has had a very busy few months and recently
completed some interesting projects, including the commissioning
of an automated box packing machine for soft tubes and jars.
The company has also recently installed a multiple jar
system which allows the customer to stack the entire shift of
boxes to be packed without an operator.
KR Plastics started operations in July 2013 by owner Keith
Reading. With 15 years’ experience in the plastics industry,
working for many well know manufacturers and servicing agents,
starting his own company was an obvious step for Keith.
Plastics recently opened a branch in Umhlanga, Durban,
ensuring the company has technical and sales support
during 2014 and can now offer the entire plastics industry
experienced sales representatives and technicians. The
company also has technicians available for the rest of Africa.
KR Plastics specialises in the supply and building of
high-tech machinery and automation lines from Europe,
China and locally. Besides supplying and building machinery,
the company also services the majority of plastics industry
machines and attends to all breakdowns.
KR Plastics’ main focus is the supply of Wittmann Battenfeld
products. Wittmann Battenfeld offers a wide range of machines
to material handling systems and injection moulders. The
company also supplies Powerjet, Mingda, Mould-Shield,
Virginio Nastri, HYS and Kaihua machines and moulds.
KR Plastics’ range of expertise is vast, including injection
moulding and blow moulding machine rebuilds and repairs;
repairs and part supplies; Techmation controller installation;
plant automation and implementation, the manufacture of all
types of moulds, 2-D and 3-D drawings and part design; and
hydraulic to servo-hydraulic conversions.
The company also supplies recycling equipment, pelletizing
lines including water treatment plants for reusable water systems,
KR Plastics has increased its range of products and can now
offer instrumentation equipment for plants including acid, dairy
and food processing; a range of valves; chemical supplies; ball
and screw drives for electric, servo and stepper motors; linear
bearings and guides, and bushed guides roller and ball guides.
Contact KR Plastics on tel 011 708 1530 or 031 556 1929,
email: [email protected]
KR Plastics grows,
www.starlinger.com
Lashen Harinarain
CONCEPT Laser and RSC Engineering
GmbH (Cologne, Germany) have
oriented component designs using
LaserCUSING for complex components.
LaserCUSING-oriented design
is ideal for bionic or lightweight
construction approaches that produce
components with optimized geometries
and new possibilities in areas such
as functionality or resilience. RSC
Engineering is one of today’s design
pioneers that know how to incorporate
the component development process.
In an additive design context, the
advantages of LaserCUSING can be
maximized: optimized design, better
performance and increased added
value. Additional functions are now
possible, such as cooling, production
of moving parts in a one-shot process
without assemblies, or lightweight
structures that can
withstand heavy
stresses. Hybrid
manufacturing
solutions
(combination
of conventional
processes and
LaserCUSING) can
bring together the
best of both worlds.
An exhaust gas probe developed
by RSC Engineering is an excellent
example of intelligent additive design.
The probe is used to determine the
composition of engine exhaust gases
in a test system. The exhaust gas is up
to 2100°C and under high pressure.
Because of these high temperatures,
the exhaust gas probe also features
addition to six pipes for collecting the
exhaust gas. Conventional exhaust
gas probes are typically welded, which
is a time-consuming process.
By contrast, the exhaust gas probe
by RSC Engineering was manufactured
channels, using LaserCUSING.
The product costing analysis for
the exhaust gas probe showed that
manufacturing costs were reduced by
almost 60%.
Exhaust gas probe: single-
stage production combined
with integrated cooling in one
extremely compact component
62 FEBRUARY / MARCH 2015
www.concept-laser.de
EQUIP-Starlinger+Concept Laser.indd 62 2015/02/17 10:38 AM
Advanced sculpting techniques deliver 1.75 litre concept bottle
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Award for highly sculpted PET bottle
SCORCREATIVE at Amcor, the award-winning structural
design studio located at Amcor Rigid Plastics in the USA,
has won a bronze award from the Pentawards, a worldwide
packaging design competition. ScorCreative captured the
design honour in the concept packaging category for its highly
innovative Growler-type 1.75-litre liquor bottle which takes
ScorCreative achieved a major technical feat by applying
Amcor’s vast industry experience along with advanced
sculpted’ PET liquor bottles. This innovative concept
package design integrates a nautical theme with several
three-dimensional qualities including etchings of an octopus
sculpted into the bottle’s shape.
Amcor used several software systems which were adapted
from the gaming, animation, movie and automotive industries,
along with its proprietary process applications to accomplish
the project in an unconventional manner. Different elements
of each software programme were combined and then put in
the hands of an industrial designer who developed an artistic
rendition of the nautical theme. The PET container includes
around the shoulder of the bottle.
ScorCreative will adapt the learnings from this concept
design to ultimately create a commercial container that is not
only eye-catching but functional. A key goal is adapting the 3-D
CAD model and creating the intricate detail through the blow
moulding process, thus taking the design from concept to store
shelf.
PRODUCTS
Complementing the
highly sculpted design
is a unique die-cut
paper label which has
a treasure map design
with assimilated ‘burned’
edges. The ‘Hard to Port’
brand is targeted for the
commercialisation of a
dark rum liquor product
in North America
www.amcor.com
PRODS-AMCOR.indd 63 2015/02/17 10:39 AM
MATERIALS
A LIGHT, bright atmosphere is important for creating a feeling of hospitality in commercial spaces. However, a warm,inviting glow often comes at a price.
energy bills.
®
®
lamps’ optical mixing chamber, the area
use of renewable raw materials in
®
by the mass balance approach.
by renewable raw materials. The
is that fossil raw materials have
64 FEBRUARY / MARCH 2015
performance properties.
with metal parts.
FEBRUARY / MARCH 2015 65
BubblesUSA-based Plastic Technologies Inc is touting a technology
called Fi-Cell that dramatically alters the appearance of PET
bottles in a way the company believes opens up new markets
for the packaging stalwart.
As director of marketing and new business development
Fi-Cell to the market. For him, it’s an easy sell. He believes
foamed PET bottles are a game-changer.
“Today, the brand owner has a few seconds to catch a
consumer’s eye on a shelf. With
this technology, they can generate
a package that isn’t ‘Plain Jane’
anymore, that has snap and appeal
long after it leaves the store shelf,”
he said.
Fi-Cell creates monolayer
containers with a “visually-exciting
expensive metallic colourants,”
according to PTI.
Fi-Cell technology, which creates
tiny bubbles within PET, was actually
created by Toyo Seikan Co Ltd, who
was looking for a partner to help
expand its adoption. It joins PTI’s
own oPTI foam bottle technology
that was introduced years ago.
Foamed PET introduces liquid nitrogen during the creation
of preforms, which then become opaque when the bottles are
blow moulded.
“The cost of any foam bottle platform, no matter which one
we talk about, is all in the capital side. You have to modify the
injection moulding system to be able to foam the package.
After that, it’s like any other blow moulded package,”
more receptive to embossing than the regular stuff.
“PET has this wonderful characteristic of self-levelling. It
never wants to be sharp. It wants to level itself. But with oPTI
or Fi-Cell, we found we actually get some nice embossing
effects,” Puvak said.
“You’ve got these little bubbles that love to move a little bit,
so that’s what’s happening. You get this very nice embossing
effect. You will not see that in a standard PET bottle,” he said.
This provides companies with the opportunity to feature
their brand equity in their PET packaging.
Foamed PET also allows for the use of less colourant as
the tiny bubbles do not need to be coloured. “We colour the
PET and the foam comes along for the ride,” he said. Foamed
PET without colourant creates white or silvery opaque bottles.
Foamed bottles also can weigh up to 5% less than their
more pedestrian cousins, but Puvak said this technology
really isn’t about lightweighting.
“We don’t see lightweighting as the big key here. Really what
we see is the shelf differentiation and use of PET in another way,”
Puvak said. “All we’ve done is given PET another pathway to take.”
MOULD BASE SADave Moore: 083 675 8325Danni: 074 589 3357Email: [email protected]
IN STOCK
IN OUR KZN
WAREHOUSE
TOPSTAR ANCILLIARY
EQUIPMENT• Granulators
• Servo Robots
• Mould Temperature Controllers
• Hopper Loaders
• Hopper Dryers
• Dosing Units
• Conveyors
• Dehumidifying Driers
• Centralised Loading Systems
• Hopper Magnets
• Mould Clamps
• Full range of spare parts ex stock
• Custom Automation Projects from Design to Completion
Dave Moore: 083 675 8325 | Fax: 086 540 0908 | www.mouldbasesa.co.za
www.plastictechnologies.com
Ron Puvak and one of PTI’s foamed PET
bottles
PRODS-PLASTIC TECHNOLOGIES-1.indd 65 2015/02/17 10:17 AM
66 FEBRUARY / MARCH 2015
SIPA received an interesting call
recently from a fellow Italian company
which was developing an innovative
range of ultralight high-performance
compressed gas cylinders. CTS,
Composite Technical Systems, near
Udine (Italy), wanted
SIPA’s help in the
creation of an all-new
‘Type IV’ pressure
containers.
Type IV pressure
cylinders comprise a
plastic liner inside a
protective skin made
from a continuous
composite. They differ from Type I, II
and III pressure cylinders, which are
either partly or completely made from
metal and which weigh a lot more.
Type IV pressure cylinders are
already on the market, but virtually all of
the types produced to date have a liner
blow moulded in HDPE. CTS wanted
to use PET, which would be lighter and
give the liner a barrier to oxygen up to
as much as 100 times higher.
Initial target application for this new
invention is oxygen breathing tanks for
is much greater, ranging from scuba
diving kit, through fuel tanks for cars to
apparatus in outer space.
CTS came to SIPA to help it perfect
a process for making PET liners
that it had begun to develop on its
own, without achieving the results it
was looking for. It had developed its
own rudimentary injection moulding
machine, as well as an equally simple
blow moulding machine, which together
were capable of producing containers
with tolerances that were
unacceptable. In fact,
dimensions varied between
containers by a centimetre
or more! No two containers
were the same, and
machine operators were
constantly adjusting the
settings. Something had to
be done.
And done it was. SIPA’s experts
worked with the CTS team to create
a PET liner perfectly matched to the
application. The two companies worked
hand-in-hand on container development,
prototyping, testing, and production.
CTS general manager Giovanni
the work SIPA has done in helping to
create a product ready for the market
that offers the very highest levels of
safety. Production is now underway on
a range of the new pressure cylinders,
with volumes ranging from 2 to 9 litres.
The smallest one weighs 0.9kg and the
largest just 4.0kg – that’s about 30%
lighter than a cylinder with an aluminium
all-steel one. They can all withstand a
service pressure of 300 bar, and CTS
gives them an unlimited service life.
For its part, SIPA is very happy to be
working with such a highly innovative
customer.
“The collaboration with CTS has
provided us with extra insight into the
capabilities of PET as a packaging
material,” says Alberto Uliana of SIPA.
worked on an application where internal
pressures are so high! We have all
gained a lot from the experience.”
The two companies are now
collaborating on experimentation
with various types of plastics for the
liners that could provide even higher
performance in terms of oxygen barrier.
CTS is a new company, but the
experience of its founders in pressure
canisters dates back some 30 years.
With its highly innovative know-
how, CTS describes itself as ‘an
organization capable of grasping the
global opportunities that the composite
materials sector has to offer in the
patented its new technology for making
the PET liner around the world.
SIPA is now present in South Africa:
ph 021 418 2750; martina.bottarel@
zoppas.com
SIPA helps lightweight composite technical cylinders
work under pressurePET tank achieves far higher oxygen barrier
EQU
IPM
ENT
SIPA regional manager Giovanni de Rosa and
communications manager Martina Bottarel at
High pressure situation – SIPA has
developed the technology to produce high
Potential for use in applications such as scuba
diving, fuel tanks and apparatus in
outer space
EQUIP-SIPA.indd 66 2015/02/17 10:34 AM
MATERIALS
FEBRUARY / MARCH 2015 67
2nd-generation high-performancepolyester compound for LED TV’s
www.solvay.com
Delivers improved processability for higher yields, faster cycle times
SOLVAY Specialty Polymers has unveiled an enhanced version of its Lavanta®
high-performance polyester (HPP) for production of light-emitting diodes (LEDs) for televisions and backlight unit (BLU)
used materials are unable to withstand the higher heat and light output, discolouring prematurely in applications
Lavanta 5115 WH 224 is a 15% glass
terephthalate (PCT) compound
packaging applications that use surface
grade provides enhanced processibility versus other available PCTs which results in higher yields and shorter cycle
at a lower temperature (125°C) than competitive PCTs and still maintains
moulds enable cycle times to be reduced, resulting in lower energy use and
The Lavanta 5115 WH 224
improved processibility while maintaining its high heat and
light stability
product – Lavanta 5115 WH 224
processibility while maintaining its high
This second-generation material is an important achievement because it
of the LED industry, enabling
enhanced processibility is achieved
whiteness and whiteness retention of
The growing trend among television manufacturers is to use fewer LEDs
by sending higher current through the
Roediger Agencies cc
Dr Andy Roediger
021 887 0010
021 886 4731
Roediger Agencies ad '014 06.indd 1 2014/05/19 12:22 PM
68 FEBRUARY / MARCH 2015
ASTRONAUTS are printing up a storm
on the International Space Station (ISS)
and if the next phases of NASA’s additive
manufacturing project go according to
plan, they will soon be doing a lot more
than banging out wrenches and spare
parts in space.
space was a spare part for the printer
itself: an extruder casing, emblazoned
with the name of the printer’s
manufacturer, Made In Space, and the
NASA logo. It was quickly followed by a
side plate for the extruder casing.
extruded plastic in space. The space
station is the only laboratory platform in
microgravity that’s available,” said Niki
manager.
during November, ISS astronauts have
moved on to bigger items, including a
designed, approved and sent to space in
less than a week and printed in about four
a $1.4 million Small Business Innovation
based Made In Space, is testing the
feasibility of astronauts manufacturing
their own parts and tools in microgravity.
Taking additive manufacturing to
space will eventually minimize taking
parts and tools from Earth to space
— which comes with a $10,000 per
kilogram of launch weight price tag,
among other issues — and increase
parts and tools from this phase will
eventually head back to Earth to be
compared with the same objects
printed by an identical printer on the
ground.
But there is much more to the next
phase of the project than sending another
printer to space. Already going by the
acronym AMF for ‘additive manufacturing
for ISS will be commercial printer by
Made In Space.
In addition to being larger than the
most likely starting with PEEK and Ultem
because of the plastics’ strength, good
safety ratings and excellent thermal
properties. Ultem is used for making a
lot of the EVA (extravehicular activity, or
spacewalk) tools already.
SIPA, a leader in PET container production
known in the PET packaging sector.
The acquisition represents an important
strategic move for SIPA. It will enable the
company to extend its existing offering in
stronger position in the market for equipment
producing specialty products, such as
containers for pharmaceuticals, cosmetics,
fully in line with SIPA’s objective of becoming
a leader in the development and supply of
Automa ISBM machines are designed
for the production of containers in smaller
lots than SIPA’s existing units, with features
also characterized by their compact layouts
ISBM 50SR unit, for example, with a 500kN
injection clamp force, has a rated power
consumption of just 18.5 kW/h for machine,
hot runner system and PET loaders. The
discharge), consumes 20 kw/h.
SIPA provides the full range of PET
container production machines (single stage
machines, linear and rotary blow molders,
www.nasa.govwww.madeinspace.us
Made In Space’s 3-D printer
during microgravity testing
– Mike Chen (left) and Jason
zero-G 3D printer was validated
First time plastic heated & extruded in space
SIPA buys Automa PET business
Testing feasibility of astronauts manufacturing own parts, tools in microgravity
EQUIPMENT
The Automa machines
are suited for specialty
containers such as
pharmaceuticals
and cosmetics; its
acquisition by SIPA
is in line with SIPA’s
goal to be a leader in
and packaging
systems
www.sipa.it
EQUIP-3D PRINTING+SIPA.indd 68 2015/02/17 10:35 AM
High-speed extruder
coextrusion line with roll stack
Low energy consumption, extremely low noise level, 10% higher
High-speedextruder triumph continues
Thermoformed
cups, manufactured
on a battenfeld-
cincinnati extrusion
line with a high-
speed extruder
EQU
IPM
ENT
FOR more than ten years Battenfeld-Cincinnati,
the German-Austrian extruder specialist, has
achieved market success with a complete series
of high-speed extruders. Now the pioneer in
this special technology is extending its machine
portfolio by adding an adiabatic extruder which
The high-speed 34D-long single screw
extruders with a screw diameter of 75mm reach
outputs of up to 1.8 t/h and operate with screw
speeds of up to 1,500rpm. This is how the high
outputs can be achieved with a small machine
size and with optimal melt attributes too. The
extruders are used for PP, PS, APET, CPET, PLA
and PE processing as well as in PC sheet lines.
has now developed an adiabatic high-speed
This new process technology has made it possible
to reduce energy consumption by yet another
10% compared to the previous high-speed
models, which already use 25% less energy than
conventional extruders with the same output rates.
This machine is laid out for a medium output
range of 800kg/h (900 kg/h for PP and PS).
In addition to its low energy consumption, the
processing machine stands out by an extremely
low noise level in operation and a 10% higher
to its environment has also been reduced
considerably by the new process technology
concept.
www.battenfeld-cincinnati.com
Welltec Plastics has theinjection moulding machines to
meet your requirements.
PO Box 4567, Luipaardsvlei 1743Tel: (011) 762 5231 - Fax: (011) 762 5228Mobil: 083 255 9865 Les PorterEmail: [email protected]: www.edmshop.co.za
Excellentprices onexisting
stock
PO Box 4567, Luipaardsvlei 1743Tel: (011) 762 5231 - Fax: (011) 762 5228Mobil: 083 255 9865 Les PorterEmail: [email protected]: www.edmshop.co.za
FEBRUARY / MARCH 2015 69
EQUIP-BATTENFELD+KREATOR.indd 69 2015/02/17 10:35 AM
RecycleNet is a new app connecting
buyers and suppliers of recyclable
material in South Africa.
The service has the potential to
change the recycling industry in SA
for the better and completely change
the way companies in this sector do
business with each other, says developer
Oscar Baruffa, Founder of RecycleNet,
Johannesburg, who is pursuing the
recycling exchange platform zealously.
smartphone use, which will allow users to
access and sell or buy actively at any time
of the day, where-ever they are. First-time
users access a free trial which allows for
the downloading of the RecycleNet app
and voilà – you’re on your way!
RecycleNet launched in late October
operation managed to register 40 users
and saw some R5-million worth of
material listed including various plastics,
metals and paper.
“Initial reaction to the app has been
really good and even better than I could
have hoped for, but don’t let me tell you
that - have a look at the testimonials on our
website!” says Baruffa, “The app is easy
to use and helps buyers and suppliers
connect directly with one another. It’s
continually being improved and with new
features being added it will soon become
an indispensable tool for anyone involved
in buying or selling material.”
70
FE
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RY
/ M
AR
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20
15
The new Norres website offers customers
a range of new online services. Thanks to
the relaunch, the new responsive website
design is compatible with all end devices.
The mobile Web app is quick and
easy to load on a smartphone, as is
introduced in autumn 2014. Using the
anytime and anywhere. The hose-
application search function. This makes it
search also improves the accuracy of the
search function.
Users can also take advantage of the
Norres online converter built into the new
Web app and optimised website. This tool
can convert a range of hose-related data
from metric to imperial and vice versa at
any time and in any location.
BATTENFELD-cincinnati has published a video on their website showing the
Battenfeld-cincinnati has successfully installed more than 100 PO and PVC pipe
extrusion lines for diameters from 800mm upwards. Thanks to its many years of
experience in the production of extruders and extrusion dies, battenfeld-cincinnati can
handle throughputs of up to 3 tons per hour and pipe diameters of up to 2,500mm.
Most of the more than 100 large diameter pipe extrusion lines installed are laid
extrusion lines for PVC pipes have already been installed for diameters of up to
1,300mm, dimensions of up to 1,600mm in diameter are feasible. With the twinEX
extruder models 135, 148 and 173, battenfeld-cincinnati offers a wide range of
large machines specially geared to gentle processing of this material. Optimal wall
thickness distribution and excellent pipe attributes are achieved by double spider dies.
In the youtube video, Mohámed Hageb, general manager of Union Pipes Industry
(UPI), in the United Arab Emirates, explains the reasons the UPI management’s
decision in favour of battenfeld-cincinnati: “Besides quality attributes such as excellent
wall thickness distribution and low ovality, we have come to appreciate above all the
can operate with a shorter cooling section than conventional models. This saves
us production hall space, energy and material as well, thanks to the optimal pipe
pipes.”
WEB NEWS
Norres launches new responsive website design
Mobile app links suppliers and buyers of recycled materials
Many new online services
on www.norres.com
Visible competence for large diameter pipe extrusion lines
www.norres.com
www.recyclenet.co.zaThe RecycleNet app allows for
easy access and participation in the selling and buying of recycling materials
Large diameter pipe produced on a line from battenfeld-cincinnati at
Union Pipes Industry, United Arab Emirates
www.youtube.com/BattenfeldCincinnati
www.recyclenet.co.za/register
WEB news.indd 70 2015/02/17 10:35 AM
BOOKS
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Market Study: Polypropylene
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Ceresana forecasts chances for polypropylene
Trends in plastics decoration
Latest perspectives on global packaging industry
72 FEBRUARY / MARCH 2015
World rubber demand forecast to increase
at 1.8% and 4.1% in 2015, 2016
Books.indd 72 2015/02/17 10:39 AM
WORLD NEWS
PLASTIC composites replaced titanium
in key components of the Orion space
capsule, which both launched into and
returned from space in early December.
USA company TenCate Advanced
Composites North America developed
the heat-resistant composites for the
heat shield and backshell structure of
Lockheed Martin.
Lockheed Martin’s thermal protection
group worked with TenCate to develop
a heat-resistant composite resin for the
16.5-foot diameter heat shield and the
crew vehicle backshell. The shield’s large
area and 4cm thickness entailed high
parts consolidation using only a low-
pressure vacuum bag moulding process.
During re-entry the heat shield loses
about 20% of its thickness due to
vaporization as the capsule speeds into
the earth’s atmosphere at over 32 000km
per hour. Re-entry temperatures can
exceed 2,000°C.
The Orion project is in the early stage
for development of spacecraft capable
of carrying humans into interplanetary
space. Space engineers hope the project
eventually will lead to humans landing on
the planet Mars. The prototype capsule
launched the morning of 5 December
was unmanned. It splashed back into the
launch after completing two Earth orbits.
TenCate did not disclose the
ingredients of its high-tech composites
on Orion but the company said a range
of polymers are used in its aerospace
composites, including epoxies, cyanate
ester, bismaleimide and high-temperature
polyimides.
TenCate Advanced Composites North
America is a subsidiary of Koninlijke
Ten Cate NV of Almelo, Netherlands.
The parent company’s common name is
Royal Ten Cate.
SAUDI International Petrochemical Co
and South Korea’s Hanwha Chemical
Corp have opened a $40 million EVA
Saudi Arabia.
The facility, in the special economic
zone of Hail, will have an annual capacity
of 4,000 tons of ethylene-vinyl acetate
The operation is part of the Saudi
company’s efforts to bring more plastics
processing and downstream operations
to the Kingdom to complement its resin
manufacturing.
It was also reported in 2013 that the
two companies are also building a joint
venture plastic mould making facility in
Riyadh, Saudi Arabia, with a capacity to
manufacture moulds up to 1,000 tons.
making operations are part of the Saudi
Specialized Products Co, which is a joint
venture that is 75% owned by Sipchem
and 25% by Hanwha.
Saudi media reported in 2013 that the
project would be a total investment of
about $60 million.
The Korean partner, Hanwha, also has
large manufacturing capacities for solar
announced a merger that said would
make it the world’s largest maker of solar
cells, with a manufacturing capacity of
3.28 gigawatts.
Hanwha and Sipchem also have larger
Composites replace titanium in key components on OrionComposites replace titanium in key components
www.nasa.gov
www.tencate.com
74 FEBRUARY / MARCH 2015
Sipchem, Hanwha open
NASA astronauts Cady Coleman and Ricky
Arnold step into the Orion Multi-Purpose Crew
Vehicle hatch during a series of spacesuit
check tests conducted at the agency’s Johnson
Space Centre in Houston (Image: Bill Stafford)
WORLD NEWS-1.indd 74 2015/02/17 10:30 AM
FEBRUARY / MARCH 2015 75
AROUND THEWORLD
World Plastics Council takes on sustainabilityTHE recently formed World Plastics
Council (WPC) has set marine
debris and post-consumer recycling
and energy recover as its initial top
priorities.
The council, created during K
and key topics for the group.
Mosaed Al Ohali, executive vice
president polymers at SABIC, was
elected as the new chairman of
WPC at the assembly. He replaces
Patrick Thomas, the CEO Bayer
MaterialScience, who had taken up
the role during the formation phase of
WPC.
The WPC is intended to accelerate
cooperation and alignment of the
plastics industry at the international
level with regard to common issues
faced by the industry, society and
consumers.
“provided strategic direction on key
areas of the sustainability agenda,”
including marine debris and end-of-life
product issues.
Bayer wraps up major investment in GermanyMATERIALS manufacturer Bayer
MaterialScience has successfully
concluded a major capital expenditure
project in Germany. The company brought
world-scale plant for the production of
the chemical TDI, a main component
in high-quality foams, on stream at its
site in Dormagen, located in the state of
North Rhine-Westphalia. Valued at some
€250 million, the high-tech plant was
inaugurated at a ceremony attended by
representatives from politics, industry,
public administration authorities and the
local community.
Including infrastructure and supplier
costs, total capital expenditure at
Chempark Dormagen amounts to more
than €400 million. The site is to become
Bayer MaterialScience’s European centre
for TDI production. Under construction
for 30 months, the new plant replaces
a smaller production unit for toluene
diisocyanate (TDI). The chemical is used
foams, which is used to produce many
everyday articles including mattresses,
car seats and upholstered furniture.
www.materialscience.bayer.com
IT looks like something out of a
‘Transformers’ movie – a huge robotic
arm that moves and spins to pick
programmed patterns to deposit those
of transforming from machine to Autobot,
aerospace structures and parts.
NASA’s Langley Research Centre
has installed the advanced composite
research capability, called ISAAC
(Integrated Structural Assembly of
Advanced Composites) at its Hampton,
Virginia facility at a cost of around US$1.7
million dollars to develop and install.
The researchers plan to have ISAAC
up and running by early 2015 with the
Research Mission Directorate’s
Advanced Composites Project (ACP).
The ACP is a public-private
partnership that is geared toward
reducing the amount of time and
money it takes to bring new, advanced
composites from test tube to vehicles.
NASA’s space projects also plan to
use the ISAAC system in their research.
The second project planned for the robot
is the Composites for Exploration Upper
Stage (C-EUS) Project, a partnership
between the Space Technology Mission
Directorate and Human Exploration
Mission Directorate that is led by the
Marshall Space Flight Centre. The
C-EUS Project is a three-year effort to
suitable for the second stage of the
Space Launch System.
joint investments in resin manufacturing in
Saudi Arabia. In August they announced
the start-up of a plant making 200,000 tons
a year of EVA
and low-density
polyethylene
materials, an
investment of
$800 million.
Hanwha is
making sizable
investments – in
November it bought plastics and chemicals
assets from Samsung, making it the largest
Composites replace titanium in key components on Orion
The 6.4m tall robot is placed on the track. The robot head will make large composite pieces
(Image:NASA/David C. Bowman)
Saudi Arabia
www.nasa.gov
Giant robot helps NASA make composite parts
WORLD NEWS-1.indd 75 2015/02/17 10:30 AM
AROUND THEWORLD
76 FEBRUARY / MARCH 2015
Mitsubishi develops bio-based polycarbonateMITSUBISHI Chemical Corp. says it has
developed a bio-based polycarbonate
resin. Durabio is based on isosorbide as
a comonomer that replaces bisphenol A.
Isosorbide is derived from glucose, widely
available as a biological feedstock.
The Tokyo-based materials giant
says Durabio is not biodegradable
and its durability suits it to a range of
engineering applications. Key properties
include high transparency, excellent
optical properties and higher resistance
to abrasion than conventional PC.
Mitsubishi claims Durabio’s optical
properties are superior to conventional
PC. Its impact resistance characteristics
compare favourably with conventional
PC, according to the company.
Mitsubishi cites optical and energy
components, electronics, automotive
and décor schemes as potential
applications for Durabio.
optical properties relate to its isosorbide
ingredient, which unlike BPA is an
aliphatic chemical. In addition to
transparency and optical homogeneity,
the resin yellows only slightly when
exposed to light. Its transparency
promotes freedom for coloration, even
for deep hues and metallic effects.
Parx Plastics winner of World Technology AwardONCE a year The World Technology
Network brings together many of the
world’s most innovative individuals
and organizations in science,
present, discuss and celebrate
innovations and accomplishments. In
this year’s edition, Parx Plastics was
awarded for its inventions creating a
biocompatible antibacterial plastic.
The technology developed by
Parx Plastics is unique as it is fully
biocompatible, ecofriendly, non-toxic and
without substances leaching from the
plastic. These characteristics make this
solution the only antibacterial technology
that without limitations can be used in
food packaging materials to improve the
shelf life of food, and can be used for
medical applications such as implants
where it will reduce the chances on
infections. Earlier this year the European
Commission announced Parx Plastics as
one of the top tech startups of Europe.
www.wtn.net
www.parxplastics.com
Plastics play part in architectural illusion
TAKING residence on the East Piazza
at Covent Garden in London is a new
and unique artwork which sees a section
of the building magically levitate – with
one of the key structural elements of the
illusion provided by Brett Martin Plastic
Sheets.
Modelled on the original architecture
of the 184 year old market building,
the artwork ‘Take my lightning but don’t
steal my thunder’, has been designed by
London artist Alex Chinneck and built by
a 100-strong team who have conjured up
the illusion that a 40-foot-long building
has broken from its stone base and
bewildering weightlessness.
With this unusual engineering marvel
designed around both weight and
aesthetics, the building had to be as light
as possible but still look like a stone and
brick building. Built from a steel and
timber frame, the walls were created
using Brett Martin’s Marlon ST Longlife,
a structurally strong, lightweight multiwall
polycarbonate sheet.
Polystyrene was then intricately carved
using robotic hot-wire cutters, and glued
to the polycarbonate sheet prior to the
application of the plaster and granite
building.
10mm Twinwall Marlon ST Longlife
was chosen for the artwork for its
exceptional strength and rigidity.
applications, the multiwall structure
of Marlon ST Longlife provides a very
high stiffness to weight ratio. The
sheet is strong yet light in weight, a
key consideration for this architectural
illusion.
A proposed merger between two
Australian bioplastics companies will
create a publicly listed entity with
annual sales of almost US$25 million.
Melbourne-based, publicly listed Cardia
Bioplastics Ltd and Melbourne-based
privately held Stellar Films Group Pty Ltd
have reached an agreement to merge,
subject to shareholder and regulatory
approval.
The companies have worked together
pioneering sustainable plastic packaging
products, particularly for the personal
hygiene products market. Cardia was
established in 2002 and Stellar has
operated for about 25 years. Stellar
has two factories, in Melbourne and
Selangor, Malaysia. Cardia has three
factories – one each in Melbourne;
Nanjing, China; and São Paulo. Both
companies have business development
disposable diapers, feminine hygiene,
incontinence and medical disposable
markets, and for packaging surgical
instruments, surgical drapes and gowns.
Artwork sees a section of the building levitate
Designed by London artist Alex Chinneck, the illusion that a 40-foot-long building has broken
(Images: Jeff Moore)
WORLD NEWS
WORLD NEWS-1.indd 76 2015/02/17 10:30 AM
[email protected], [email protected] and [email protected] (Cape Town)[email protected] and [email protected] (Cape Town) www.exxonmobilchemical.com
78 FEBRUARY / MARCH 2015
A HEAT-absorbing panorama roof made
of shatterproof polycarbonate brings
more light into the interior and creates
a sense of greater spaciousness in the
smart ‘fortwo’ smart car.
panorama roof for the third generation
of the smart fortwo. The 1.2m2,
transparent roof panel is made of
lightweight polycarbonate Makrolon
from Bayer MaterialScience. The roof
system admits a lot of light into the
interior, creating a pleasant, generous
sense of space for the passengers.
front windshield.
The technical highlight of the roof
system is its ability to absorb solar
energy and thus prevent the interior
from heating up too much. In a nutshell,
the IR rays stay where they belong
– outside. This is made possible by
infrared absorbers integrated into the
the panels are made of. Makrolon
AG2677 in the colour and temperature-
stable, heat-absorbing colour 771079
is being used on the new smart for the
resistant, weatherproof and lightweight.
A roof made of PC can be up to 50%
lighter than a glass equivalent. The
plastic panel on the new smart fortwo
weighs only 9.8kg.
The roof is manufactured by
means of two-component injection-
compression moulding. Besides the
transparent Makrolon AG2677, the
black-coloured polycarbonate ABS
blend Bayblend T95 MF is used as
the second component. It enables the
integration of additional functions such
as screw bosses on the bottom side
of the roof. Attached to them is the
used to control the brightness of the
interior.
A coating layer makes the panorama
roof resistant to scratching and
is the world’s largest injection-moulded,
transparently coated car roof with an
infrared absorber.
Webasto manufactures the
polycarbonate roofs in its own
lightweight competence centre in
Schierling near Regensburg.
www.webasto-group.com
MILACRON LLC, the global
leader in high precision plastic
processing technologies and
control systems, has entered into
a partnership agreement with
Foam injection moulding. The
Milacron to incorporate the MuCell
technology into its injection moulding
equipment.
“We believe Milacron is uniquely
capable to provide the complete
melt distribution and control
solution for MuCell systems. Our
processing equipment, combined
with industry leading hot runner and
control systems, will allow MuCell
and untapped markets” said Bruce
Catoen, Milacron’s chief technology
“Milacron has proven the viability
of MuCell in blow moulding, co-
and high cavitation packaging
applications. The light weighting,
low tonnage, reduced warp and
previously not possible,” added
Catoen.
CLARIANT, a world leader in
specialty chemicals, is to build a
masterbatches plant in Sydney,
Australia. The new plant will
mainly serve the Australian market
with a full range of colour and
additive masterbatches, technically
innovative solutions and services
to meet the growing local needs.
Construction on the plant is
currently underway, with plans of
commissioning in the fourth quarter
2014.
Working closely with Clariant’s
site in Albany, New Zealand, the
Australian plant will produce a
full range of colour and additive
masterbatches tailored to local
customer requirements, along with
colour matching and QC capabilities.
www.clariant.com
World’s largest injection-moulded, transparently coated car roof
with infrared absorber
WORLD NEWS
WORLD NEWS-1.indd 78 2015/02/17 10:30 AM
ELASTOMERS
ACMCREPDMEpichlorohydrinFKMHNBRHTV SiliconeIRNBRNRPVC/NBR BlendsSBR & BR
PLASTICS & COMPOSITES
ABSAcetalAdditivesCompositesCPECSMEVAHIPS & GPPSNylonPCPVCTPE & TPVTPU
FILLERS & ADDITIVES
AluminasAntimony ProductsBlowings AgentsCarbon BlacksFlame RetardentsHydrocarbon ResinsMagnesium OxideMasterbatchesMC & PE WaxesMineral FillersPeroxidesProcess AidsRubber ChemicalsSilanesSilicaSulfurZinc Oxide
AUXILIARIES & SERVICES
Curing BladderMachineryOther ServicesRelease AgentsRelease linersSpares
ANCHOR CHEMICALS
Batch OffBonding SystemsCoated PowdersFacticeMasterbatchingProcess AidsToll Mixing
African Marine Debris Summit in June
Afrimold will be at Indutec in May
THE second instalment of the African Summit on Marine Debris takes place in Cape Town from 3-5 June.
At present there are four large net-works active internationally that cooper-ate in addressing the issue of marine debris. This second Africa summit is intended to serve as the basis for the formation of a planned Southern African Network on Marine Debris.
As African economies grow, the ills associated with rapid expansion are becoming more apparent, but up till now marine debris along the African coast has received limited attention in Africa, and it is because of this lack of under-
problem on the continent is necessary.The Summit is being held in con-
junction with UNEP (United Nations Environment Programme), South Africa’s Department of Environmental Affairs and the South African National Biodiversity Institute. The goal is to work towards increased research and awareness, raising of the issue as well as actions to
AFRIMOLD is to be presented as part of the SA Industry & Technology Fair (INDUTEC) in May.
The event, presented by Exhibition Management Services (EMS), is to take place at Gallagher Convention Centre in Midrand from 20-22 May.
“We are very excited about our new
THE Italian plastics and rubber ma-chinery sector, including ancillaries and moulds, achieved good growth last
upcoming PLAST 2015 show (5-9 May).According to analysis by Assoco-
maplast (the Italian trade association, uniting some 170 companies), sales abroad from January-September 2014 reached €1.89-billion, as opposed to the €1.82-million in the corresponding period in 2013, recording growth in excess of 4%.
But imports for the same period also grew, by an impressive 7%: from
www.exhibitionsafrica.com
www.plastonline.org
Goal to set up Southern African network to keep coast clean
reduce marine debris.The second summit will address is-
sues that are seen as a way to mitigate the issue, such as using cellulose-based material in the plastics industry, recycling, deposit systems for contain-ers and showcase research being done in this area and awareness projects.
Speakers include Dr Mike Biddle, named by Popular Science magazine as ‘Mr Garbage’; Prof Dr-Ing Chris-tian Bonten, director of the Institut für Kunststofftechnik (IKT; Institute for Plastics Engineering) at the University of Stuttgart; Fabiano Barretto of Brazil, director of the Global Garbage NGO; Prof Peter Ryan of the Percy Fitzpatrick Institute of Ornithology and Prof Henk Bouwman on the issue of persistent organic pollutants in micro plastics.
The function is to be held at the Kirstenbosch Botanical Gardens.
For further information, contact John Kieser:
South African operation,” said John Thomson, managing director of EMS.
“This development gives added depth to an already comprehensive specialist manufacturing fair. It is fast becoming a leading showcase for industry on the African continent,” said Thomson.
Afrimold is managed by Ron MacLarty.
€423-million euros in 2013 to over €454-m in 2014. This corresponds to consolidation (+3%) of an already strongly positive balance of trade, said Asscomaplast.
Expectations for the current year, de-spite the rapidly shifting political frame-work and uncertainties in the markets, are marked by optimism, it added.
With just a few months before the cut-ting of the ribbon for the Milanese fair, the number of exhibitors has exceeded 1,200 – almost 4% more than Plast 2012 with full, across-the-board repre-sentation of all the different segments and categories in the six pavilions.
‘Gravity II’Global Closure Systems launched a new standard closure for the water market at Pharmapack Europe in Paris in February. The beverage market is continuing to move towards light weighting. The objective of the Gravity II closure, which has a lightweight
changeable solution by offering a single-thread closure while maintaining the same
26/22 (GME 30.28) and allowing a simple customer line conversion. Developed for
in its own right, with 2.05g against 3.85g for
www.gcs.com
Hostex in SandtonHOSTEX, Africa’s leading hospitality and food services expo, takes place at the Sandton Convention Centre from 15-18 March. The event includes the SA Chefs Village; the Liquid Kitchen; the Shaker
Barista Championship and actually quite a lot more. Many plastic and composite accessories are used in the sector, so it’ll do no harm to drop in. www.hostex.co.za
UTech Europe in AprilUTECH Europe, from 14-16 April, at MECC, Maastricht, The Netherlands, runs alongside the UTECH Europe exhibition. The conference is designed to give attend-ees a competitive edge through state-of-the
rigid foam innovations and case studies. It will explore key themes affecting the Euro-pean and global polyurethane industry in 2015 and beyond. Key sessions will cover renewables, innovation, automotive and polyureas. www.utecheurope.eu/page.cfm/Link=13/t=m/goSection=1
IISRP annual general meeting in Cape TownTHE International Institute of Synthetic Rubber Producers (IISRP) has launched a website for its 56th AGM being held in Cape Town from 20-23 April. The AGM website provides complete information on the meet-ing agenda as well as online meeting and hotel registration. The business programme
theme, ‘Future Vision … Forward Move-ment’, with broad appeal to the business leaders of the rubber industry.
The AGM website also provides informa-tion about committee meetings, business and social programmes and general infor-
our speakers. www.iisrp.com/agm
80 FEBRUARY / MARCH 2015
PLAST 2015: positive signs from sector
CO
MIN
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PDIARY
Technology advances expected
Erema harnesses increase in recycling in USAInterest in the recycling of post-consumer plastic material is currently growing at a rapid pace in the USA. The complex mate-rial mixtures, high degree of moisture and heavy contamination of the input materials call for the most reliable recycling systems. With this in mind, Erema of Austria will show its Intarema TVEplus® system which,
upstream of extruder degassing, plus the
Another Erema highlight at NPE 2015 will be the latest product innovation Intarema K, enabling visitors to see for themselves how intelligent in-house recy-cling solutions can maintain consistent end
labour costs at the same time.
PET improvement systemNGR (Next Generation Recyclingmaschin-en GmbH) will hold the world premiere of
PET at the show. P:REACT follows the
condensation) and considerably improves the properties of PET – which is ideal for PET convertors or recyclers.
capability of PET to post condensate in the molten phase under vacuum. This post condensation leads to an increase of IV. The high performance vacuum effectively decontaminates the material from harmful chemicals, securing further use of the material for 100% food contact.
As molten PET enters the vertical part of P:REACT, strands are formed to create a suitable surface-to-volume ratio. The mate-rial is then collected in a horizontal drum and slowly pushed forward. Post conden-sation starts immediately as the strands are formed and is set forth until PET exits P:REACT.
IV increase is controlled by the residue time of the molten PET inside P:REACT and therefore can be adjusted to a desired level.
The cleaning of the material exceeds lim-its set by recognized food safety standards, but also effectively removes spin oil from
approximately 0,01 dl/g per minute.
www.ngr.at
The P:REACT polycondensation system from NGR actively controls the residue-time of the PET melt inside the reactor and automatically adjusts the machine parameters to recweive the desired IV at a consistent level
MANY of the world’s leading machinery, material and service suppliers to the plastics industry will exhibit at the NPE show in Orlando, Florida, USA from 23-27 March. Here we look at some of the expected technology advances.
Arburg will present an innovative light-
injection moulding with a side feeder that
melt. The advantages of this innovative
lengths of up to 50mm, a low incidence
The process will be demonstrated on a hydraulic Allrounder 820 S, operat-ing with a mould from Georg Kaufmann Formenbau. Through the over-moulding of
inserts (organic sheets), high-strength, re-silient composite parts are created, which weigh less than 200g at a length exceed-ing 500mm.
A six-axis robotic system picks up two organic sheets of different thicknesses
gently heated, process-reliably, using a new technology in the gripper system
Integrated Process Application) mould at a precise forming temperature. Here, form-ing of the inserts and injection moulding of the functional and reinforcement elements are performed simultaneously in a cycle time of around 55 seconds.
Laserfi lter
– The recently enhanced
Erema is particularly
processing of post-consumer materials with a high degree of contaminants
such as wood, paper, aluminium or
The composite part
provides a good illustration of how
– for example, for the automotive industry – with a high level of functional
Cannon celebrates
50th anniversary at JEC
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will be highlighted: ESTRIM, a complete moulding solution for HP RTM process designed for the produc-tion of automotive, leisure and sport parts; A third-generation preformer for carbon-reinforced composites will be illustrated. Its design has been optimised in the past 15 years, obtaining an industrially-proven solu-tion able to cope with the demanding cycle times dictated by the automotive industry parts; A new generation presses suitable to be used with different technologies (HP RTM, gap injection, compression moulding, etc) and different reinforcements (carbon and
The industrialisation phase of the innova-tive CRESIM (Carbon Recycling by Epoxy Special IMpregnation) project, aimed at the development of proper processing methods for the manufacture of CFRP parts using
The new, completely redesigned mixing head for co-injection of polyurethanes and
CANNON SPA IS REPRESENTED IN SOUTHERN
AFRICA BY REAC PU TECHNOLOGIES OF
JOHANNESBURG.
A 3D CAD rendering and photo of the new InterWet 30 mixing head designed by Cannon Afros for high-output co-injection of polyurethane
process). This head provides superior wetting performanc-es of the chopped reinforce-ment, leading to optimum mechanical properties of the
THE Cannon Group will present its most re-
technologies for composites and thermoform-ing at JEC Composites 2015 in Paris, France, Porte de Versailles Exhibition Centre, from 10-12 March.
Both Cannon and the JEC Europe Show celebrate their 50th anniversaries this year!
Examples of the most innovative solutions introduced by Cannon for the manufacture of carbon and glass-reinforced composites for all their possible applications will be illustrated in detail at JEC Composites with dedicated videos, samples and articles published in the Cannon Group’s website.
Over the past 50 years, Cannon has
technological solutions for the process of ure-thanes and, more recently, of epoxy-based composites.
Complete manufacturing lines for the pro-duction of a thermosetting or a thermoplastic composite part – from glass- or carbon-pre-
dispensing unit and mixing head, moulds, mould carriers, handling and heating systems and controls – are available at Cannon, from
Among other available tech-nologies, the following
www.reac.co.za www.cannon.com
Carbon-reinforced structural parts for components such as satellite dishes and innovative hybrid vehicles are made using
The third generation Cannon E-System high-pressure dosing unit, designed for HP RTM technology, that can be applied with epoxy or polyurethane resins
ment of the relevant tonnage and investment
CRESIM, the Cannon R+D project aiming at the industrialisation of the use of re-
The ‘cockpits’ of BMW i3 and i8 cars are made on a framework
made by Benteler in Ried, Austria, using Cannon machines
NPE: ‘KeepAmericaBeautiful’campaign
THE Plastics Industry Trade Association in the United States will partner with the Keep America Beautiful (KAB)
KAB’s ‘I Want to Be Recycled’
from 23-27 March in Orlando, Florida.
‘I Want to Be Recycled’ mes-
waste disposed of by show attendees. In addition, it will be prominently displayed in the Zero Waste Zone, a special sector of the show
mandate to reduce, reuse and recycle plastics. Visitors there will also be able to view a video
sponsored by Keep America Beautiful and the Ad Council, a
and directs audiences to the website at
Recycling areas at show dedicated to industry’s pursuit of zero waste
COMING UP
PPP Expo Africa events
the 18th PPP EXPO AFRICA events from 7-9 May 23-25 May
“PPP EXPO Africa is the only event
bio!PAC conference on bio-based packaging
from bio-based materials (i.e. from renew-able resources) is to run on 12/13 May in
all areas of bio-based materials will present their latest developments. Besides bio-
from suppliers and brand owners, different disposal options (end-of-life scenarios) will also be addressed.
www.bio-pac.info
84 FEBRUARY / MARCH 2015
A campaign poster showing a plastic bottle and a park bench bears which will be on show at NPE in March as well as to the wider public in the United States
which has been very successful
and diversion. “You can create
public participation you still don’t
Convention Centre, the Zero
tions, multiple displays of prod-ucts made with post-consumer recycled material, a cradle-to-
the Zero Waste Zone will be the
the environment.
Wallmart to spend big in USA – Retail/brand group Wallmart has committed to sourcing an additional $250-bil-lion worth of US-made goods over the next 10 years, a topic to be addressed by Cindi Marsiglio, Walmart vice-president of US Manufacturing. She is featured speaker at an SPI/IHS Key Market Seminar at NPE
www.inthehopper.org www.npe.org
Conductive Plastics
on the development and application of elec-trically and thermally conductive compounds.
29 June-1 July in Düsseldorf, Germany.
thermally conductive and electrically conduc-tive thermoplastic compounds to replace
and production of thermally conductive or electrically conductive plastics components.
www.amiplastics.com
Tomato clamshell packaging
made from PLA (looks identical to PET)
Sumitomo Demag will demonstrate nine machines at NPE (23-27 March), including one
with which the company will attempt to beat the world speed record for production of water bottle
caps. The machine will be running a 96-cavity hot runner mould. Each hour, the machine will
be producing over 180,000 lightweight 1.3-gram HDPE water bottle caps with tamper-evident
band moulded by mechanical slides. “The sub-two-second cycle, the waterfall of 96 caps out
the IMDvista vision inspection system – it will
Sumitomo-Demag USA
Engel customised, integrated systems increase competitiveness
DIARY
ENGEL of Austria, an international sup-plier of injection moulding solutions, is to present a number of innovative solutions at NPE2015 from 23-27 March in Orlando,
automotive, packaging, medical, teletronics
moulding solutions. The exhibits will show that the key to increased competitiveness can be found in both customised, highly-
standard machines.The highlights at the Engel booth include
tured in a one-shot process, the new high-performance Engel ‘e-speed’ machine, the particularly dynamic Engel ‘e pic’ pick-and-place robot as well as innovative service tools for an even higher level of process security and machine availability.
The plastics industry in North America continues on a course of growth. In particu-lar, there is an increasing demand for in-novative techniques and economic solutions for high-performance applications.
A main emphasis will be on lightweight construction, which is currently one of the areas with the strongest growth.
“In the next few years we can look for-ward to strong growth in the injection mould-
composite engineering,” points out Mark Sankovitch, CEO of Engel North America with headquarters in York, Pennsylvania.
established themselves in high-performance products, in the aircraft industry for example.
wider use in high volume applications, such as in the automotive sector, the biggest challenge at present is to develop manufac-turing processes that provide low unit costs despite high volumes.
One of the most interesting aspects of the display will be that of a ‘cell’ to produce a geometrically optimised and stress-resistant plastic brake pedal. The concept for manu-facturing a hybrid, brake pedal from ther-moplastic fabric is a venture by Engel and its partner ZF-Friedrichshafen. It received the Composite Innovations Award in 2011, and has been consistently enhanced by ZF since then.
Engel will be offering a glimpse into the
Hybrid brake pedal is 30% lighter than conventional steel pedals, and makes previously used process steps unnecessary
FEBRUARY / MARCH 2015 85
at its stand at the exhibition. Using a vertical Engel insert 1050H/230 single machine with an Engel ‘easix’ multi-axis industrial robot
(known as thermoplastic fabric) will be heated, preformed in a mould and imme-diately over-moulded with polyamide. The
no cutting is necessary.Thermoplastic fabric offers high strength
and rigidity. In addition, the product develop-ers at ZF have adapted the layer structure to the component load when designing the brake pedal. This enabled the component weight to be reduced by around 30% com-pared to conventional steel brake pedals—without impairing load-bearing capacity. In addition, the lightweight construction method makes many conventional manufacturing process steps unnecessary, thereby in-creasing productivity and cutting unit costs.
Process integration leads to greater
Engel duo 2550/610 US injection mould-ing machine with an integrated Engel viper 20 robot, Engel will demonstrate the fact that not only can process steps upstream or downstream of the injection moulding machine be combined, but also different process technologies. To produce centre console components of PC-ABS, Engel will combine two technologies: Engel foam-melt, the MuCell® foam injection moulding process developed by Trexel of Wilmington, Massachusetts, USA, and the vario-thermal injection moulding process from Roctool (Le Bourget du Lac, France). The goal is to pro-duce thin-walled parts with very high surface quality along with the excellent reproduction
moulding step.To demonstrate the versatility of this
combination of processes, the part being moulded will have varying wall thicknesses and surface structures. Thanks to Engel
including the undercuts, and the component has no sink marks after cooling. At the same time, the Roctool technology provides a
applications aimed at car interiors, this dual technology integration opens up new
goods and household products.
America, this system solution introduces the new design of the Engel duo injec-
in particular from improved ergonomics thanks to a lower operating height provid-
area. Other features of the new machine generation include roller rail systems for
movement and a much cleaner mould area thanks to the removal of central lubrication.
Hybrid pedal – The
Extremely rapid growth in India presents different dynamic
Innovation through technology at KZN show
THE extremely rapid growth of the plas-tics industry in India, where consumption of the material is expected to double between now and 2020, suggests that PlastIndia in February could present a different dynamic to most of the other global scale trade shows.
Consumption of plastics in India is an-ticipated to increase from about 4.5 mil-lion tons p/a at present to about 9 million tpa by 2020, which is a rate in excess of anything experienced anywhere to date.
That sudden increase suggests that India’s processors are going to run short of just about everything as this quest unfolds, according to Jayesh Rambhia of the PlastIndia Foundation, who gave a promotional presentation about the show in Cape Town in November.
“We’re running short of machinery, we’re running short of materials, we’re running short of capital and just about everything else,” said Rambhia, of Prem-sons Plastics in Mumbai. Premsons is a manufacturer of sports drink bottles. Rambhia is a PlastIndia Foundation volunteer, with part of his undertaking being to promote the event in his busi-ness activities. He spent a week in South Africa, making business contacts as well as for sightseeing.
national market for plastics internation-ally, a stat which may change soon if Rambhia’s forecast is even close to cor-
EXHIBITION space is in high demand for this year’s KwaZulu-Natal Industrial Technology Exhibition (KITE) which will be held at the Durban Exhibition Centre from 9-12 June.
The biennial event is the province’s leading industrial showcase offering exhibitors a unique marketing opportunity. Established in 1984, KITE has become a key component in the industry’s exhibition calendar, and the 16th installment promises another opportunity for local and international businesses to showcase their products and services while providing a platform www.kznindustrial.co.za
Consumption expected to double to about 9 million tons by 2020
More robotics technology at Durban event in June
for business networking.“The 2015 exhibition is themed
‘Innovation through Technology’ with a focus on clean, green technology,” explained Gary Corin, MD for Specialised Exhibitions Montgomery, organiser of the show.
“This year’s event will also feature more robotics technology, alongside an array of other advanced technological types,” said Corin.
The 2013 edition drew 5131 visitors
86 FEBRUARY / MARCH 2015
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rect. Other unusual stats include the fact that India is home to an estimated 20% of the world’s population and the cost of living for labourers of about $40 a month suggests that labour rates in the country are among the lowest in the world – factors which could make the Indian market attrac-tive to international suppliers.
www.plastindia.org
Jayesh Rambhia of the PlastIndia Foundation hosted a promotional event for PlastIndia in Cape Town in November, and promptly presented gifts to his hosts on the day, Loretta Welcomets and Isabella Brettenny of Plastics|SA
DIA
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COMING UP
Pipeline Coating: 17-19 February Trend Hotel Savoyen, Vienna, Austria www.amiplastics.com/events
European Additives & Colors: 23-25 February Barcelona, Spain: www.4spe.org/ace15
Austrian Plastics Industry Showcase: 9-13 March
ICE Europe: 10-12 MarchMunich, Germany: www.ice-x.com
JEC Europe: 10-12 MarchParis, France: www.jeccomposites.com
World Elastomer Summit: 12-13 March Lyon, France: www.wplgroup.com
Hostex: 15-18 March Sandton Convention Centre: www.hostex.co.za
Propak East Africa: 17-19 March Nairobi, Kenya: www.propakeastafrica.com
Green Polymer Chemistry: 18-19 March Maritim Hotel Cologne, Germany: www.amiplastics.com
Plastics in Auto Engineering: 18-19 March Mannheim, Germany: www.kunststoffe-im-auto.de
NPE 2015: 23-27 MarchOrlando, Florida, USA: www.npe.org
World Rubber Summit: 24-25 March Singapore: www.singex.com
Polymer Foam: 14-15 April New Jersey, USA: www.amiplastics.com
Utech Europe: 14-16 April Maastricht, Netherlands: www.utecheurope.eu
MedTech Europe: 21-23 April Stuttgart, Germany: www.medtecheurope.org
Plast 2015: 5-9 May Fiera Milano, Italy: www.plastonline.org
PPP Expo Kenya: 7-9 MayNairobi, Kenya: www.expogr.com
Bio!PAC: 12-13 May Amsterdam, Netherlands: www.bio-pac.info
Test Methods for Composites: 19-20 May Manchester, United Kingdomwww.SeminarsForEngineers.com
ARMSA Rotation 2015: 20-21 MayBlades Conference Centre, Pretoria: www.armsa.co.za
Afriplast Expo: 20-22 MayGallagher Convention Centre, Johannesburg www.exhibitionsafrica.com
Indutec: 20-22 MayGallagher Convention Centre, Johannesburg www.exhibitionsafrica.com
ChinaPlas: 20-23 May Guangzhou, PR China: www.ChinaplasOnline.com
PPP Expo Tanzania: 23-25 May Dar-es-Salaam, Tanzania: www.expogr.com
Conductive Plastics: 29 May-1 June Hotel Nikko, Düsseldorf, Germanywww.amiplastics.com
African Summit on Marine Debris: 4-5 JuneKirstenbosch Gardens, Cape Town [email protected]
KZN Industrial Technology Show: 9-12 June
Durban Exhibition Centre: www.kznindustrial.co.za
Plastics Closures Innovations: 9-12 June
www.amiplastics.com
IOM³ National Rubber Conference: 18-21 JuneCathedral Peak Hotel, Drakensberg: www.iom3.co.za
Saitex: 21-23 JuneGallagher Convention Centre, Midrand www.exhibitionsafrica.com
ExtruAfrica: 3-7 AugustPotchefstroom, North West: www.extruafrica.org.za
Euromold: 22-25 September Messe Düsseldorf, Germany: www.Euromold.com
CLASSIFIEDADVERTS
Contact: Desire’ PrestonPh: 011 894 3520 • Fax: 086 673 9018 • Email: [email protected]
or visit us at www.jcl.co.za
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E-mail:
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Ampa Group 17
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Cabletech Marketing 55
Carst & Walker 24
DemaPlastech 35
DH Polymers 69
Eder Design 13
Extrupet 09
GF Plastic Machinery 45
Hosaf 79
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Masterbatch SA 71
MGMW Trading 61
Miracle Mould 64,65
MJH Machine Tools 41
National Tooling Initiative 57
Nissei ASB 37
Orion Engineered Carbons 51
Performance Colour Systems 85
Piovan 69
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PlastiChem IFC
Plastomark 73
PMS Plastics OBC
PolyOne 25
Polysaf Chemical 49
Protea Chemicals IBC
Rawmac 81
Reac PU Technologies 23
Relloy 63, 75
REPI S.p.A 01
RNL Plastics 21
Safripol 05
SAPY Colours 31
Scinergy Chemicals SA 67
SES 87
Ultra Polymers 93
Welltec 27
Advertisers:Februay / March 2015
FEBRUARY / MARCH 2015 95
The Albatross hull weighs just 28kg and the deck a mere 22kg. The parts are between 2 and 6mm
thick and enable a 25 to 30% increase in rigidity compared with the classic reinforcement stack
www.chomarat.com88 FEBRUARY / MARCH 2015
FOLLOWING on from its successful use
in the aeronautics sector, C-PLY™ is set
to be a key material in Jean-Marie Finot’s
latest yacht, the Albatross. Both the hull
and the deck of the boat will be made
from C-PLY, Chomarat’s range of carbon
multiaxial reinforcements.
Because C-PLY is both light and ultra-
resistant, it helps to make the Albatross a
boat that is fast, sturdy and easy to handle.
Thanks to its composite reinforcements,
the boat’s hull weighs just 28kg and the
deck a mere 22kg! The parts are between
2 and 6mm thick and enable a 25 to 30%
increase in rigidity compared with the
classic reinforcement stack.
C-PLY structure, which totally respects
cost effective solution.
“The combination of different C-PLY
reinforcements in a monolithic laminate
has a sandwich structure effect that
enables a 25 to 30% increase in rigidity
compared with the classic reinforcement
stack (0/90),” says Jean-Marie Finot,
founder and CEO of FINOT group.
By layering multiaxials in a monolithic
the length of the boat, the boat’s rigidity
waves is supported by the boat’s shell,
comprised of all the vertical structures
that make up the exterior part of the
boat’s hull. This shell must have bend
resistance from one longitudinal section
to the other, from one rail to the other.
more demanding characteristics (parts
vector, visible automobile parts or those
subject to impact loading in aeronautics),
placed on the perpendicular of the main
effort axis and/or by using extremely thin
basic plys (50g/m²).
Totally innovative multiaxial materials
“This means we can develop totally
innovative multiaxial materials,” said
Philippe Sanial, Group R&D director
at Chomarat. C-PLY enables parts to
be mass produced because it can be
manipulated without risk during the
RTM stage and because it is a drapable
material that can be moulded around the
component.
“We chose these carbons because
they are compatible with Vinylester
resin, a material with the best resistance
to corrosion and water absorption that
carbons also enable parts to be mass
produced using the innovative RTM
process we developed for large-scale
parts. The Albatross is the only boat
currently manufactured using this
process,” said Finot.
Chomarat supplies some of the carbon
for the Albatross.
A C-PLY™
boat for everyone
Sports.indd 88 2015/02/17 10:16 AM
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Untitled-2 1 2014/05/14 9:28 AM