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Industry concerned about Govts proposed

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Plastics for Life global parts competition

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VOL 14 ISSUE 3 JUNE / JULY 2016 www.saplastics.co.za

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ASS

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STICS IN

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SOUTH

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(PISA)

Multi-million

investment for Ferro

the loopPolymers closing

MCG INSTALLS MAJOR

INJECTION PLANT

Plastics|SA latest

recycling fi gures

Alpha Plast hits the jackpot

fi rst local 90 MFR resin for injection moulding

For more info call 0800 006 772 or go to www.plastichem.co.za

Durethan and Pocan are registered trademarks of LANXESS

Give you a reach that stretches far

beyond other materials.

3VUNLYV^WH[OZc,MJPLU[LULYN`\ZHNL-SV^WH[OZILJVTLSVUNLY[OHUL]LYPTHNPULK^OPSL[OLWYVK\J[WYVWLY[PLZYLTHPU]PY[\HSS`\UJOHUNLK6W[PVUVMYLK\JPUN^HSS[OPJRULZZ^P[O[OLPTWYV]LKV^WYVWLY[PLZ*`JSL[PTLZJHUHSTVZ[ILJ\[I`[VPUJYLHZPUNV\[W\[HUKZH]PUN[PTLHUKLULYN `

2016 Copyright by SABIC.

All rights reserved.

THE MORE WECOLLABORATETHE MORE WEINNOVATEInnovation never happens in isolation.Our ten thousand-plus registered patentsare the product of collaborations withcustomers. These have resulted in smarterfertilizers, stronger plastics and lightertransportation. Thats why ambitiousglobal companies choose to work with us.They know that collaborating with expertscreates Chemistry that Matters for them.

SABIC.com

Summit Publishing cc

t: +27 (21) 712 1408

f: 086 519 6089

c: +27 (82) 822 8115

e: saplastics@iafrica.com

Postnet Suite 42, Private Bag X16,

Constantia 7848, Cape Town, South Africa

Unit 8, Bergvliet Village Centre, Cnr Hiddingh &

Childrens Way Roads, Bergvliet 7945

www.saplastics.co.za

GAUTENG

Lowrie Sharp

t: (011) 793 4691

f: (011) 791 0544

c: 082 344 7870

e: lowrieplasticsmedia@absamail.co.za

KZN

Lynne Askew

t: (031) 764 2494

f: (031) 764 0676

e: lynne@summitpub.co.za

Printed by: Tandym Print, Maitland, Cape Town

SA Plastics Composites + Rubber Technology is published

six times a year and focuses on these industries in South

and southern Africa. We welcome news, articles, technical

reports, information in general and photographs about

events and developments related to the plastics industry.

The views expressed in the magazine are not necessarily

those of the publisher. Views expressed are not necessar-

ily those of the Plastics Converters Association, Institute of

Materials or Association of Rotational Moulders either.

Copyright: All rights reserved.

ISSN number: 1684-2855 (ISDS Centre, Paris)

Summit Publishing: CK 9863581/23

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

(martin@summitpub.co.za)

Editor: Tessa OHara

(tessa@summitpub.co.za)

Editorial assistant: Heather Peplow

(heather@summitpub.co.za)

Financial manager: Lisa Mulligan

(lisa@summitpub.co.za)

Designer: Jeanette Erasmus Graphic Design

(jeanette.erasmus@lateraldynamics.co.za)

Bronwen Moys Blinc Design

(bronwen.clarke@gmail.com)

PVC was

used in an

unusual application

at the Two Oceans

Aquarium in Table

Bay recently when a

cone produced out of

H[LEOH39&ZDVXVHGto capture the female

ragged tooth shark

here and lift her out of

the tank; after which

she was transferred to a holding tank and transported to East London,

where she was released into the big blue.The cone is made of a soft PVC

which has the advantages of being both strong and transparent. The

VKDUNKDVEHHQWWHGZLWKDWUDQVPLWWHUWKDWFRXOGODVWDVORQJDV10 years. The soft PVC cone was produced by Brians Canvas in what

looks like a fairly rare application.

Dow convenes Africa media indabaDOW Packaging & Specialty Plastics convened an unusual event in South

Africa recently when it brought together trade journalists from across Africa

LQZKDWPXVWVXUHO\EHWKHUVWHYHUPHHWLQJRI$IULFDVSDFNDJLQJDQGplastics writers. Two dozen journalists from across the continent from as

IDUDHOGDV0RURFFR$OJHULD1LJHULD*KDQD.HQ\DDQG6RXWK$IULFDmet for the two-day event at a hotel in Johannesburg in April.

With the recent enthusiasm for trading into Africa having come off its

highs of late, Africa certainly needs help where it can get it. Dows range

of packaging products and polymers could go some way towards helping

turn the tide. Many hurdles lie in wait, not least the challenge of actually

getting the products to the people. Among the obstacles are the fact that

intra-Africa trade has been declining, as has manufacturings contribution

to GDP, which has fallen from 3% to just 2% which is extremely

worrying (if you consider that manufacturings share of GDP in Thailand,

for example, is 28%).

We wish Dow well in the quest and many in South Africa will share

that sentiment.

Study predicts Plastic Age to last millennia6&,(17,676KDYHEHHQDEOHWRGHGXFHDJUHDWGHDODERXW(DUWKVSDVWthrough examining fossils. But in the future the story of our present may

be yet gleaned from an alternate source plastics. Published in the

journal Anthropocene, scientists from the University of Leicester have

sought to examine the long-term impact of polymers on our planet. It is a

study which claims we may be on the brink of a Plastic Age.

According to the research, human activity will bury the lands and

oceans under a layer of plastic waste by the mid-century. In addition, the

planets surface itself will be altered by these polymers.

Jan Zalasiewicz, Professor of Palaeobiology from the University of

Leicesters Department of Geology, explained: Plastics are pretty well

HYHU\ZKHUHRQ(DUWKIURPPRXQWDLQWRSVWRWKHGHHSRFHDQRRUDQGcan be fossilised into the far future. Once buried, being so hard-wearing,

plastics have a good chance of becoming fossilised and leave a signal of

the ultimate convenience material for many million years into the future.

3ODVWLFVWUDGHTXDOL FDWLRQDFRUUHFWLRQTHE article in our April/May issueSDJH3ODVWLFVWUDGHTXDOLFDWLRQDSSURDFKHVFHUWLFDWLRQZDVLQFRUUHFW7KHIDFWLVWKDWWKH7HFKQLFDOWorking Group (Plastics Manufacturing Setter Trade Test) and parties

involved in the trade test process are still in discussion about entrance

requirements for the Plastics Manufacturing Machine

6HWWHUWUDGHTXDOLFDWLRQ7KH0HUVHWD3ODVWLFVChamber is also still in discussion about the Part

4XDOLFDWLRQVWKDWQHHGWREHGHYHORSHG IF YO

U HAVE

SOMETHING TO SA

Y

Look at the brigh

t side: if you

have some gem of

wisdom to

impart, please wr

ite to us at

saplastics@iafrica

.com

BY THEWAY

2-3.indd 2 2016/06/08 11:18

for large injection moulds,

extruders, rollers, autoclaves and

other processing equipment

Simultaneous readout of temperature set-point and actual value

Clear arrangement of operating and indicating elements

Solid state relay (SSR) instead of heating contactor

All components exposed to water are made of non-rusting materials, hence long service-life

Achieves estimated 24% reduction in rejects and 20% increase in productivity

REGLOPLAS

High-performance

temperature control units

New, more effi cient

Type 90 Smart

Temperature control units for water up to 90C RT 70 control system

Solid-state relay

(SSR)instead of

heating contactor

Automatic phase-

changer for pump

direction (clockwise)

Alarm buzzer

Heating capacity 9 kW

Cooling capacity 24-90 kW

Pump capacity 60 litres/min,

3.8 bar

JENOWILL SERVICES

Type 150 Smart

Temperature control units for oil up to 150C

Controller RT61 PID

Outlet temperature

max 150C

Heating capacity

at 400V 6 kW

Cooling capacity

28kW @ 140C

Pump capacity 60

litres/min, 3.8 bar

Contact Willy Tschopp

Tel: 021 551 7241

Fax: 021 551 7243

28C Lilly Park, Railway Rd

Montague Gardens, Cape Town

jenowill@iafrica.com

www.regloplas.com

NEW

JUNE / JULY 2016

Contents

www.mpact.co.za

ON THE COVER

Find out more at www.saplastics.co.za

VOLUME 14 NR 3

44

6

8

10

12

14

16

18

20

24

28

30

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36

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44

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38

MPACT Polymers unveiled

its new 20 000m bottle-to-

bottle Savuka rPET factory

in Wadeville on 10 May and

immediately announced that

6000 tons of the expected 21,000

tons of rPET it will produce

annually has been contracted

to Coca-Cola bottler ABI. Read

more on page 6-7

INDUSTRY NEWS

Mpact Polymers closing the loop in bottle-grade recycling

Recycling stats: Lack of quality material

MCG installs major injection plant in Malvern

Alpha Group signs distribution agreement with Ampacet

Continental Compounders unveil state-of-the-art

polymer testing facility

GreenacresLQWURGXFHVLWVUVWIRDPFXWWLQJV\VWHPFerros multi-million investment in black,

white masterbatch lines

Safripol SURGXFHUVWORFDO0)5UHVLQIRUinjection moulding

Maverick Engineering is a leader in pouch bag machines

Industry concerned about Govts proposed

packaging charge or tax

ASSOCIATION NEWS

POLYCO focuses on building strong recycling value chain

Plastics|SA: Userve donates machine for training

SAVA: 9LQ\O9HULHGPRYHVVRXWK

PEOPLE

Sun Ace 6RXWK$IULFDWKDQQLYHUVDU\

DESIGN

Plastics making our lives better!

COMPOSITES NEWS

Formo )LEUHJODVVFHOHEUDWHV\HDUV

MATERIALS & EQUIPMENT

Bhler changes the dynamics of polymer sorting

Latest version of Gapa machine from Technimac

2-3.indd 3 2016/06/08 11:18

Material, machinery makers progressSA companies invest to boost supply and quality

COMMENT

4 JUNE / JULY 2016

New rPET line Mpact Polymers unveiled its new 20 000m bottle-to-

bottle rPET factory in Wadeville in May. It is expected to manufacture

about 21,000 tons of Savuka rPET annually. The main polymerization

unit in the R350-million project plant includes the Krones processing

unit and Piovan decontamination system seen here

THIS ISSUE

Martin Wells, Publisher

MOST companies around the country and even across the UHJLRQDUHQGLQJWKHJRLQJWRXJKat the moment but its not as if one

can switch the lights off and walk out although some people have been known to do that and leave the lights on.

So we may as well make the best of it and, as you will see in the following pages, quite a lot of companies are doing just that.

We publish reports about plant improvements by the material manufacturers Alpha Plast/Elco Plastics, Continental Compounders, Ferro Plastics, Mpact Polymers and Safripol, all of who have made substantial investments to improve quality and supply, plus in some cases get into exports (and some instances not only into Africa).

Then we also look at developments in the machinery manufacturing area where Technimac has continued its virtually ceaseless evolution of the Gapa bag-making machine, Maverick Engineering has succeeded where few would have expected by becoming a world leader in the manufacture of stand-up pouch machines (it recently supplied a system to the USA to produce 1000-litre pouches, a beast of machine which is 33m long). and then, in a nice little surprise, Greenacres based in 0DOPHVEXU\RQWKH:HVW&RDVWKDVLQWURGXFHGLWVUVWfoam-cutting machine, an entry level yet world class system it says.

Now its quite easy to say these developments are incidental, but the fact is that these achievements are the result of extensive teamwork and planning on the part of all those mentioned, starting with the owners and management of these businesses the people with the vision to progress with their enterprises and all the individuals involved in the teams.

The weakening of the rand exchange rate is obviously also a factor, especially for equipment manufacturers, but it appears ironically that most of the components are imported. Thats the case at least partly because

South African engineering companies are seen as over-priced and lead times are too long, in other words uncompetitive. However, it appears a slight shift is underway and that some local manufacturers are becoming more competitive.

On the converting side, there are also some impressive achievements, not least by MCG, which has installed a world-class injection moulding plant at its site in Malvern, Johannesburg with a price tag estimated at about R60-million; and then Jannock Tool & Die and Jannock Plastics on the West Rand are celebrating 30 years. Their operation has succeeded partly due to their ability to manufacture their own tools and, using that advantage, to partner effectively with customers, particularly during the product development phase.

One of the most important aspects behind the success of these companies is their ability to support their customers on an on-going basis that leads to lasting working relationships.

Packaging tax

We also report about Packaging SAs drive to engage with government on the proposed tax on packaging. Given the history of the failed Buyisa-e-Bag project and the disappearing funds from the plastic bag levy, plastic packaging companies are nervous about the prospect. If the bag levy had been used to boost recycling and litter collection and recycling, there would probably have been at least some enthusiasm, but thats not the case.

One of the interesting things thats come out of the process is the situation of plastics within the broader packaging sector: of the four main materials in use, plastic is the only one which KDVVKRZQVWHDG\JURZWKRYHUWKHODVWYHyears for consumption and recycling, whereas consumption of glass, metal and paper have all declined which is not a good sign.

Achievements are the result of extensive teamwork and planning

3137_Safripol_Generic_Ad_PRINT.indd 1 2014/07/24 3:02 PM

ONE could quite easily drive by MCGs plant in Johannesburg without even noticing that a factory operates from the spot. About the only thing that gives the place away is the steady stream of trucks emerging out of the tight little side street in Malvern, transporting mainly crates to beverage manufacturers around the country.

The site in fact houses one of the largest injection moulding installations in the coun-try, and there has been plenty of activity of late: in what was one of the major capex projects in the industry last year, MCG installed four KraussMaffei injection mould-ing machines together with a major Frigel cooling plant plus a complete new materials KDQGOLQJV\VWHPIURP0RUHWWR$IWK.0machine is on order, due to arrive in August, together with new chillers and material handling equipment.

NEWS

The crate moulds, from Schoeller Allibert Germany, are serviced

by personnel from the in-plant Schoeller toolroom at the MCG

site in Malvern, Johannesburg

Crates for the beverage sector

constitute the main product

The plant now boasts a complete

new materials handling and blending/

dosing system from Moretto of Italy

MCG installs major injection plant in Malvern4x KM machines plus one on order complete cooling and materials

handling systems in R60m-plus project for the 2015/16 year

6

JU

NE

/ J

ULY

20

16

The project is estimated to have come in at over R60-million. And the high perfor-mance capability of the plant is expected to shake up the plastic crate market in South Africa.

In what was effectively a standard replacement of older equipment, MCG installed the four fast-cycling Krauss Maffei machines, starting late in 2015, including three 1000-ton clamp force MX systems plus a single 650t GX machine and a 1300-ton MX to be installed in August.

The hydraulic Krauss Maffei systems, reputed to be among the most expensive available, were chosen by the MCG team for their high reliability, high output and low mainte-nance requirement.

Supplied by Plastic & Chemical Trad-ing, the KM machines exhibit optimum power-to-performance criteria, achieving really low kW/hr/kg ratios and very high kg/

KUSURFHVVLQJVSHHGVZKLFKDUHGHQLQJcriteria for convertors.

The KM units replace a number of older machines, some of which have been moved to the new MCG plant in Windhoek while the other excess machines have apparently been cut up or earmarked for further expansion.

To back up the injec-tion cell, and with the goal of doubling the output of crates on the same footprint, MCG installed a high-volume water chiller system from Frigel of Italy plus a materials handling

system from Moretto (also Italian).The 1200kW Frigel Ecodry cooling sys-

tem, one of the largest chilling plants in the industry in SA, was a prerequisite for the project: fast-cycling large injection systems require highly dependable supply of chilled ZDWHUDWDVSHFLFSUHVVXUHLQWKLVFDVH4 bar at the machines. The Frigel system

Capability of plant expected to shake

up plastic crate market.

JUST BRIEFLY

also supplies the new Microgel chilling system, which operates at 5.8 bar for the mould cooling. At present the unit supplies chilled water to the four new machines with additional capacity to accommodate the new 1300-ton machine arriving in August.

The Frigel Ecodry closed-loop adiabatic cooling tower uses up to 99% less water than conventional open cooling towers. The system does not require insulated pipes (further reducing installation costs) and cools the returning process water via heat exchangers that are cooled via variable speed fans further reducing energy con-sumption. Due to its modular construction, the system can also be expanded.

The chiller installation is backed up by an enhanced materials handling system from Moretto, together with a DVX dosing unit. This dosing unit, with vertical mixer, can dose up to 10 machines simultaneously.

Both the Frigel cooling system, the Micro-gel and Moretto equipment was supplied by Demaplastech.

www.mcg.co.za

Operations director Bobby Damalis,

who has been at MCG for over 30 years,

LVDORWKDSSLHUZLWKWKHHIFLHQWPDWHULDOsupply achieved on the Moretto system. The

DVX dosing system with vertical mixer can

accommodate up to 10 dosing units

Fluidra of Spain buys WaterLinx in SAWATERLINX, the pool and spa supply

business which, almost unseen by all

except those in the plastics pool cleaner

supply sector, had over the past few

years put together a virtual cluster of

associated suppliers, has just as un-

noticed been purchased by Fluidra, a

Spanish group.South Africa was at one stage a

world leader in automated pool clean-

ing systems, with marques such as

Kreepy Krauly and Aquanaut becoming

household names worldwide. WaterLinx

gained ascendancy in this market over

the past few years by buying compo-

nent manufacturers such as Injecta

Plastics and Sharmark Plastics, backed

up by its supply of pool chemicals

and other consumables and pool/spa

products. This duly attracted the interest

of Fluidra, a multinational group listed

on the Spanish Stock Exchange, which

recently acquired 72% of WaterLinx; the

founding WaterLinx shareholders retain

the remainder.Fluidra operates in 44 countries and

its products are distributed to more than

170 countries. The company special-

ises in solutions for water conservation,

handling, treatment and enjoyment.

South Africa is the sixth largest pool

market in the world with an estimated

800,000 residential pools (surely not?)

and about 2000 public pools; it also

serves as a gateway towards other

markets on the African continent, the

company said in a statement.

Fluidra-WaterLinx SA has just completed

a move from Wynberg in Johannesburg to

Denver, where it has taken over the premises

previously used by the Astrapak companies

Cinqplast and Plastop.

GreenTech is new Engel agentGREENTECH Machinery is the new

Engel representative in Southern Africa.

One of the most widely used injection

moulding machines in South Africa,

(QJHORULJLQDOO\RSHUDWHGLWVRZQRIFHin Johannesburg. Then, in about 2009;

WKHRIFHZDVVKXWDQGWKH(QJHOSHUsonnel merged into Maritime Marketing,

and moved to Maritimes premises in

Kyalami.The new GreenTech team recently

separated from Maritime and moved to

premises in Quellerina, Johannesburg.

Patrick Bracke is the managing direc-

tor of GreenTech and Johnny Lendia,

Martin Uys and Marc van Tonder are

the new companys service engineers.

The change is fully supported by

Engel Austria GmbH, said Bracke.

MCG is making maximum

use of factory space and has

literally squeezed the four new

KraussMaffei machines as it

progresses towards the goal

of doubling crate output from

the same footprint

In a project with an estimated value of R7-million, MCG installed what is effectively an entirely new

toolroom at its plant in Malvern, Johannesburg, late last year. Enjoying themselves at the opening of the

tool room were Chris Oberem, Riccardo Paoletti from Frigel Italy, Ian Victor, managing director of MCG

Industries and Jacques Kleynhans, managing director of Demaplastech.

So cool! The massive Ecodry closed-loop

cooling system from Frigel supplies chilled water

to the new machines at 16 and 4 bar pressure

The peripheral equipment was vital for the KraussMaffei machines to achieve optimum performance, but the project management at MCG must have held their nerves as the bud-get ballooned. Now, according to MCG opera-tions director Bobby Damalis, all the systems production targets have been achieved and its all systems go at the Malvern site.

THE lack of a consistent incoming stream of recyclables was the single biggest challenge plastics recyclers had to face during 2015.

This is according to the latest

Plastics|SA recycling report which

points out that a large quantity of the

materials that were made available

for recycling were recovered by waste

SLFNHUVRIIODQGOOVLWHVZKHUHWKH\ZHUHcontaminated and very poor quality.

In the Northern Province, where the

demand for recyclable materials exceeds

supply, up to 40% of materials had to be

scrapped or rejected due to impurities.

According to Plastics|SA executive

director Anton Hanekom, this clearly

highlights the need for an effective

separation-at-source infrastructure to be

implemented throughout the country.

The plastics recycling industry around

the world is taking strain. Analysts agree

that 2015 was one of the toughest years

for recyclers both locally and abroad

in more than a generation, owing to

historically low oil prices that led to lower

polymer prices. This in turn had a direct

impact on the price of recycled material,

which resulted in minimal growth and a

slowdown in the amount of plastics we

DUHDEOHWRGLYHUWIURPODQGOOKHDGGHG.H\QGLQJVIRUWKHSODVWLFV

UHF\FOLQJJXUHVLQFOXGHSouth Africa mechanically recycled

292 917 tons of plastics in 2015 an

increase of 3% year-on-year from 2014.

2YHUWKHODVWYH\HDUVWKHFRPSRXQGHGgrowth in plastics recycling was 5.5%

per annum

Domestic production of virgin polymers totalled 1 490 000 tons in 2015,

growing 6.4% from 2014. This growth

is a result of the weakening exchange

rate against international currencies

that lead to local procurement of

plastics products rather than imports.

A total of 310 641 tons of plastics were

GLYHUWHGIURPODQGOOLQless than in 2014 and is due to the

VLJQLFDQWUHGXFWLRQLQWKHH[SRUWRIrecyclable waste.

7KHRYHUDOOGLYHUVLRQIURPODQGOOUDWHwas 20.8% decreasing from 22.5 %

in 2014.

Strong growth was seen in the recycling of PET, PE-LD/LLD and PS

due to new capacities that came on

line in 2015.

Recycling rates of PE-HD, PP and PVC declined as some of the

products traditionally made from

recyclate of these materials are

directly linked to consumer spending

and mining activities.

Formal employment in the recycling sector increased by 3.3% to 6 234

permanent jobs.

Informal employment has grown by 3% to an estimated 48 820 collectors.

The recycling industry invested 48% more in capital equipment per ton

of material processed in 2015 to

deal with increasing demands and

improved quality requirements.

Processing costs increased 15.4% year-on-year with the biggest

contributors to cost being water,

electricity and transport.

The way forward

According to the Plastics|SA report, the

following elements are needed to grow

6RXWK$IULFDQUHF\FOLQJJXUHVRYHUWKHQH[WIHZ\HDUVWRFRPHSROLWLFDOwill, stakeholder commitment, quality

RIUHF\FODEOHVHQHUJ\HIFLHQF\SXEOLFawareness and education, alternate

technologies.

The plastics recycling industry has

achieved outstanding results in the

face of many obstacles and challenges.

However, we need to use these

challenges to help us adapt to changing

market needs and expectations. With

the help of brand owners and retailers

who are willing to get actively involved

by putting pressure on the converters

to design products that are recyclable

and contain a percentage of recycled

material, we will be able to take

SODVWLFVUHF\FOLQJWRDWRWDOO\QHZOHYHOHanekom concluded.

To read the complete 2015 Plastics Recycling report or for more

information, visit

8 JUNE / JULY 2016 www.plasticsinfo.co.za

Lack of quality material highlights need for waste separation at source3ODVWLFV_6$UHOHDVHVSODVWLFVUHF\FOLQJJXUHV

INDUSTRY NEWS

$QQXDO6RXWK$IULFDQFRQVXPSWLRQDQGUHF\FOLQJIRUWKHODVWYH\HDUV2011 2012 2013 2014 2015

Total tons converted 1 300 000 1 370 000 1 400 000 1 400 000 1 490 000

% growth (conversion) -1,0% 5,4% 2,2% 0,0% 6,4%

Total tons locally recycled 230 111 254 054 260 930 284 521 292 917

% growth (recycled) 0,9% 10,4% 2,7% 9,0% 3,0%

Recycling rate 17,7% 18,5% 18,6% 20,3% 19,7%

Waste exported 9 758 14 744 18 919 31 087 17 724

% growth (waste exported) 7,8% 51,1% 28,3% 64,3% -43,0%

7RWDOWRQVGLYHUWHGIURPODQGOO 239 869 268 798 279 849 315 607 310 641'LYHUVLRQIURPODQGOO 18,5% 19,6% 20,0% 22,5% 20,8%7RQQDJHVODQGOOHG 1 060 131 1 101 202 1 120 151 1 084 393 1 180 459JURZWKODQGOO -1,4% 3,9% 1,7% -3,2% 8,7%

120 000

100 00

80 000

60 000

40 000

20 000

0

To

nn

ag

es

re

cy

cle

d

PE-LD/LLD PE-HD PET PP PVC PS & PS-E Other

2011 95 852 38 979 30 690 40 282 16 704 3 213 4 388

2012 98 971 45 950 35 786 47 080 16 812 3 394 6 060

2013 97 778 50 519 41 302 46 331 16 205 3 796 4 998

2014 98 563 62 809 42 911 50 718 18 488 4 801 6 231

2015 104 881 59 992 53 493 47 685 15 363 5 873 5 631

3ODVWLFVPDWHULDOVUHF\FOHGLQWKHODVWYH\HDUVDOOPDWHULDOV

NEWS-RECYCLING.indd 8 2016/06/08 11:36

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NEWS

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VWHSZDVWRRIIHUFRORXUFRPSRXQGLQJDQGSolar solution The photo-voltaic inverter system at Alpha

Plast is generating approximately 1000 KVA a day. An A grid

tied solution, in which all the self-generated current is used

in the compounding operation, the roof-mounted PV panels

and inverter system were supplied by Kaco Energy and

Solareff, with most of the accessories sourced from China

The PV systems control panel shows

how much CO2 is saved daily, on this

day an estimated 990kg was kept out of

the atmosphere, the equivalent of half a

barrel of oil

Ready to roll The name of the game at all

stages of the PVC compounding operation

LVWRPDLQWDLQUPFRQWURORISURGXFWLRQcosts and QC; here bulk bags and bagged

material await shipment

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One notable achievement is sales of a

luminous grade WRD3DFLF5LP

country.

Steve van Rensburg and Hermann Naud, veterans of the PVC compounding

sector, have been steadily honing the systems at Alpha Plast in Johannesburg for

close to three decades, partly by focusing on different parts of the business, with

Steve running admin and Hermann production. This has enabled the Alpha ship to

sail steadily as well as expand into the Cape and export markets.

with on-going plant improvementsAlpha Plast hits jackpot Strategy enables Johannesburg compounder to expand into Cape, Elco turnaround

colour spectrophotometers were installed at both Alpha and Elco. The DataColour units have presented a value-adding opportunity and both group companies are now seeing the colour service gaining popularity. One of the early successes from this venture has been an increase in exports, one notable achievement being sales of a luminous JUDGHWRD3DFLF5LPFRXQWU\7KLVVXUSULVing boost has spurred the Alpha/Elco sales team on and increased exports now offer real potential.

Elco team The management team at Elco

Plastics, the now wholly-owned Alpha Plast

subsidiary in Bellville, includes general

manager Richard Black, factory manager

Gerd Koekemoer, sales manager Ewert

Schnetler and FM Dave Dollman

Colour match Colour spectrophotometers installed in

the labs at Alpha Plastics in Devland as well as at the Cape

Town subsidiary Elco Plastics have proved extremely

useful, allowing the companies to add colour match to their

materials. This is a new service from Alpha and Elco which

has proved popular in all the sectors they supply

That is just one side of the new service though: batch tracking had to be improved si-multaneously and that too has been achieved with commensurate coding and labelling to en-able effective traceability and hence analysis of problem areas. But, according to the sales team, that hasnt been necessary so far as there have been very few returns.

Nauds licence to automate and improve is largely due to the scope created by co-MD 9DQ5HQVEXUJVDVWXWHPDQDJHPHQWRIWKHgroups admin and sales areas. That has freed the respective teams up to do what they do best. Both gentlemen seem averse to being involved with the others responsibilities and, with the formula working, long may it last.

The combined Alpha/Elco output is in the region of 40,000 tons a year, making the group one of South Africas top PVC compounding operations. Although Elco is now a wholly owned subsidiary of Alpha, the separate names have been retained and give the group dual brands. Main applications include pipe, FDEOHSUROHIRRWZHDUDQGPLQLQJSURGXFWVDVwell as, surprisingly, containers. Many thought PVC had been phased out of the container market in favour of PET, but PVC is still the material of choice in several instances, includ-ing cosmetic containers.%RWK1DXGpDQG9DQ5HQVEXUJKDYH

SDVVHGWKHPDUNDQGWKHQLVKLQJWRXFKIRUthem must surely be a continuity plan, which now too appears to be in place.

www.elcoplas.co.za

with on-going plant improvementsAlpha Plast hits jackpot

Here we see the Alpha/Elco owners in front

of one of the lines which has been moved to

the Johannesburg plant, where maximum

utilisation is the order of the day

JUST BRIEFLY

ReproPlast takes over shareholding of BurcapNEWS in the industry is that the sharehold-ing of Burcap Plastics has changed hands, LQDVWUDWHJLFSDUWQHUVKLSZLWK5HSUR3ODVWa Durban company focused on polypropyl-HQHXSF\FOLQJ5'DQGFROOHFWLRQLQYLHZRIUHGXFLQJSRO\ROHQSDFNDJLQJWRODQGOO

Burcap Plastics re-opened its doors in 2015 with the introduction of a paint container using recycled material, along with a novel closing ring and lid system originating in the USA. The concept of decorated recycled packaging is in line with 5HSUR3ODVWVYLVLRQRIXSF\FOLQJSRO\ROHQVfor packaging and other injection moulded products.

It made sense to partner with a sustain-able brand like Burcap Plastics, who become the missing puzzle piece that completes the pictures of a company able to consistently supply high quality recycled material in packaging through a premium, sustainable outlet.

As all players in the industry know, the quality and consistent supply of recycled polymers has historically been a problem, VR5HSUR3ODVWKDVLQYHVWHGKHDYLO\LQpremium equipment, securing exclusive rights to a European technology that is able to recycle and compound in one process. What this means is that the companys upcycling capacity has grown to over 1000 tons a month.

Through sophisticated processes and a PDWHULDOVFLHQFHODERUDWRU\5HSUR3ODVWLVable to re-engineer polymers and con-sistently supply compound that performs even better than virgin material. Using this material to supply the range of Burcap decorated packaging is a very exciting innovation into the marketplace, said a 5HSUR3ODVWVSRNHVPDQ

Japanese pneumatics +WWXMV[;)WNKMSMC Pneumatics of Japan, a world leader in pneumatics and industrial automation, RIFLDOO\RSHQHGLWVGRRUVLQ6RXWK$IULFDLQApril, with plans for expansion into the rest of Africa. Established in 1959, SMC has been voted one of the worlds most innova-tive companies in Forbes Magazines Top 100 for three consecutive years. It supplies a staggering 12 000 basic automation components in over 700 000 variant forms, offering solutions for almost every industry imaginable, ranging from electronics and automotive to food and packaging and life sciences.

SMC has invested heavily in the SA operation and its production lines at its new Midrand HQ are equipped with the latest technology. The facility will be fully operational by July. SMC will also offer an extensive training programme.

MPACT Polymers unveiled its new 20 000m bottle-to-bottle Savuka rPET factory in Wadeville on 10 May and immediately announced that 6000 tons of the expected 21,000 tons of rPET it will produce annually has been contracted to Coca-Cola bottler ABI.

The R350-million state-of-the-art recy-cling operation was opened by Minister of Environmental Affairs Edna Molewa. The Krones process being used complies with European Union (EU) Food Safety Author-LW\VSHFLFDWLRQVDQGLVWKHUVWLQ$IULFDto meet The Coca-Cola Companys full FHUWLFDWLRQIRU3(7ERWWOHVWRSDFNDJHLWVsoft drinks.

It enjoys the backing of the departments of Environmental Affairs (DEA), Trade and Industry (DTI) and Economic Development (EDD) in promoting job creation, reduc-LQJZDVWHWRODQGOODQGLPSURYLQJU3(7production that will ultimately help to reduce

NEWS

the carbon footprint of the food and bever-age industry.

This successful venture illustrates what is possible when industry and the public sector collaborate on initiatives with a positive societal impact, in this case, waste reduction, said Molewa.

Mpact Polymers will process 29 000 tons of post-consumer PET bottles diverted from land-OOVHDFK\HDUWRSURGXFH21 000 tons of food-grade rPET, supplied under the brand Savuka (revival) which is to be used for food and beverage packaging.

Recovered labels and lids will be sold to customers for IXUWKHUEHQHFLDWLRQ

Krones supplied the state-of-the-art rPET processing line, in which area the German machine manufacturer has a proven track record as well as a reputation for excel-lence and innovation. Another primary mo-tivation was the lines low energy and water

consumption compared to other options.

PET recycling growing rapidly

The opening of the Mpact Polymers plant, one of the biggest ventures in the industry over the past few years, comes at a time when collection and recycling of plastic PET bottles is on the rise in South Africa.

According to PETCO, post-consumer PET collec-tion and recycling grew from 16% in 2004 to 52% in 2015 with tonnages processed going from 9840 tons to 73 710 tons p/a over the period.

PETCO believes the PET container recycling

sector will collect and recycle a landmark 70% by 2022. Currently 68% of all virgin and recycled PET is processed into PET bottles for the beverage industry.

Mpact Polymers has, together with industry partners Coca-Cola South Africa, ABI and PETCO, spent a lot of time and ef-

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Mpact Polymers is closing the loopWill process 29 000 tons of post-consumer PET bottles annually

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No society can sustain itself

without proactively tackling the

wastage of any resource

JUST BRIEFLY

fort researching the PET recycling industry and developing a PET recycling business that would be sustainable, said group CEO Bruce Strong.

Mpact Polymers is backed by the re-quired skills, experience and infrastructure to take advantage of the prospects in the collection and recycling of PET bottles in South Africa.0SDFW3RO\PHUVDOVRUHHFWVWKHLPSRU

tance of our governments manufacturing incentive programmes, which we hope will be granted a greater proportion of the national budget in the future, considering the importance of manufacturing in South Africa, said Strong.

The rPET facility has been granted a Section 12i tax allowance incentive. Income opportunities will be created through an es-timated 1 000 jobs as there will be greater demand for collectors, small businesses and buy-back centres which will assist Mpact in reaching their collection targets.

www.mpact.co.za

Near-infrared (NIR) sorting This faster sorting

stage looks at the wavelength for different

material chemistries and consequently can be

used to separate materials by resin type. It is

used extensively in MRFs to separate HDPE

and PET containers

Helukabel: Demand for quality cable is growingINTERNATIONAL cable and acces-sories manufacturer and distributor Helukabel is growing beyond bounds in South Africa, necessitating a second move to considerably larger premises in just six years since entering the local market.

Escalating demand for its prod-ucts has once again prompted the company to seek larger warehousing and operations facilities, this time in the more centrally-situated Lazer Park industrial area north of Johan-nesburg, where it is now operating from 6000m premises.

Helukabel SA managing direc-tor Doug Gunnewegh ascribes the rapid growth of the local operation to a strong trend towards quality approved cables that meet both local and international standards. Another key to the companys success is its high availability of stock.

Mondi to buy

CONTINENTAL Compounders (Pty) Ltd recently unveiled its upgraded, state-of-the art polymer testing facility located at the FRPSDQ\VKHDGRIFHLQ3LQHWRZQ.ZD=XOX1DWDO2QHRIRQO\Dhandful of similar facilities in South $IULFDWKHQHZWHVWLQJODERUDWRU\LVVSHFLFDOO\DLPHGDWSURGXFWWHVWLQJDQGQHZSURGXFWGHYHORSPHQWIRUContinentals local and international FXVWRPHUV7KHZRUOGRIHQJLQHHULQJSRO\PHUV

LVERWKH[FLWLQJGLYHUVHDQGG\QDPLF1HZFRPSRXQGVDUHFRQWLQXRXVO\EHLQJdeveloped in this ever-evolving industry in order to meet the requirements of

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NEWS

Aimed at product testing and new product development

unveil state-of-the-art polymer testing facility

CompoundersContinental

WKHHQJLQHHULQJIUDWHUQLW\*OREDOO\compounding companies are at the forefront of these developments, pushing WKHHQYHORSHRIPDFKLQHDQGPDWHULDOVIn order for Continental Compounders to remain on the cutting edge of these DGYDQFHPHQWVZHLQYHVWHGDVLJQLFDQWDPRXQWRIQDQFHVWHFKQLFDOLQQRYDWLRQand intellectual capital into creating a ODERUDWRU\WKDWLVFDSDEOHRIRIIHULQJRXUcustomers a highly specialised, technical VHUYLFHZKLFKJRHVKDQGLQKDQGZLWKWKHUHFHQWLQYHVWPHQWZHPDGHLQWRRXUQHZHQJLQHHUHGSRO\PHUVFRPSRXQGVIDFLOLW\H[SODLQHG*HRUJH'LPRQGFKLHIH[HFXWLYHRIFHURI&RQWLQHQWDO

Continental manufactures engineering polymers that are primarily used for

LQMHFWLRQDQGH[WUXVLRQLQZKLWHJRRGVautomotive, metal replacements and RWKHUKLJKSHUIRUPDQFHSURGXFWV7KH\KDYHDOVRUHFHQWO\H[SDQGHGWKHLUrange and product offeriQJE\DGGLQJpolypropylene (PP) and nylon (PA66 and 3$WRWKHLUORFDOFRPSRXQGUDQJH2XUQHZH[SDQGHG(QJLQHHULQJ

3RO\PHUVIDFLOLW\DOORZVXVWRGHYHORSDQG

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Continental Compounders

offer various tests at their new

laboratory: +HDW'HHFWLRQ7HVWV+'70HOW)ORZ,QGH[0),

$VK&RQWHQW,PSDFW6WUHQJWK7HQVLOHV(ORQJDWLRQ/LPLWHG2[\JHQ,QGH[/2,'HQVLW\

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JUNE / JULY 2016 15

produce compounds that were designed to meet the unique requirements of the African continent, as well as ensure that our products meet and maintain stringent quality standards, Dimond said.

They are now able to perform various QHZWHVWVLQFOXGLQJ+HDW'HHFWLRQTests (HDT), Melt Flow Index (MFI), Ash Content, Impact Strength, Tensiles, Elongation, Limited Oxygen Index (LOI), Density, Shrinkage, Flexural, Congo

Red, Colour Spec, Melt Rehologies and Volume Resistivity (VR).

Having this facility in place gives our customers the peace of mind that the compounds we supply them, will meet their product and process requirements, allowing smooth and consistent operations, Dimond added.

ZZZFRPSRXQGHUVFR]D

GREENACRES -BUMER of the Western Cape has designed, built and commis-VLRQHGLWVUVWIRDPFXWWLQJPDFKLQH7KHMalmesbury company used key compo-nents from its global partner Bumer to build the VBK-1 (Vertical Band Knife se-ries 1) unit, which is an entry-level yet world FODVVIRDPFXWWLQJV\VWHP7KHPDFKLQHLVUREXVWFRVWHIIHFWLYH

and aimed at emerging markets, said Des Green of Greenacres, a man who although now operating happily from the Swartland, has extensive experience from WKHJOREDOIRDPDQG38PDUNHWV*UHHQeven spent an extended period in Singa-pore heading up a multinational polyure-thanes subsidiary responsible for the SE $VLDPDUNHW*UHHQDFUHV%lXPHUUHFHQWO\VROGLWVUVW

foam cutting system to a happy customer in &DSH7RZQ7KHFRPSDQ\KDVEHHQLQSDUWQHUVKLS

with Bumer, of Germany, since 2008: it quite literally got involved in cutting edge technology at that point when it began to manufacture blades and cutting equipment IRU38IRDPLQDMRLQWYHQWXUHZLWK%lXPHU7KHEODGHVDUHXVHGLQWKHSURGXFWLRQ

environment for the continuous cutting of PUs as well as plastics, rubber and WHFKQLFDOIRDPV*UHHQDFUHV%lXPHUhas steadily expanded its activities since, including the manufacture of complete cutting systems, such as band and WRRWKHGNQLYHVDQGEDQGVDZV

Main applications for the new cutting system are foams for bedding, mattress,

NEWS

UVWIRDPFXWWLQJV\VWHPMalmesbury company takes its cutting edge technology to next level

automotive, technical and furniture prod-ucts, where high levels of accuracy and FRQVLVWHQF\DUHQHFHVVDU\,WLVDOVRHVsential for the blades to remain extremely sharp to achieve minimal friction, which is necessary for accurate cutting of the foam VWUXFWXUH$OOWKHVHIHDWXUHVDUHRIIHUHGE\WKHQHZFXWWLQJV\VWHP

Whats really interesting is that, with its streamlined South African operation, Greenacres- Bumers operating costs DUHORZ,WLVIRUWKLVUHDVRQWKDWLWUHPDLQVVRFRPSHWLWLYHLQWKHORFDOPDUNHW*UHHQDFUHVKDVDVWDIIFRPSOHPHQWRIMXVWQLQH,WVZHOGLQJHTXLSPHQWDQGWHFKQLTXHLV

state of the art, ensuring superior quality that is so sought after in WKLVPDUNHW,WRIIHUVORFDOVXSSRUWin terms of spares, consum-ables, after sales service and WHFKQLFDOVXSSRUW

Blade and cutting products and equip-ment are produced mainly for the export market, and containerised for shipping into $IULFD0RVWUHFHQWO\*UHHQDFUHV%lXPHUappointed Kenzar Limited in Nairobi for UHSUHVHQWDWLRQLQ(DVW$IULFD7KLVLVDQimportant market for the companies which ZLOODVVLVWLQZLGHQLQJWKHLUIRRWSULQW$VDresult, Des is spending a lot of time travel-OLQJLQWKDWUHJLRQ

Processes at the Malmesbury plant are managed in accordance with the Albrecht Bumer Quality Management System 'LUHFWLYHV7KHQHZPDFKLQHWKRXJKEDVLFLQ

design, is set to transform Greenacres EXVLQHVV$WWKLVVWDJHWKHFRPSDQ\LVaiming to produce two or three machines a PRQWKGHSHQGLQJRQGHPDQG

www.baeumer.comwww.greencorp.co.za

The new VBK-1

(Vertical Band

Knife series 1)

cutting system

from Greenacres

of Malmesbury,

Western Cape, used for

the cutting of PU foam,

is designed for

emerging market

applications

16 JUNE / JULY 2016

*UHHQDFUHVLQWURGXFHVLWVBY SHAWN VAN BAALEN

Weusthoff SA pty Ltd, trading as Seecor | www.seecor.com

+27 21 532 2144/5 | +27 83 326 2187 | info@seecor.co.za 23 Thor Circle, Viking Place, Epping, Cape Town

yView production videos of all these systems on our website yTurnkey project management yBlow mould design and production

(including moulds for closures)

ySupply of ancillary equipment (leak testers, neck cutters, conveyors, granulators, compressors, chillers)

ADDITIONAL SERVICES

SIKA (Taiwan), a world leading manufacturer of extrusion blow moulding shuttle machines for containers up to 2000-litres, including handle/non-handle and multi-layer systems. Over 60

SIKA systems are in daily operation in South Africa, including: continuous extrusion machinery

for containers from 50ml to 30-litres; accumulator head systems for technical parts and large

containers up to 2000 litres; fully electric machines; machines for multi-layer and multiple

cavitation production. All these systems are available with fully automated handling technology.

ERMP (France), wheel extrusion blow moulding machines for lightweight non-handle containers with multi-layer capability for the UHT and food markets. The ERMP team includes

experts previously involved at Sidel in France, a world leader in ISBM machinery. The ERMP

machines have capability for up to 28 cavity production of volumes up to 15,000 containers/hr.

Side (Spain), linear PET stretch blow moulding machines for the water, CSD and juice sectors with outputs up to 9000 bottles/hr and containers up to 50-litres. Side has exceptional expertise

in electronics and its linear PET/PP reheat stretch blow moulding machines are popular for

full-electric, high output production of both standard and complex shape containers. Side (in

operation for over 40yrs) is a leader in T-handle (deep grip) container production.

Baixing (China), lower cost ISBM machines for low output production of PET containers and specifi cally for start-up companies (for basic round or square containers up to 20 litres)

Keli (China), injection blow moulding (IBM) machines for the low-to-medium output of small containers up to 700ml (medical bottles and jars, roll-on deodorant and cream jars)

Rocheleau Tool & Die (USA), recip blow moulding machines for lightweight containers suited for high-quantity production. RTD offers reciprocating-screw and continuous-extrusion

machines suited for high-speed production of small containers.

WE REPRESENT

SeecorSEECOR BLOW MOULDERS, manufacturer

of a wide range of blow moulding machines

over the past three decades, has mainly

supplied systems based on European

technology but designed to suit the African

environment. We have now widened our

scope in order to supply built-for-purpose

and ultra-effi cient production systems.

We now represent a wider range of machine

manufacturers who in every case offer

optimum cost-performance value. Our goal

remains, as before, to supply technology

that it suited for profi table production in

Africa, and even further afi eld.

Blow moulding systems for every application yExtrusion, IBM and PET blow

moulding machinery

yCustom rebuilds of blow moulding machines, with enhanced controls

and automation

ySupply of technical service, spares and automation system to the

entire blow moulding industry

in Africa

SEECOR supplies

Clive CorderJeffrey Weakley Darrin Botha John Craw Joe Spohr

130 000 litres water for drought affected Thaba Nchu & surrounds

MGMWs new, larger premises now enable the company to refurbish barrels and screws up to 8 metres long

Wolfgang and Gunther

Maralik of MGMW Trading

hosted Lyzon Lee,

managing director of Hitech

China, on their stand at

Propak Africa this year

MGMW Trading has moved to larger premises in Johannesburg to handle increased demand from customers.

The larger premises at Unit 17, Log Road, Roodekop, Germiston, now enable MGMW to refurbish barrels and screws up to 8 metres long.

MGMW offers three different welding processes. Besides refurbishing barrels and screws, the company can join broken

screws, tiebars and granulator shafts, amongst others. Other popular services LQFOXGHWKHUHIXUELVKPHQWRIEORZQOPGLHVas well as T-dies.*XQWKHU0DUDOLN:RO0DUDOLNDQG0LNH

Grandcourt also offer customers design advice on how to upgrade old extruders to improve output and material quality, as well as queries regarding any other plastic machinery.

Besides its standard metallic work, MGMW Trading also represents Hitech China, a manufacturer of recycling systems. Lyzon Lee, MD of Hitech China, has worked on several projects with Gunther and has so far installed systems in Malawi, Zambia, Zimbabwe, Namibia, Botswana and Mo-zambique, and South Africa.

www.mgmwtrading.com

JoJo Tanks aid for drought stricken communities

GLOBAL humanitarian aid organisation, World Vision South Africa has in partnership with Bloemwater and the Mangaung Metropolitan Municipality successfully installed 26 Jojo Water Tanks in Thaba Nchu and surrounds as part of its 150-tank/750 000 litres of water project funded by the FirstRand Foundation and other stakeholders. The project was headed by World Visions Thaba Nchu Area Development Programme (ADP).

The 26 tanks will provide 130 000 litres to community members residing in Thaba Nchu and surrounding villages and bring critical relief in an area which is still plagued by drought and resultant food shortage. The tanks will EHOOHGUHJXODUO\E\%ORHPZDWHUDQGmaintained by the various communities and the municipality.

In celebration of the project completion, two water tanks were handed over to the community of Middeldeel village situated outside Thaba Nchu. The ceremony was attended by members of the Mangaung Municipality, Bloemwater, Barolong traditional leaders, World Vision and the community.

The 5000-litre Jojo water tanks were constructed on ground level concrete slabs and met municipal engineering criteria during quality control and sign off of the installations.

The remaining 124 water tanks are currently being rolled out in KwaZulu/Natal (Ixopo and Umzimkhulu), and Limpopo (Thusalushaka, Kodomela and Giyani) provinces.

Two JoJo Tanks water tanks were handed over to the community of Middeldeel

village situated outside Thaba Nchu

www.clariant.com

18 JUNE / JULY 2016

NEWS

MGMWs new premises will accommodate increased demand

Space! MGMWs new

premises certainly have a lot

of that which they will need

to accommodate increased

demand from customers

MGMW Trading advert Edited-BLEED.indd 94 2016/04/07 1:17 PM

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FERRO Plastics, a division of Ferro South Africa, has made a multi-million rand invest-ment in two new lines for its black and white masterbatch plants.

Tinus van der Merwe, Ferros director in charge of plastic masterbatches, said the investment resulted as a response to the dramatic increase in both local and export demand for quality masterbatches over the past few years.

Situated on the East Rand, Ferro Plas-tics has been producing both black and white masterbatches for over four decades; it is the largest manufacturer of black mas-terbatch in sub-Saharan Africa.7KH%ODFNSODQWZDVWKHUVWWRDFTXLUH

an additional extruder, a Coperion ZSK twin-screw unit, considerably expanding output above the existing capacity.

Ferros priority is to meet customers preferences with regard to pellet conforma-tion, said Tinus. The 92mm, twin-screw

The recently acquired Coperion ZSK twin-screw extruder can

produce more than a ton per hour of Black masterbatch pellets

in die-face cut formation

The White masterbatch plant, where a new Giant SHJ-92 co-rotating

twin-screw extruder was installed earlier this year, is skillfully managed

by Raymond Dyzel, Daniel Dhladla and Warren Morton

NEWS

Ferros multi-million rand investment in black, white masterbatch linesDramatic increase in local and export demand for quality masterbatches

ZSK machine was commissioned at the end of 2015 and can produce more than one ton per hour of pellets in die-face cut formation, similar to the existing German-engineered Berstorff extruder in the same facility.

The Black plant produces 24/7 and manufactures a variety of black masterbatch grades, from entry-level material to high quality, in a variety of polymers.

With its twin screw technology and highly accurate gravimetric material handling sys-tems from Brabender Europe, the new ZSK and Berstorff extruders are able to maintain and uphold the quality of product which is manufactured and distributed within the domestic and international plastics markets, said Tinus.

Ferro Plastics White plant also received a new SHJ-92 co-rotating twin-screw extruder which was commissioned earlier this year. This line can also produce at a rate of one metric ton per hour, generating water-ring

die face cut pellets.Various formulations of Filler or White

masterbatch, in a variety of polymers, can be produced.

The SHJ-92 extruder now runs alongside a Farrel CP45 system, with the increased capacity able to meet demand for both Filler and White masterbatch.

Along with these multi-million rand investments, a substantial amount of management time and preparation was DOVRGHYRWHGWRQHWXQLQJERWKSURMHFWVsaid Tinus.

With the upgrade of both production plants, Ferro Plastics can remain a cost HIFLHQWSURGXFHUDQGFDQRIIHUDVVXUDQFHthat market demands will be met, all the while ensuring quality. It is with pride that we continue to be the market leader in all Black, White and Filler masterbatch grades and continue to produce high quality mas-terbatches at competitive prices.

www.ferrosa.co.za

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Ensuring that Ferros produces black

masterbatch 24/7 are Warren Morton,

Douglas Lushaba, Sipho Simelane

and Kenneth Mngomezulu

CHECKMATE WE REMAIN KING IN

THE INDUSTRY OF BLACK, WHITE AND

FILLER MASTERBATCH.

HEAD OFFICE - GAUTENG

Telephone: +27 (0) 11 746 4000

KWA-ZULU NATAL - New Germany

Telephone: +27 (0) 31 713 0636

EASTERN CAPE - Port Elizabeth

Telephone: +27 (0) 41 451 2571

WESTERN CAPE - CAPE TOWN

Telephone: +27 (0) 21 935 1788

www.ferrosa.co.za

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JANNOCK, which is celebrating 30 years in operation, has established its industry leading position through building its own extremely reliable tools. That skill in turn gave the West Rand company the springboard to create its own manufacturing business, in the form of its injection moulding subsidiary Jannock Plastics, which in turn has allowed it to partner effectively with clients.

Jannock Tool & Die was established in 1986 as a general toolmaking facility to industry, manufacturing injection moulds as well as press tooling and tooling for the rubber industry.

Our facility has the equipment to handle all aspects of tool making consisting of CNC milling, including full 4-axis machining, wire cutting, Ren-ishaw scanning, lathes and cylindrical grinding as well as all the standard conventional equipment, said Jannock technical director James Warne.

The businesses premises in Roodepoort, West Rand Jannocks Tool Room manufactures all tooling to complement its

production facility which has proved to be an important advantage

NEWS

Jannock Tool & Die, Jannock Plastics celebrate 30yrs+LJKHIFLHQF\WRROVSOXVHTXDOO\HIFLHQF\SURGXFHZLQQLQJFRPER

Handling of the CAD, industrial GHVLJQEXLOGLQJRIKLJKHIFLHQF\WRROVand tool maintenance on an in-house basis by Jannock has obviously been an advantage and the positive momen-tum gained is self-evident.

It later expanded into the manufactur-ing sector, resulting in the formation of Jannock Plastics in 1999.

Key to Jannocks success is their approach to a turnkey solution to all their customers, from technical support product & tooling design, mould build and manufacturing and understanding tooling requirements to ensure the most cost effective solution ensuring project success.

Jannock processes a variety of engineering Polymers (such as PBT, polysulphones, PEEK, Nylons, polycar-bonate to name a few) and precision machinery is thus a prerequisite.

A major aspect of the continuation of this successful cooperation has been Jannock Plastics choice of machinery: it has purchased a large number of TMC injection machines over the past

one-and-a-half decades. Supplied by local agent Maritime Marketing, these reliable, robust machines built in Taiwan have proved to be mainstay in the on-going production programme.

ISO 9001-accredited Jannock has just recently taken delivery of an-other three new TMC servo machines, including a 150-ton and two 200-ton machines.

James is happy with the impressive-O\HIFLHQW70&LQMHFWLRQPDFKLQHV

The servo energy-saving machines allowed for reduced energy cost, plus the excellent back-up support from Maritime Marketing and TMC over the years has allowed us to keep mainte-nance costs at exceptionally low rates.

The reliability of the TMC machines also means we have had minimal downtime, which is obviously very good from a cost ratio point of view, he added.

www.jannock.co.za

Jannock managing director Jimmy Warne with the companys production manager Willem van Zyl, TMC product manager Marc Gerasimo and

-DQQRFNVQDQFHGLUHFWRU-RKQQ\3UH]LDWLWHFKQLFDOGLUHFWRU-DPHV:DUQHDQGJHQHUDOPDQDJHU&DU\QH:DUQHZLWKVRPHRIWKH70&PDFKLQHVLQWKHLUWLG\DQGXOWUDHIFLHQWPRXOGLQJSODQW

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SAFRIPOL has introduced an improved Polypropylene impact copolymer for high-speed injection moulding. The new grade, produced with Spheripol technology, DIIRUGVSRWHQWLDOVXVWDLQDELOLW\EHQHWVWRconvertors, including cost saving and a decreased environmental footprint.

This new PP resin is aimed at the thin-walled injection moulding (TWIM) market, which includes end products such as yoghurt and margarine containers, promo-tional drink cups and many more.

Safripols continued commitment to product innovation provides the local mar-ket with a high quality resin that offers the

NEWS

reliability and quality consistency required to compete on the international stage, said Mark Berry, sales and marketing manager at Safripol.

The resin, commercialised as Safron C790-90RNA (MFR2.16kg@230C of 90 g/10min), shows a further enhancement LQRZSURSHUWLHVRYHUWKHSUHYLRXVO\XVHGSafron&51$ZKLOHVLJQLFDQWO\and very importantly, retaining impact and stiffness properties. This enables packaging manufacturers to achieve cost savings as a result of faster cycle times, lower processing temperatures, future lightweighting and pressures and energy

cost savings.Safron C790-90RNA is South Africas

UVWORFDOO\SURGXFHGFRPPHUFLDOO\DYDLOable 90 MFR resin.

Safripol has been a committed poly-ROHQVXSSOLHUWRWKH6RXWKHUQ$IULFDQplastics market for more than 40 years, providing a wide range of high density polyethylene and polypropylene grades that conform to high global standards.

Technical information about this grade can be found on the Safripol website.

www.safripol.com

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$ UVWIRU6DIULSRONew PP resin aimed at thin walled injection moulding market

Suits high-speed canister insertion

Safripols new PP resin is aimed at the thin-walled

injection moulding market, which includes end

products such as yoghurt and margarine contain-

ers, promotional drink cups and many more

&ODULDQWVQHZUDQJHRI$URPD&DQFDQLVWHUVCLARIANTS Healthcare Packaging unit is introducing a new and improved family of Aroma-Can canisters to enhance nutritional products by adding a pleasant scent to product packaging.

Modelled after Clariants desiccant canisters for pharmaceutical and nutraceutical packaging, Aroma-Can canisters employ aroma technology that can give consumers a positive

www.clariant.com

sensory experience when they open product packaging. The technology HPEHGVIRRGJUDGHDYRXUVVXFKDVvanilla, orange and lemon, directly into a plastic canister, which can be inserted easily into a container.

Although the new Aroma-Can bears the same overall dimensions of standard desiccant canisters, its new and innovative one-piece design reduces further process and assembly and contains more surface area, which improve the canisters DURPDSUROH%HFDXVHRIWKHLUdimensional uniformity with desiccant canisters, Aroma-Can canisters can be automatically inserted into packaging at rates up to 300/minute using standard desiccant canister insertion equipment.

24 JUNE / JULY 2016

*UHDWHUIUHHGRPIRUFRIIHHORYHUVGLOBAL Closure Systems (GCS) has developed a bespoke closure solution to help the worlds largest food company Nestl Coffee-mate 2GO satisfy the lifestyle expectations of on-the-go coffee drinkers in North America.

Nestls new Coffee-mate 2GO creamer dispenser incorporates a silicone valve sub-assembly designed and manufactured by Zeller Plastik, GCSs production plant in Libertyville, Illinois. Coffee-mate 2GO is a conveniently-sized 90ml portable creamer that doesnt require refrigeration. 7KHVLOLFRQHYDOYHKDVEHHQVSHFLFDOO\GH

signed to match the product formulation. The FORVXUHVUHGJORVV\QLVKRIIHUVVWDQGRXWon-shelf appeal, while the need for tamper evidence is provided by a full body sleeve.

www.gcs.com

MGMW Trading advert Edited-BLEED.indd 94 2016/05/30 11:11

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EXECUTIVES with Dows Packaging & Specialty Plastics business met with African media recently to discuss Dows commitment to sustainability and WKHLPSRUWDQWUROHRIH[LEOHSODVWLFpackaging in spurring economic development and supporting a more sustainable world.

Africa is the worlds fastest growing region after Asia, together with the Middle East. In total, 45% of GDP growth on the continent comes from consumer-facing sectors, pointing to rising consumer power and income. Africa is also undergoing rapid urbanisation, with 40% of the population now living in cities. As a consequence, food safety, shelf life and supply chain transportation assume greater importance as food will have to travel much longer distances to supply growing urban populations.

Demand for more sophisticated shopping and retail in Africa is increasing.

'RZUHDI UPVFRPPLWPHQWWRVXVWDLQDELOLW\LQ$IULFD&LUFXODUHFRQRP\IRFXVHVRQUHGXFLQJIRRGZDVWHLPSURYLQJUHVRXUFHHIFLHQF\DQGLQFUHDVLQJUHF\FODELOLW\

Offers huge variety of advantages over existing solutions

Consumers have rising disposable income, and they want food which is fresh, healthy and conveniently packed, said Diego Donoso, business president of Dow Packaging & Specialty Plastics.

To better meet rising demand for plastic products from Africa and other regions, Dow entered into a joint venture with Saudi Aramco in 2011 to construct the worlds ODUJHVWLQWHJUDWHGFKHPLFDOFRPSOH[HYHUbuilt in a single phase Sadara. The project recently achieved a key milestone ODVW'HFHPEHUZLWKUVWSRO\HWK\OHQHproduction, meeting previously announced targets to begin production by year-end 2015. This landmark investment has been a key pillar of Dows targeted, strategic growth actions over the last several years and all 26 of Sadaras manufacturing assets remain on schedule for a sequenced start-up process, beginning ZLWKWKHSRO\ROHQVHQYHORSHWRPD[LPL]Htiming in the ethylene cycle, followed by HWK\OHQHR[LGHSURS\OHQHR[LGHDQGWKHLUderivatives.

Committed to sustainability

In 2015, Dow announced a strategic set RIFRPPLWPHQWVGHVLJQHGWRUHGHQHWKHrole of business in society, to be achieved by 2025. This includes a commitment to advance the worlds transition to a circular economy, where waste is designed into new products and services.

Dana Mosora, sustainability director for Dow Packaging & Specialty Plastics for Europe, Middle East and Africa, said the circular economy would focus on reducing IRRGZDVWHLPSURYLQJUHVRXUFHHIFLHQF\and increasing recyclability, as well as work with initiatives globally to address marine debris.)OH[LEOHSODVWLFSDFNDJLQJSOD\VDNH\UROH

LQUHGXFLQJIRRGVSRLODJHDQGZDVWH)OH[LEOHSODVWLFSDFNDJLQJFDQH[WHQGWKHVKHOIlife of food from three days to over 14 days in-store, with in-store waste reduced from an average 3% of stock to less than 1%.

Diego Donoso, president of Dow Packaging & Specialty Plastics; Javier Constante, vice president for EMEA; Carsten Larsen (MD of Dow Southern

Africa); and Dana Mosora, director for sustainability and advocacy, gave presentations at the Dow Africa media event in Johannesburg

SDF;SHUW H[LEOHDOWHUQDWLYHWRULJLGFRQWDLQHUVA NEW system presented by Dow at the media event in Johannesburg in April, PacXpert Packaging Technology is an innovative technology that enables the transition from larger traditional rigid FRQWDLQHUVWRH[LEOHSDFNDJLQJRSWLRQV7KHGLVWLQFWLYHH[LEOHVWDQGXSSRXFKis durable, lightweight and cost effective. :KLOHH[LEOHWKHFXEHVKDSHGSDFNDJHis shelf stable and can stand equally well upright or on its side.$YDLODEOHLQDUDQJHRIVL]HVIURPRQH

to 20 litres, the innovative packages made possible through PacXpert Packaging Technology has the potential for use in

numerous household, institutional, and industrial applications.$IWHURSHQLQJWKHH[LEOHSDFNDJLQJ

made using PacXpert Packaging Tech-nology can be compacted as its contents are dispensed.

PacXpert Packaging Technology is licensed globally by Dow through an H[FOXVLYHDJUHHPHQWZLWK6PDUW%RWWOH,QF'RZLVVXEOLFHQVLQJWKLVH[FLWLQJtechnology to select converters who may then leverage the technology to promote GLIIHUHQWLDWHGH[LEOHSDFNDJLQJVROXWLRQVto the marketplace.(PacXpert is a trademark of The Dow Chemical Company)

pacXpert containers can be used for the

packaging of a huge range of products,

such as edible oils, sauces, water/juices, dry

foods such as rice and grains, ground coffee,

SDLQWDQGFRDWLQJVPRWRURLODQGIXHOQHaggregates you name it

NEWS

www.dow.com

e-mail: nickie.s@hestico.co.zaSERVING THE PLASTIC AND PACKAGINGINDUSTRY FOR MORE THAN 50 YEARS

SINCE 1962

Recycling and grinding

Water flow regulators

Injection moulding machines

Robotics and IML

Injection stretch blowmoulding machines

Gravimetric blenders &central feeding systems

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MAVERICK Engineering has sur-prised just about everyone, including itself, by its unexpected success in the global market: the Cape Town machine maker has become one of the world leaders in pouch making systems in a little over 15 years.

One of its recent successes was the sup-ply of its biggest machine yet, a 33m long Juggernaut Combo line for the production of 1000-litre pouches, to the United States.

Maverick Engineering was started in 1999 by Derek Fay, formerly of Nampak. The company began manufacturing pouch making machines immediately and sup-SOLHGWKHUVWVPDOOHUPRGHOVIRUWKHSURduction of bag in a box or liquid packaging pouches shortly thereafter. Fays formula has worked exceptionally since: Maverick Engineering handles design and assem-bly, with all components being bought in. The bulk of machine components are now sourced from China, after it became ap-parent that Cape engineering component makers were uncompetitive in terms of both price and availability.

Having seen the opportunity in the mar-ket for pouches, which has shown dramatic and above-average growth since the mil-lennium, Fay and the Maverick Engineering

Commercial manager Andrew Slater on the assembly line at the

Maverick Engineering plant in Cape Town with one of the larger

pouch-making machines under construction

9DULRXV[WXUHVFDQEHEXLOWLQWRWKHSRXFKHVDVWKHZHESURFHHGVDORQJWKHPDFKLQHWKHMLJVKHUHSRVLWLRQHGRQWKHDQNRIWKHPDFKLQHDUHWRKROGDQGRULHQWWDSVIRUWWLQJ

NEWS

SAs Maverick Engineering is a leader in pouch bag machinesCape companys modular, automated system prove a hit among bag-in-a-box manufacturers

team have honed their process to the point where machine assembly is expedited to a high degree. The machines systems are PRGXODUDQGH[LEOHZKLFKKDVKHOSHGGULYHtheir popularity. Basically, laminated and/RUFRH[OPVHQWHURQHHQGRIWKHPDFKLQHand just about anything that can happen to DOPLVFRPSOHWHGDXWRPDWLFDOO\DIWHUWKDWwhether it be the insertion of a tap, a gusset, ]LSORFNRURWKHUGHVLUHG[WXUHVLVSRVVLEOHafter that.

Mavericks journey from a virtual standing start reached an early milestone in 2002 ZKHQLWVXSSOLHGLWVUVWOLWUHPDFKLQHto Cape cargo securing specialist Stopak. Impressively, the machine continues to oper-ate 24/7.

Maverick was subsequently bought by GN Packaging of Canada, which at that point specialised in 1000-litre bag lines. This resulted in Maverick focusing on machines for smaller pouches, from 2-200 litres, and it zoned in on the development of high-speed solutions. Cooperation with its Canadian partner opened some international markets for Maverick, particularly in the United States, where few South African companies have managed to compete. Then, after GN closed its operation, Maverick returned to the 1000-litre market, with lessons learned

with the smaller machines proving useful. Also, the company was by that stage famil-iar with international sales: in fact, Maver-icks machines with catchy names such as Beast, Dream, Double-Up and Super, let alone the aforementioned Juggernaut have become relatively sought-after by major bag-in-box manufacturers around the world.

Maverick has spread its wings local too, ZLWKOPPDQXIDFWXUHU0DYHULFN)OH[LEOHVand packaging contractor Maverick Pack-aging now also part of the group.

Over at Maverick Engineering in Airport Industria, MD Hilton Traviss and commer-cial manager Andrew Slater are oversee-ing the construction of several machines simultaneously. The team includes expert OPEORZHUVODPLQDWLRQVSHFLDOLVWVEDJmakers and engineers who together form a highly skilled and specialized team.

The technology has now reached a mature stage, and there are possibly op-portunities for further development, but the emphasis remains on using quality compo-nents throughout: according to sales man Slater, It costs a bit, but if you stuff it up the cost is going to be far higher.

www.maverickengineering.co.za

Coordinated assembly :LWKDVPDQ\DVIRXUPDFKLQHVXQGHUFRQVWUXFWLRQDWRQHWLPH0DYHULFN(QJLQHHULQJKDVEHHQPDNLQJPD[LPXPXVHof its factory at Airport Industria in Cape Town; the design and planning department at left is situated conveniently close to the action

WITH pending changes to the legislation and tax on packaging, South Africas packaging industry is concerned that increased government regulation may have a detrimental effect on all concerned.

The pricing strategy document

gazetted last year, in what is being

referred to as the Paper & Packaging

Industry Waste Management Plan,

suggests that:

an Extended Producer Responsibility (EPR) scheme for

paper and packaging may become

government-managed;

existing EPR schemes will have two years to align their funding models

to the pricing strategy and other

waste management legislation;

that a South African Revenue Services collected waste

management charge or tax would

be charged for all paper and

packaging placed onto the market;

Charles Muller, director of

Packaging SA, who has been closely

involved in the dialogue process

between the industry and the

Department of Environmental

Affairs (DEA), said Packaging SA

has responded to the Gazette and

requested formal feedback from

the Department of Environmental

Affairs.

Theres been no formal response

from the DEA yet. We understand,

however, that both the pricing strategy

and the intention to call for plans are

sitting with the Minister for signature,

which means well probably get no

content feedback prior to these being

QDOO\JD]HWWHGVDLGCharles.

Industry concerns

Obviously industry

has concerns that,

with increased

government

regulation (including

the possible

imposition of a

SARS collected waste management

charge), the paper and packaging

industry may abdicate their current

responsibilities as they are unlikely to

want to or be able to pay twice i.e.

both a voluntary levy and a mandatory

waste management tax.

With some exceptions, the

packaging manufacturers in South

Africa are not in good economic

shape. Government needs to use

caution that undue taxation and

interference does not negatively

LPSDFWWKHSDFNDJLQJVHFWRUVDLGCharles.

Another fear is that the many

successful voluntary initiatives,

particularly those of the seven

mainstream material organisations,

may collapse as they

are currently all funded

through voluntary

contributions which

are generally collected

upfront. Delays in

funding could see

the disintegration of

projects.

A further concern is

that industry may seek

to recover costs through increased

automation and job reduction.

It is even possible that a

government imposed waste

management charge or tax could also

result in a decrease in recycling rates.

There is ample international

evidence to suggest that recycling

rates will regress, such as what

occurred in Hungary and Croatia

where the State assumed control from

Industry concerned about Govts proposed packaging charge or taxGovt must be integral part of solution, work with the successes already achieved within the industry

The complexity of the packaging sector is

evident in differing trends prevailing with the

different materials, and the changes have

been quite dramatic over the last few years.

For example, consumption of glass packaging

increased from 2009-2011 (from 872,296 tons to

897,790 tons) and then declined quite sharply

from 2012 to 2014 (865,507 tons to 712,714 tons).

Metal has been the most consistent performer,

but tonnages are the lowest of the four materials

recorded; consumption of paper (the largest sector,

although not all paper is used in packaging) also

increased steadily to 2012 (1,936,695 tons), but

then fell sharply in 2014 (1,696,163 ton). All three

show relatively high recycling percentages. Plastic

is possibly the odd one out: consumption has increased

throughout the period recorded here and recycling of plastic

DOVRVKRZHGDVLJQLFDQWLQFUHDVHIURPWRFORVHWRSHUFHQWEXFNLQJWKHWUHQG

Irrespective of

where a levy is

applied it will

ultimately get

passed on to the

consumer

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NEWS-PACKAGING TAX.indd 30 2016/06/08 11:19

privately-run recycling organisations. In Hungary the recycling rates fell

from 59% to 49% within a year,

Charles said.

A key objective of the previous

Paper & Packaging Industry Waste

Management Plan was to increase

the recycling rate for new packaging

and paper from 44.2% in 2009 to over

54% by 2018. The industry, however,

wants to revisit these targets as

they believe that much more is still

possible.

Another concern is that the revenue

collected by the waste management

charge will be swallowed up by the

national treasury. Government has

advised that there will be no soft or

hard ring-fencing of any revenue

generated and collected. This could

mean that other State expenditure

such as housing and education may

take preference.

Also, the SA consumer can ill

afford any further cost of living

increases. Irrespective of where a levy

is applied it will ultimately get passed

onto the consumer. Packaging is also

an integral part of the food sector and

cost increases here will affect the

lower LSMs as well, Charles added.

The way ahead

$OWKRXJKQRWKLQJKDVEHHQQDOLVHGyet, the packaging industry in SA

would like to have answers to the

following:

Single or multiple EPR schemes?

Charles: The industry is multi-facetted

so it is likely that a number of different

schemes will be required.

Who in the value chain (obliged

industry) will pay?

Charles: The Government has

indicated that converters should be

the obliged industry. Converters,

KRZHYHUJHQHUDOO\FDQRQO\LQXHQFHthe choice of packaging the decision

lies with the brand-owner. Packaging

SA believes that brand owners is

the correct place to levy a charge

as it is ultimately the brand-owners

who decide and specify the type

and nature of the packaging to be

used. This will also capture imports.

Another consideration is that all

in the value chain play a role, so

a combination of raw material

producers, brand owners,

converters and retailers share

the cost.

How will the tax or levy be

calculated?

Charles: Probably by using a Rand-

per-kg charge which will vary between

substrates. Some, however, favour

a straight percentage of turnover, for

example, as it is easy to calculate and

manage.

How will free riders and imports be

handled with regards compliance

and enforcement?

Charles: Government assistance

will be required here. Packaging SA

and the other PROs will act as a

watchdog.

What marketing and awareness

campaign will be rolled out?

Charles: National anti-litter

programmes will be required.

Information campaigns to support

household separation-at-source

initiatives are also key to getting the

recycling rates up.

What will be done about education?

Charles: This is a massive and

expensive challenge, but to get to

all the 26000 or so schools in South

Africa is absolutely key to our future.

Packaging SA awaits formal

feedback from the Department of

Environment Affairs on the Gazettes.

Meanwhile we continue to engage

with the DEA, Department of Trade &

Industry and other stakeholders. We

recognise that government must be an

integral part of the solution and work

with the successes already achieved

within the industry, said Charles.

There are also many other

challenges facing the paper and

packaging waste management

sector, including issues around

transformation, formalizing the waste

SLFNHUVQGLQJHQGXVHPDUNHWVIRUadditional recyclate and maximizing

job creation through developing the

2nd resources economy added

Charles. These will have to form an

integral part of all future plans.

INDUSTRY NEWS

JUNE / JULY 2016 31

www.packagingsa.co.za

NEWS-PACKAGING TAX.indd 31 2016/06/08 11:19

THE low market demand for recycled

SRO\ROHQVWRJHWKHUZLWKULVLQJFRVWVKDVPDGHWKHUHF\FOLQJVHFWRUDWRXJKVSDFHWRRSHUDWHLQ7KHLPSDFWRIWKHVHGLIFXOWWUDGLQJFRQGLWLRQVZDVVHYHUHO\IHOWE\32/

USERVE Machinery has, together with its principal Tederic

of China, a manufacturer of a complete range of injection

moulding machines, donated a machine for training at Plastics/

SA in the Western Cape.

According to Umberto Favini of Userve, the basic Tederic

injection system is very suitable for training and he had

approached Tederic with a request that a machine be made

available for this purpose, the aim being to improve the level

of setter training education. Tederic, based in Zhejiang, China,

responded positively and the machine was installed at the

Plastics|SA training centre in Cape Town in May.

David Venter of Spicoly Plastics of Cape Town was the

initiator of the project. Spicoly is one of the biggest users of

7HGHULFPDFKLQHVLQWKHUHJLRQDQGVLQFH9HQWHULVDUPconvert to the value of training, he suggested that Userve

consider making such a donation to the cause.

The wheels were set in motion and the 100-ton machine was

installed by a joint Userve-Spicoly team, amidst considerable

enthusiasm by the Plastics|SA training staff.

The machine operates on a Techmation electronic control

system, also supplied by Userve, which is a big plus for

the training process. Now a full setter programme can be

conducted at the setter, thanks for Favini, Venter and co.

100-ton machine was installed by a joint Userve-Spicoly team

Userve donates machine for training at Plastics|SA

QC, extrusion, bag-making trainees achieve success in Plastics|SA programme

A GROUP of ten Transpaco Flexibles

employees recently graduated to NQF

OHYHOVDQGDWWKHOPVDQGEDJmaking groups Cape Town plant. The

Transpaco plant in the Cape is one of

the largest in the country, processing as

much as 50 tons a day and supplying

both printed shopping and boutique

bags to retailers across SA and sub-

Saharan Africa.

The process was guided by Transpaco

HR manager Martin Nel, with the

training programmes supplied by

Plastics|SA. Three of the trainees

completed the NQF (National

4XDOLFDWLRQV)UDPHZRUNOHYHO

which involved training at the PSAs

UHJLRQDORIFHWKHRWKHUWUDLQHHVZKRachieved NQF level 2, underwent in-

plant training.

A varied group, including trainees

from all parts of the business such

as QC, extrusion and bag-making,

undertook the programme. Individuals

who showed potential and the ability to

accept responsibility were selected.

The NQF level 3 training involves setter

OHYHOWUDLQLQJDQGEHVLGHVEORZQOPextrusion (the obvious need at the

7UDQVSDFREXVLQHVVLQFOXGHVEORZDQGinjection moulding setter training with

the result that graduated trainees have

the ability to set and control all these

main processing technologies.

The main