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Editors Comment

December 2018

Looking forward to GIFA 2019

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News

December 2018

Use of thermochemical data in inductive melting – ABP Induction

Minimising the energy consumed during inductive melting of metal alloys is an ongoing concern for plant and equipment manufacturers and operators. Surprisingly enough, little thought is given to the potential provided by the enthalpy of the melt in question. It is demonstrated that the composition of the input materials has a considerable influence on the heat content of alloy melts and therefore on their energy consumption.

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Workhorse Bronze Foundry – Creating a space for artisans and artists

The term ‘craft’, when referring specifically to the niche recreation of a certain product normally already in existence, but reimagined and produced by someone or a group of people on a smaller but more artisanal scale, for example craft cheese or craft beer, solidifies the characterisation of the bronze sculpture work produced at Workhorse Bronze Foundry.

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In memory of a true visionary – Professor Dimiter Marinov Dimitrov (1944 – 2018)

It was with great sadness that we learned about the passing of Professor Dimiter (Dimitri) Marinov Dimitrov on Thursday 8 November 2018 after a short illness. The timing of his passing was poignant as it happened during the RAPDASA 2018 Conference – an association and conference where he had a great influence.

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Scamont Group optimises its foundry project in partnership with ChemSystems Foundry Division

At just over 25% complete, it’s a project that clearly demonstrates how forward-thinking leadership, sustainable technology, and strategic partnerships can be used to create value internally and for customers alike. Over the past four decades, the Scamont Group has emerged as an engineering powerhouse in Southern Africa.

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Metals Trader App launched

Metals are commodity assets, which are initially mined from the earth and then converted and processed via different methods. For hundreds of years, governments have been using metals as indicators of value and mediums of exchange, making metals an ideal trading instrument. Precious metals such as platinum, silver, gold, and industrial metals such as copper are listed for trading based on price movements for each metal.

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Atlantis Foundries casts its one-millionth Daimler HDEP engine block

Earlier this year, the Bosnian family conglomerate Hastor acquired the Saarbrücker Foundry Group Neue Halberg-Guss (NHG) through its Prevent Group. A further restructuring of Atlantis Foundries within the new group means that Atlantis Foundries is now 100% owned by a South African based investment company Ukuvela Holdings (Pty) Ltd.

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SK Capital completes acquisition of SI Group

SK Capital Partners, a private investment firm focused on the specialty materials, chemicals and pharmaceuticals sectors, has announced an agreement to acquire SI Group, a leading global developer and manufacturer of performance additives and intermediates. Headquartered in Schenectady, New York, US, SI Group operates 20 manufacturing facilities on five continents with more than $1 billion in annual sales and over 2 800 employees worldwide.

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GIFA, NEWCAST, METEC and THERMPROCESS 2019: Theory and practice go hand in hand

2 000 exhibitors and 78 000 metalworking professionals are expected to attend from around the world and Düsseldorf, Germany will once again become a hotspot for international foundry and metalwork technology from 25 to 29 June 2019. “The Bright World of Metals”, the trade fair quartet, comprising GIFA, NEWCAST, METEC and THERMPROCESS, covers the entire spectrum both in-depth and with a wide scope, ranging from foundry technology, casting products, metallurgy and thermal processing technology.

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Trade Fair Tours and Castings SA tour to GIFA, METEC, THERMPROCESS and NEWCAST 2019

Now with more hotel options added – five to choose from. Trade Fair Tours, a specialist travel agency for trade fairs internationally and in particular Germany, in conjunction with the SA German Chamber of Trade and Industry and Castings SA have put together a very reasonable tour package to visit this exhibition.

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SAIF 2018 Annual Golf Day

The South African Institute of Foundrymens’ Annual Golf Day took place on Thursday 15th November 2018. The event was held at the Reading Country Club. Coming in first on the day with 98 points were Brad Simpson, Twaine Stewart, Gareth Dane and Michael Welman. Coming in second, also on 98 points were Duan Maritz, Leon Joubert, Gerrie Pretorius and Werner Joubert and in third place were Charles McGeer, Louis Miller, Riaan van Tonder and Garth Tosh on 97 points.

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October 2018

No bake workshops – cost saving methods: SI Group | HA

As with many industries across South Africa, the foundry industry is plagued by numerous factors that have forced the foundries to look at ways to minimise costs and maximise efficiencies in the workplace in order to survive. The macro and micro environmental factors are limitless, escalating raw material costs, increasing energy and labour costs, amongst others.

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Flexibility and speed the core at Ukuthela Foundry Projects

While Minika van Aswegen – wife of Ukuthela Foundry Projects owner Cobus van Aswegen – describes herself as being a jack-of-all-trades but a master of none, the same cannot be said of husband Cobus. Within the company he has had to take on the role of jack-of-all-trades while at the same time being master of all of them, right down to driving the forklift.

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Insimbi increases stake in scrap metal recycling industry with the acquisition of Group Wreck for R120 million

The company has also changed its name to Insimbi Industrial Holdings Limited. JSE-listed Insimbi Industrial Holdings has announced that it is acquiring another scrap metal recycler, this time Group Wreck International, for R120 million. In 2016 Insimbi acquired Amalgamated Metals Recycling (Pty) Ltd for R284 million.

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Mitak targets the imported cast mill liner business

Like most industries in South Africa the foundry industry has suffered due to the influx of cheap imports from countries such as China. South Africa is not unique to this problem though. However, unlike most first world countries South Africa has not addressed the threat to its manufacturing base despite the government claiming that it had put in place localisation rules, which are largely ignored for very obvious reasons to most of us.

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The sun is shining on Duvha Foundry

“Starting your own business is not easy especially when you need to seek finance to fund capital equipment and working capital to get the business operational. The biggest problem is that most of the banks don’t understand what manufacturing in the metal environment is all about and even less so in the foundry industry. Their interest wanes even more if you don’t have a track record and assets to back-up your business plan,” explained Stanley Tshivhase, director and owner of Duvha Foundry.

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Steel Best Group puts new life into Zealous

The long-established Springs based aluminium foundry operations Zealous Automotive and Zealous Pressure Castings have been given a lifeline by the Steel Best Group, a company with manufacturing facilities in Port Elizabeth, Eastern Cape but with its head office in Pretoria, Gauteng. Zealous Pressure Castings was established as a zinc die casting company in 1970 before changing emphasis to the aluminium die casting industry in 1996.

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Renewal of the policy directive on the exportation of ferrous and non-ferrous waste and scrap metal

On 10 May 2013 the Minister of Economic Development (the Minister) issued a Trade Policy Directive to the International Trade Administration Commission of South Africa (lTAC) in terms of Section 5 of the International Trade Administration Act 71 of 2002 (the ITA Act) on the exportation of ferrous and non-ferrous waste and scrap metal.

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Eskom offers free load profile audits

Eskom, the South African power utility, has announced that it was offering its business customers free electricity load profile audits, which would assist businesses to free up existing electrical capacity without having to invest in new points of supply and/or upgrades in supply. Eskom said that sufficient capacity enabled customers to optimally improve their productivity and expand their operations.

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Dti pledges support for companies implementing Industry 4.0

The Department of Trade and Industry (dti) will over the next few years focus on supporting companies that are actively participating in the Fourth Industrial Revolution. Speaking at the 20th anniversary celebration of the Workplace Challenge programme hosted by the dti and Productivity South Africa in eMalahleni, Mpumalanga, Deputy Director-General of Special Economic Zones and Economic Transformation at the dti, Sipho Zikode, said the department would support these companies.

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August 2018

When you can’t afford metal mistakes

When it comes to metals specifications, the news is full of wrong measurements, mistakes, and scandals in a host of industries. It’s increasingly clear that quality-conscious organisations can’t afford to give off their responsibility for metals verification. Inspecting the metals makeup of incoming and outgoing components has become a critical quality control (QC) task for companies worldwide.

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Boschpick Engineering announces new business partners

Newcastle, KwaZulu-Natal-based Boschpick Engineering has announced that it has concluded a successful agreement with local entrepreneurs Bongani Khumalo and Phillip Majali and their company Lipsobex, a 100% black youth owned industrial investment company backed by the IDC, whereby the new partners will acquire a 70% shareholding in the company. The remaining 30% shareholding will continue to be held by existing directors.

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Acquisition by Sinto opens doors for Endeco Omega Sinto

The recent acquisition of UK manufacturer Omega Foundry Machinery by Sintokogio, Ltd (Sinto), located in Nagoya, Japan, has opened up doors for Omega’s South African subsidiary Endeco Omega, which in future will be known as Endeco Omega Sinto Pty Ltd. Sinto acquired a majority shareholding in Omega in February this year.

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JC Impellers transforms into a jobbing foundry

“While orders for impellers and other pump components from the South African wear resistant engineered product manufacturers were strong, we could compete and survive in specialising in these areas of component manufacturing. We always knew that we were limiting ourselves but we also knew that our focus brought other benefits to our clients,” said Greg Smith, owner of the Wadeville, Gauteng based foundry.

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Insimbi confirms improved results

In the June 2018 issue of Castings SA it was indicated that JSE-listed Insimbi Refractory and Alloys Supplies expected an improvement of between 55% and 65% in both earnings per share and headline earnings per share, according to a SENS announcement. The actual release of the company’s year-end results at the end of May 2018 was too late for publishing in the June 2018 issue.

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Modern foundry on Gary Bell’s wish list as he hands over CEO position to Leon Goosen

For the first time in its 64-year existence, there will be no one with the Bell surname at the helm of the Richards Bay-based equipment manufacturer and distributor, Bell Equipment. After 34 years of steering the company as CEO, Bell retired at the end of May 2018, taking over the position of nonexecutive chairperson. COO Leon Goosen has taken over as CEO from Bell.

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Mineral Zone opens new doors with Amava Mining Investments partnership

Mineral Zone, a specialist supply partner servicing the metallurgical and mining sectors in South Africa and internationally with a range of metals and minerals, ore and services, has entered into an agreement with Amava Mining Investment. The agreement means that Amava has acquired a 26% shareholding in Mineral Zone as of July 2018. “This strategic partnership is beneficial to Amava and ourselves, for many reasons,” explains Mineral Zone’s Managing Director Brendan Homann.

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SAIF’s 55th Annual Awards Dinner

The South African Institute of Foundrymen’s 55th Annual Awards Dinner was held at Summer Place (Boksburg), Gauteng on Friday 1 June 2018. 188 foundrymen, guests, wives and award winners attended this year’s event. The dinner was well supported by sponsors in the form of prizes for the award winners, and ticket sponsors for the award winners and VIP guests invited by the Institute. The SAIF would like to thank their sponsors for their valuable contributions.

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Agni Steels SA given the green light to expand

Additional furnaces will double production and allow the company to produce 180 000 tons of steel billets per year. Steel recycling and processing plant, Agni Steels SA located in Zone 6 of the Coega SEZ recently received authorisation for its Phase 2 and Phase 3 expansion plan from the Department of Economic Development, Environmental Affairs & Tourism (DEDEAT). In 2009, DEDEAT authorised Agni Steels SA’s Phase 1 development with amendments done in 2011.

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DataProphet: Building smart factories with AI

Vehicle manufacturing companies are looking for cost-effective ways to painlessly transition into the cutting-edge, data-driven world of smart factories, and AI integration represents a significant part of this process. Numerous AI providers are jostling for the privilege of unpacking manufacturers’ hard-earned process data; however, few can guarantee automakers the real, quantifiable ROI they are looking for.

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United Scientific appointed partners for Presi sample preparation equipment

“The preparation of samples for the materialographic investigation includes working steps such as cutting, mounting, grinding, polishing, and etching,” said Jaco le Roux, National Sales Manager of United Scientific. “Metallography is the study of the physical structure and components of metals, by using microscopy. In materialography, a sample obtained from a work piece is referred to as a specimen,” continued le Roux.

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Global casting production growth stalls

In 2016, worldwide casting production was 104.4 million metric tons, a near match to 2015’s reported 104.1 million metric tons, according to this year’s Census of World Casting Production conducted by Metal Casting Design & Purchasing’s sister publication Modern Casting. Casting growth from 2014 to 2015 was 0.4%, and from 2015-2016, it was 0.2%. This year’s census includes 36 nations from four continents. Of the 32 countries with data for the last two years, 14 reported an uptick in production.

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June 2018

Future proofing foundries: How ChemSystems makes sure tomorrow’s relevance starts now

Foundries have long since been considered one of society’s oldest businesses, originating from the time when man first began casting tools and weapons from metal. Hundreds of years later, foundries continue to make an important contribution to economies around the world.

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Matt Cast Supplies modernises its sand mixing equipment

“Foundries that want to remain competitive casting suppliers must adapt to changing developments in the industry, and react to domestic and international challenges deriving from increased automation and lower labour costs,” says Allan Bruggeman, CEO of Matt Cast Supplies. “A business owner has to look at other areas of the operation and one area is modernising your equipment and production processes.”

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Competition Commission approves Amsted Rail Company Inc’s merger with the Cast Products Division of Scaw SA (Pty) Ltd

South Africa’s Competition Commission has approved the proposed merger, with conditions, whereby Amsted Rail Company Inc. (Amsted) intends to acquire the Cast Products Division of Scaw South Africa (Pty) Ltd (Cast Products SA). Amsted is an American company, ultimately a wholly-owned subsidiary of Amsted Industries Incorporated.

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Larger than life Velona tackles a man’s world

The foundry industry is probably the least glamorous of all the manufacturing engineering industries you can choose to make a career move into when you have very little experience to speak of, and especially if you are a woman. However, these days it is not that unusual anymore to find a woman heading up or finding herself in a senior position in the male-dominated world of foundry production.

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Insimbi expects improvement of between 55% and 65% in both earnings per share and headline earnings per share

In an updated trading statement posted on SENS on the 11th May 2018 Insimbi shareholders were referred to the trading statement issued on the 15 March 2018 wherein they were advised that the company expected an improvement of between 55% and 65% in both earnings per share (“EPS”) and headline earnings per share (“HEPS”), for the period ended 28 February 2018.

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IMP appointed agents for Metkon sample preparation equipment and Akasel consumables for metallography

IMP, suppliers of laboratory equipment and services for the analytical, biological, industrial, metallography, pharmaceutical, coal and construction industries since 1987 has announced that they will now be marketing and supplying the Metkon sample preparation equipment and Akasel consumables for metallography.

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“The Bright World of Metals” is just over a year away

GIFA, METEC, THERMPROCESS and NEWCAST 2019 to take place in Düsseldorf, Germany from 25 to 29 June 2019. The time has come round again to start preparing for the four trade fairs GIFA, METEC, THERMPROCESS and NEWCAST. From 25 to 29 June 2019, everything will be focussing on foundry technology and castings, metallurgy and thermoprocess technology in Halls 3 to 5 and 9 to 17 at the exhibition site, where the joint motto will be “The Bright World of Metals”.

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Trade Fair Tours and Castings SA tour to GIFA, METEC, THERMPROCESS and NEWCAST 2019

Trade Fair Tours, a specialist travel agency for trade fairs internationally and in particular Germany, in conjunction with the SA German Chamber of Industry and Castings SA have put together a very reasonable tour package to visit this exhibition. The tour includes return airfare Johannesburg/Düsseldorf, airport taxes, airport/hotel transfer, accommodation, full breakfast daily and medical and travel insurance.

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Naledi commissions new heat treatment plant for grinding media production

Just under three years ago Naledi Foundry, the foundry division of the Naledi Inhlanganiso Group, began implementing a plan that had increased capacity, improved quality and diversification as the pillars of its strategic blueprint. In order to achieve this the foundry embarked on a restructuring process that included investment in new equipment as part of an approximate R100 million investment programme in the foundry.

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In memory of the ‘Sand Man’ – Vic du Plooy

It is with regret and great sadness that we learned of the passing of Christiaan Martin Lodewyk du Plooy (Vic) in April 2018 at the age of 78. Vic du Plooy was born in the small farming town of Makwassie situated in the North West Province on 20 December 1939. Vic first attended school in the nearby town of Leeudoringstad before continuing his schooling at Brentwood Park Primary School and thereafter at Brandwag High School in Benoni, Gauteng.

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Struers appoints Advanced Laboratory Solutions as agents

Advanced Laboratory Solutions have announced that they have been appointed the sole distribution agents for Struers products in Southern Africa, effective from 1 May 2018. Struers is a manufacturer of equipment and consumables for materialographic surface preparation and analysis of solid materials. Advanced Laboratory Solutions has more than 25 years’ experience in the materialography industry as a supplier of laboratory and scientific instrumentation in South Africa.

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Car exports bring in R164 billion

South Africa’s automotive industry achieved total export sales of vehicles and components worth R164.9 billion last year, which represented almost 14 per cent of the total South African exports according to newspaper reports. This enabled the domestic automotive industry to register its third consecutive annual trade surplus at R10.3 billion despite a 3.6 per cent decline in the total export value from R171.1 billion in 2016.

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April 2018

The development of Stelex ZR Ultra – Foseco

Through a combination of filter framing and ceramic technology, Foseco is introducing Stelex ZR Ultra 10 and Stelex ZR Ultra 15 to complement their other steel filtration offerings, which include Stelex ZR, PrO, Kalpur and Hollotex. Many steel castings are sophisticated, high technology components, and are often an important part of complex assemblies and systems for a huge range of applications. The castings are used in many industries.

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Atlantis Foundries well advanced in Smart Foundry ambitions

Last year Atlantis Foundries revealed that the company had embarked on an ambitious plan to turn the company’s Atlantis, Western Cape facility into a Smart Foundry. The announcement attracted worldwide attention in the foundry industry, from both equipment suppliers and other interested foundries.

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Foundry revolution

DataProphet is a Cape Town, Western Cape based company that provides consulting and product development services to a wide range of industries. As machine learning specialists they are comprised of a diverse team of skilled computer scientists, statisticians, actuaries, engineers and mathematicians that are poised to deliver something which has previously been unavailable to entities – actionable artificial intelligence solutions.

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Mondeco Solutions and the Norican Group of companies launch partnership

In February 2018 Mondeco Solutions and the Norican Group of companies held an event to announce the appointment of Mondeco Solutions as the new agent for the Norican Group of companies in Southern Africa to foundry owners and operators. Provided was information on product news and available services from all four companies within the Norican Group.

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PCS Foundry increases capacity with installation of new mechanised moulding line

Doubles floor space by adding 4 000m² to its existing facility. Brakpan, Gauteng based foundry PCS Foundry has recently completed a major expansion that will enable the company to expand its stainless steel and steel alloy production capacity. It will also diversify into other manufacturing industries other than the ones that the company already services and allow the foundry to offer production runs.

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GOM and RGC Engineering conference

New developments in optical measuring techniques for industrial casting processing presented. GOM, a global industrial company that develops, produces and distributes software, machines and systems for industrial and automated 3D coordinate measuring technology and 3D testing and local partner RGC Engineering held a one day conference in March 2018.

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Cast Products South Africa established as IDC awaits Competition Commission approval

Last year South Africa’s state-owned Industrial Development Corporation (IDC) announced that the restructuring of its steel subsidiary Scaw Metals into three standalone entities was at an advanced stage, as were plans to secure strategic equity partners (SEPs) for each of the units.

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Changes at Malleable Castings: Now part of West Rand Engineering Group

When Ben Dyson joined Malleable Castings as Managing Director at the beginning of 2011, one of his briefs was to look at all areas of the foundry and to come up with solutions to improve productivity, improve quality, reduce costs and scrap rates. The foundry was established in May 1963 to manufacture malleable iron castings by Ben’s grandfather Joe Peers.

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Omega Foundry Machinery sells out to Sinto

Omega Foundry Machinery Ltd. is a manufacturer of no-bake foundry equipment with subsidiaries in the United States, India, South Africa, Malaysia, and other countries. Omega and Sinto have enjoyed a working relationship since 2006 and the next step will allow both companies to benefit from the expanded equipment range in the field of chemically bonded sand and the combined global reach of the two companies.

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Prevent Group acquires Neue Halberg-Guss

Earlier this year, the Bosnian family conglomerate Hastor acquired the Saarbrücker Foundry Group Neue Halberg-Guss (NHG) through its Prevent Group, as reported by the “Frankfurter Allgemeine Sonntagszeitung (FAS)”. A publication of the German Federal Cartel Office shows that the NHG Group was sold to the investment company Castanea Rubra Assets, based in Berlin, Germany. Castanea Rubra belongs to the Prevent Group.

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February 2018

Endeco Omega Foundry Machinery joint venture realising results

“South Africa is a very important market for Omega and since gaining some significant projects in the region it was obvious that we needed to take the next step and establish a local presence. I am very pleased that an agreement to partner with Endeco has been reached and we will be looking to build on the synergies between our companies,” stated Mark Fenyes Chairman of Omega Foundry Machinery.

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Family ethos still high on the agenda at High Duty Castings

“There might have been changes in some of the shareholders recently but as one of the original shareholders I am still very much involved in the day-to-day operations of High Duty Castings and have been since the company was established in 1991,” said Fred Venter.

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Connectivity deepens operators’ understanding of events and sharpens decision-making at Pressure Die Castings

Adopting the Industrial Internet of Things (IIoT), Industry 4.0 and Artificial Intelligence (AI) to become a Smart Factory has long been part of the company’s culture. However, the challenge for industry in South Africa in the future is educating and getting employees to adopt and understand the technology.

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ArcelorMittal South Africa welcomes designation of local steel for rail sector

ArcelorMittal South Africa welcomes the decision by the Department of Trade and Industry (dti) to regulate the designation of locally produced services and goods or locally manufactured goods with a stipulated minimum threshold for local production and content in the Rail Permanent Way sector.

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Mondeco Solutions appointed new agent for Norican Global Group of companies

Mondeco Solutions have announced that they have been appointed the new agent in South Africa for the Norican Global Group of companies as of January 2018. The Norican Global Group is home to five leading globally active brands: DISA, Italpresse, Gauss, StrikoWestofen and Wheelabrator.

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IDC assessing 21 applications under R1.5 billion downstream steel incentive

The Industrial Development Corporation (IDC) is currently assessing 21 potential transactions, worth a combined R437 million, arising from applications for support under a R1.5 billion industrial financing scheme set up in 2017 to support manufacturers of value-added steel products.

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Kutana Steel purchases Saint-Gobain Pipelines

Verdant Capital has facilitated selling Saint Gobain Pipelines, a subsidiary of Saint Gobain South Africa, to Kutana Steel, a wholly owned subsidiary of the Kutana Group. Saint Gobain South Africa is a subsidiary of Compagnie de Saint Gobain, one of the largest top100 industrial companies in the world, is listed on the Euronext Stock Exchange and has a market capitalisation of USD 32 billion.

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Focus on digital skills. Technology to reignite South Africa’s manufacturing sector

“The manufacturing industry’s role in the South African economy has seen a long and sustained decline. From contributing nearly a quarter of GDP in the 1980s, the sector added a mere 13% to the country’s GDP in 2016. Job creation has also not materialised,” says Daniel Schwartzkopff co-founder of DataProphet.

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Acerinox to install $6million cutting line at South African stainless mill

Spanish stainless steelmaker Acerinox will invest €5 million ($6 million) in a new cutting and slitting line at its Columbus stainless steel mill in South Africa. The new line will allow the Columbus mill, which has capacity for 500 000 tons per year, to increase exports by 3 000 tons per month, Acerinox said.

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December 2017

ABP Induction Systems GmbH

ABP is one of the world’s leading creators of induction furnaces and heating systems for the metalworking and foundry industry. With design, production, assembly and other services offered for foundries and forging plants using induction, ABP manufactures a range of equipment for melting, pouring, holding and heating of steel, iron and non ferrous metals.

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Foundry Solutions thrives on non-ferrous bushes and liners

Now adding spin casting to its portfolio. Foundry Solutions might not be your modern casting facility with all the bells and whistles often associated with a foundry that is perhaps servicing the OEM automotive market and is required to have the latest production equipment and is deploying the cutting-edge technologies.

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Insimbi’s first half results ‘satisfactory’ and encouraging

JSE-listed Insimbi Refractory and Alloys’ earnings before interest, taxes, depreciation and amortisation increased by 273% year-on-year to R179.8 million for the six months ended 31 August 2017. Earnings a share were up by 142% year-on-year to 11.97 cents and headline earnings a share increased by 150% year-on-year to 11.95 cents.

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Endeco Omega 8-station carousel moulding line installed at wear resistant product manufacturing foundry

Just over 11years ago a large international company manufacturing wear resistant engineered products commissioned an in-house foundry at its Isando manufacturing facility in Gauteng. Traditionally the company procured their castings from either local foundries or imported them from sister companies elsewhere in the world.

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GOM and RGC Engineering to hold a one day conference on optical measuring techniques for industrial casting processing

GOM, a global industrial company that develops, produces and distributes software, machines and systems for industrial and automated 3D coordinate measuring technology and 3D testing and local partner RGC Engineering will hold a one day conference on 15 March 2018.

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Ecosafe Plus – a fire-resistant hydraulic fluid introduced for use in high-pressure systems

“Actually, Ecosafe Plus is a revolutionary product, because it combines the advantages of a HDFU, which are biodegradable, high temperature resistance and good lubricity, with the advantages of a water-glycol based HFC, having no fire point. Due to these parameters and characteristics, Ecosafe Plus is the ideal hydraulic fluid for non-ferrous metal foundries,” says Alexander Saam, Managing Director of Silca South Africa (Pty) Ltd.

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Unlikely that SEIFSA-NUMSA agreement can be extended to non-parties – SAEFA

A war of words is currently waging between employer bodies in the engineering and metal industries, with the mud-slinging centering on the wage negotiations, which were concluded separately from all negotiating parties by the Steel and Engineering Industries Federation of Southern Africa (SEIFSA) and the trade unions in August this year.

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SAIF 2017 Annual Golf Day

The South African Institute of Foundrymens’ Annual Golf Day took place on Thursday 9th November 2017. The event was held at the Reading Country Club. The competition on the day was four ball alliance with two scores to count. The winners of the SAIF Golf Day on an acceptable score of 94 were Hanno Viljoen, Afzal Chothia, Edward Jansen and Darryl MacIntosh.

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H W Schmidt Industrials motors ahead with new contracts

When H W Schmidt Industrials invested in a new Bühler Die Casting Cell in 2005 – with the main star being an Evolution 84 D840 ton high pressure die casting machine – it was a commitment to the local manufacturing ambitions of the company. H W Schmidt Industrials was established in 1952 by the late Heinz-Werner Schmidt, and has in excess of forty years’ experience in high-pressure aluminium die casting manufacturing.

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Ford to invest R3 billion for production expansion in South Africa

Ford Motor Company of Southern Africa recently announced it was investing R3 billion to expand production capacity at its South African manufacturing operations in order to meet growing local and international demand for the trendsetting Ford Ranger. It has also been confirmed that the thrilling, first-ever Ford Ranger Raptor will be produced in SA.

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US client acknowledges Pressure Die Castings

Specialist die caster Pressure Die Castings (PDC) was recently visited by company executives from Reliable Automatic Sprinkler Company at the PDC production plant earlier this year and the executives complimented the management and staff of PDC on the transformation of the production processes at PDC since the two companies first began dealing with each other over 30 years ago.

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October 2017

Smart chemistry that solves global challenges

SI Group, a leading global developer and manufacturer of chemical intermediates, specialty resins and solutions announced the implementation of a global brand transformation in September 2015. The project that impacted customers in more than 90 countries and facilities on five continents and took 18 months to implement also included the launch of a new logo.

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Atlantis Foundries embraces the Fourth Industrial Revolution

Atlantis foundries have embarked on a process that will pave the way to becoming a Smart Foundry by embracing the Fourth Industrial Revolution. This project aims to combine various technologies available to gather and analyse process data, with the aim of improving product quality and cost efficiency.

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SA Metal Group – maximising the value of scrap metal

SA Metal Group might be one of the oldest and largest scrap metal collectors and recyclers in South Africa but when you visit the company’s head office in Epping Industria, Western Cape, you are introduced to an aspect of the company that is not commonly known – beneficiating the scrap metal it collects and processes.

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IDC starts to sell off struggling Scaw units

After a reported a loss of over R1 billion for 2016, the restructuring of its steel subsidiary Scaw Metals into three standalone entities is now at an advanced stage with plans to secure strategic equity partners (SEPs) for each of the units, said CEO Geoffrey Qhena while presenting the IDC’s results in Polokwane, Limpopo.

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Metso investing in Isithebe foundry to increase manufacturing capacity for crusher wear parts

Metso is increasing its manufacturing capacity for large crusher wear parts castings used in minerals processing by investing in a second melting furnace at its Isithebe foundry in South Africa. The EUR 3.5 million investment will ensure the availability of Metso’s heavy crusher wear parts globally.

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Constitutional Court dismisses challenge to state’s scrap metal export rules

The Constitutional Court has dismissed an application by a local exporter of scrap metal for leave to appeal the judgment of the High Court of South Africa and the Supreme Court of Appeal upholding the State’s scrap metal export provisions, known as the price preference system, and ITAC’s decision to refuse to issue export permits to the SA Metal Group.

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Lauds achieving results with patented secondary reclamation plant

“As was the case with the atmospheric emissions licenses (AEL) the Department of Environmental Affairs (DEA) in South Africa is going out of its way to investigate waste management processes of local foundries and waste foundry sands is one of their primary targets.”

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New aspects in industrial 3D metrology, inspection and testing conference

This will be the first conference that GOM, based in Braunschweig, Germany, will hold of this type of event in South Africa. However, the company holds its internationally recognised GOM 3D Metrology Conference every second year. Over 600 delegates attend this conference that has been held 13 times and they include representatives from OEMs such as Audi, BMW, Opel, Porsche, VW, Boeing, Liebherr-Aerospace and Rolls-Royce.

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Mineral Zone appointed agents for LKAB Minerals

LKAB Minerals, an internationally active company in the industrial minerals market, has appointed Mineral Zone, a specialist supply partner servicing the Metallurgical and Mining sectors in South Africa and internationally with a range of metals and minerals, ore and services, as its agent in South Africa for its refractory and foundry mineral products.

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Spectrum Technical hosts successful aluminium technology seminar

“Spectrum Technical focuses on providing solutions for the processing of molten metal, in particular the casting of aluminium and zinc. We have been doing this since 1994, supplying a range of services and products,” said Kumaran Poonan, a Director at Spectrum Technical and head of the metals processing division.

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Omega and Simpson enter into a global agreement

Omega Foundry Machinery, a leading manufacturer of no-bake equipment based in Peterborough, UK and Simpson Technologies Corporation from Aurora, Ilinois, USA, a leader in foundry and chemical industries process technology, have recently signed an agreement to cooperate in the field of sand reclamation.

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August 2017

Nine elements that challenge handheld XRF analysers but are easy for OES

Handheld X-ray fluorescence (XRF) analysers are useful for many elemental measuring tasks across numerous industries and applications. Advanced models produce fast, accurate results on the spot, for sample identification, grade sorting, and metals analysis involving elements from magnesium to uranium.

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Naledi Foundry fired up and ready to grow

Just over two years ago Naledi Foundry, the foundry division of the Naledi Inhlanganiso Group, began implementing a plan that had increased capacity, improved quality and diversification as the pillars of its strategic blueprint. In order to achieve this the foundry embarked on a restructuring process that included investment in new equipment as part of an approximate R100 million investment programme in the foundry.

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Fred Botha appointed CEO of Insimbi

With the imminent retirement of Pieter Schutte as the Chief Executive Officer of JSE listed Insimbi Refractory and Alloy Supplies Limited the Insimbi Board has announced that current Commercial and Financial Director Fred Botha has been appointed as the new CEO of the company, effective 1 June 2017.

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Ceralcast sets up production facility in Gauteng

“When we established Ceramic and Alloy Specialists (Pty) Ltd in 1998 our core business was initially implementing projects in the aluminium primary and secondary sectors, upgrading launder systems and supplying consumables into metals industries,” explained Mike Retief, MD of Ceramic and Alloy Specialists.

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SAIF’s 54th Annual Awards Dinner

The South African Institute of Foundrymen’s 54th Annual Awards Dinner was held at the Emperors Palace, Convention Centre, Kempton Park, Gauteng on Friday 2 June 2017. 270 foundrymen, guests, wives and award winners attended this year’s event. The dinner was well supported by sponsors in the form of prizes for the award winners, and ticket sponsors for the award winners and VIP guests invited by the Institute.

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The Dylan Lewis Sculpture Garden

Eight years in the making, the Dylan Lewis Sculpture Garden is a place of expansive vistas, scents and the sounds of nature, with tranquil groves, hidden paths and lush indigenous vegetation. The project began serendipitously in 2009 when Lewis hired an excavator on a whim and began shaping the contours of what would become the seven-hectare sculpture garden.

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Agni Steel takes advantage of IDC fund

With the Downstream Steel Industry Competitiveness Fund, the IDC, in collaboration with government, hopes to increase competitiveness in the steel industry and incentivise production. Managed by the IDC, this fund will add to the various government interventions for the industry, which include tariff and local procurement measures as well as commitments for job retention, investment and upgrading.

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Recycling body MetPac-SA sets its sights high

“Aluminium and steel packaging are the world’s most recycled packaging and are literally worth their weight in gold. Originally, beverage cans were made from steel, and have successfully been collected in South Africa for the past 25 years. In many regards, it can be said that we have lead the way for responsible recovery and recycling of packaging in our country,” says Delanie Bezuidenhout, CEO of MetPac-SA.

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Süddeutsche Leasing look set to purchase Neue Halberg-Guss

German foundry Group Neue Halberg-Guss is on the verge of being acquired by new owners it has been reported in the German newspaper Saarbrücker Zeitung. The report says that the newspaper has been given inside information that financial services provider Süddeutsche Leasing is in discussions to purchase the foundry group but no official announcement has been made.

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June 2017

ChemSystems – uniquely service-oriented

ChemSystems Foundry division continues to bring the entire package including great products, local expertise, world-class technologies and a sincere commitment to local industry. Director of ChemSystems, Lance Dell explains how the business leverages global relationships and a service-centric approach to deliver a responsive and technologically adept local partner for ChemSystems’ customers.

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Atlantis Foundries focuses on securing new business, products and customers

In a recent report the management of Atlantis Foundries has emphasised that its focus going forward is to secure new business, products and customers, in addition to servicing the company’s existing clients. Traditionally the company has been recognised as a specialist in manufacturing medium and heavy-duty engine blocks for trucks and for industrial and marine applications.

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Prima celebrates 80 years in the foundry industry

History shows from minutes taken in the first recorded meeting that took place on the 15th April 1937, that it was decided to register a company Prima Iron and Steel Foundry and Engineering Works (Pty) Ltd. The decision was taken by two partners to start a steel foundry to supply the growing mining industry in South Africa.

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Endress+Hauser South Africa receives SANAS accreditation for local flow calibration centre

Calibration is a critical step in ensuring that a flow meter performs within expected specifications. Endress+Hauser says it is now well positioned to support its local customers flow calibration requirements, which includes third party meters. This service offering places Endress+Hauser ahead of its South African competitors, says the company.

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Zimalco appoints new MD

“I take over from a well respected individual in the industry who has many years of experience in the business and as a result I have big boots to fill. I joined the company in September 2016 to acquire some of this knowledge and experience from Willie so that there was a seamless handing over period,” said Ed Vermaak.

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Infigo Foundry up and casting

Taking over a foundry that has not been melting or manufacturing castings for a lengthy period, relatively speaking, is not an easy task. Well, this is the story of Infigo Foundry. I am sure that many members of the foundry industry are curious to know what exactly happened with Concorde Foundry Vereeniging, so this article will start by giving some answers to those questions.

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Kotze elected as new SAIF chairlady

At the conclusion of the 53rd Annual General Meeting of the South African Institute of Foundrymen, it was announced that Janley Kotze had been elected by her fellow board of non-executive directors as the new Chairlady of the SAIF. Janley takes up the position with immediate effect and will serve as Chairlady for the 2017/2018 period.

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Government aims to adopt a strategy to leverage scrap metal

dti representative Mamba says government aims to adopt a strategy to leverage the scrap metal produced by and belonging to the state and state-owned companies to enhance the competitiveness of the local steel industry, according to local reports.

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India’s foundry business in the doldrums

Blames China’s cheap imports – “The Chinese government has provided exemptions to cover nearly 40 per cent of export duties. Importing castings from China is cheaper than purchasing them from Indian foundries.” The Indian domestic foundry industry will witness a ‘dull’ 2017 in view of the impact of demonetisation and implementation of GST, but a revival was expected next year.

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April 2017

Foseco launches SMARTT degassing process control for rotary degassing of aluminium alloys

Foseco has launched SMARTT-Degassing, an innovative process control for rotary degassing of aluminium alloys. This process controlled by SMARTT, is a software programme that is based on the recently developed Foseco Degassing Model that accurately simulates rotary degassing.

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Who are we to believe?

October says new IPAP that is due to be released will support localisation. Davies says DTI is also committed to downstream steel products. Department of Trade and Industry (DTI) director-general Lionel October has revealed during a recent speech that the new Industrial Policy Action Plan (IPAP) focused on supporting the agro processing and metals industries, including foundries and the casting sector is due to be released in April 2017.

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Management buyout enables majority stake in Rely Intracast and Walro Flex

Rely Intracast’s current Managing Director Mark Hughes and the current Managing Director of Walro Flex, Carlos Palinhos, have completed a MBO (management buyout) to become majority shareholders in the respective companies that will in future fall under a recently established industrial holding company Intakobusi Holdings (Pty) Ltd.

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WFO Technical Forum 2017 & MCC 2017

The above conferences have just taken place at Emperors Palace, Gauteng, South Africa from 13 to 17 March 2017. It was the first time that South Africa hosted the World Foundry Organisation Technical Forum. There were many aspects that came together over the five days that also included the BRICS Foundry Forum. Whether you were a delegate, speaker or one of the exhibitors I am sure you have an opinion as to whether it was worthwhile attending and / or participating.

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Lauds Foundry Equipment staff subjected to traumatic murder and robbery experience

An armed gang of around 15 men stormed the Lauds Foundry Equipment premises in Wadeville‚ Ekurhuleni on Wednesday morning 22nd February 2017. The gang then proceeded to shoot Movchits before holding staff hostage for an hour while they ransacked the business premises‚ taking stock‚ computers and the staff’s personal belongings.

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Matt Cast Supplies certified for ISO 9001:2008 quality management system

Matt Cast Supplies cc was recently presented with its ISO9001:2008 quality management system certificate from Intertek, affirming that the company’s Germiston, Gauteng operation adheres to the internationally recognised standard for the quality system. Matt Cast Supplies realised several years back that it was important to have certification.

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Board changes at Insimbi

The board of directors of Insimbi Refractory & Alloy Supplies Limited have announced the appointment of Christiaan Coombs as an Executive Director and Robert Dickerson as a Non-Executive Director of the board with effect from 16 January 2017 as part of the restructure of the board following the AMR Group acquisition. The board has also announced the appointment of Brian Craig as an interim Chairperson with effect from 1 February 2017.

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Sculpture Casting Services – working closely with some of South Africa’s leading artists

During its history Sculpture Casting Services has been manufacturing bronzes for well-known sculptors and artists from around the world, casting from the smallest to the largest sculptures. Their ability to embrace and deploy innovation and the latest technology in the company’s manufacturing environment has enabled them to stick out amongst the crowd.

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Plan your trip to Machine Tools Africa 2017

Quality tools and machinery are the backbone of the South African manufacturing industry which is why Machine Tools Africa 2017 has been designed to showcase the very latest technology developments, machinery, products, services and solutions in this innovative sector.

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February 2017

Cover-Omega-Pic.3

Sand reclamation for chemically bonded sand systems

Today’s foundry using one of the many chemically bonded sand systems is under increasing pressure to reduce costs, reduce it’s impact on the environment but at the same time improve and maintain it’s casting quality. One of the ways of meeting these requirements is to invest in sand reclamation.

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Ind-News-Auto-Industrial-1

Auto Industrial Group transforms its high-volume mould, shotblasting and sand handling systems

When you are supplying a range of safety critical components to all of the automotive OEMs in South Africa your attitude towards your production operations and systems has to be progressive and inefficiency is not an option. That is why the Auto Industrial Group has spent over R50 million in the last two to three years on new equipment and systems.

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keegor

Keegor Group opens induction heating equipment company

The Keegor Group has recently expanded its product portfolio to create a new group company specialising in induction heating equipment. The new company, Keegor Power Electronics (Pty) Ltd, has been established as a result of the Keegor Group purchasing the LH-Power Electronics (Pty) Ltd intellectual property, assets and stock.

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Ind-News-Gordon

McNeilage takes up position of Senior Director, Manufacturing – Northeast Asia for SI Group

SI Group, a leading global manufacturer of chemical intermediates, specialty resins and solutions has announced that its South African Director of Operations, Gordon McNeilage, has been promoted to the position of Senior Director, Manufacturing – Northeast Asia for the Group.

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wfo

World Foundry Organisation Technical Forum 2017

The WFO Technical forum is being held in conjunction with the South African Metal Casting Conference 2017 (MCC) where 60 technical presentations will be given. These presentations include speakers from Germany, Norway, UK, Romania, Poland, USA, China, India, Netherlands, Denmark, Spain and South Africa.

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Int-News-scrap-metal

The true cost of scrap within the metalcasting industry

Imagine a high volume automated foundry running an overall 21% scrap rate with suspect castings making it to the customer’s production line. A new general manager takes the helm and mandates that scrap will be no higher than 4%. Within two weeks and without any tooling changes, production changes, or scrap analysis, the new scrap target was achieved.

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Ind-News-PDC-2

Mentorship is just the first step at Pressure Die Castings

Company records 24% growth for 2016. Progressive and success-hungry Pietermaritzburg, KwaZulu-Natal based Pressure Die Castings (PDC) has just completed a year that the company’s management says they will look back at with great satisfaction on many fronts.

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India

President of Institute of Indian Foundrymen calls for import of key raw materials to be duty-free for foundry sector

“The Indian foundry industry is third largest globally with revenue at US $18 billion and exports of approximately US $2.7 billion. It employs directly and indirectly two million. Over the last few years the Indian foundry industry has gradually risen from the fifth to the second largest producer of castings globally.”

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Ind-News-Silca-1

Silca South Africa adds more products to its portfolio

Well-known German manufacturer of high performance, asbestos free calcium silicates in a density range of 200 to 1 100kg/m, Calsitherm Verwaltungs-GmbH, opened a subsidiary in South Africa 18 months ago. The new company was established as Silca South Africa (Pty) Ltd in line with the Calsitherm Group’s marketing and branding development of subsidiaries worldwide.

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