50 years of achievement at Insimbi Alloy Supplies
Insimbi Alloy Supplies has undergone significant change since its beginnings in 1970. These developments have resulted in a much larger and more diversified group of companies than the founding members could ever have imagined 50 years ago. Insimbi Alloy Supplies has emerged as the name of the division that includes the products and roots from the original company.
Atlantis Foundries – 40 years of history
Atlantis Foundries has evolved over the years, originating from Atlantis Diesel Engines (ADE), an engine machining and assembly plant that was built in the late 1970s. The brand ‘ADE’ died away, but the company was purchased by Daimler/Mercedes-Benz in 1999, and has continued to cast cylinder blocks for heavy-duty trucks ever since.
Ultrafine Vacuum Impregnators acquire Casting Material Company and its vacuum impregnation services
Vacuum impregnation seals porosity without changing the castings’ dimensional or functional characteristics. This means manufacturers can use parts that would otherwise have been scrapped. It is a simple method and is approved by OEMs for a variety of components.
Celebrating the life of Thomas Wiese
It is with deep regret and sadness that we announce the passing of Thomas Wiese (56) in August 2020. Thomas was well-known to most of us in the foundry industry, especially to those on the aluminium side. Born in 1964 in Düsseldorf, Germany, Thomas started his career in the foundry and related industries in 1984 when he joined Austrian company Rath AG, a specialist manufacturer of refractories.
Industry study shines a light on the challenges facing foundries
The National Foundry Technology Network (NFTN) recently completed a survey of all South African foundries to evaluate the industry status quo and level of environmental compliance in the sub sector. The study, conducted by researchers from the Environmental Services unit of the Council for Scientific and Industrial Research (CSIR), aims to provide an informed and up-to-date overview of the foundry industry in South Africa.
Dispelling untruths about the historic standstill agreement
South African Engineers and Founders Association (SAEFA) Executive Director Gordon Angus writes: “Many of you will have seen propaganda sent out by SEIFSA referring to the adoption of their agreement with the trade unions. It’s unfortunate (although not surprising), that SEIFSA is once again being extremely liberal with the truth in this circular. SEIFSA and the trade unions proposed that their agreement be formally adopted as an agreement of the MEIBC. [But] this did not happen.”
Vexila wins four-year Eskom contract
Vexila has announced that the company has been awarded a tender for the procurement of designing, manufacturing, testing and supplying of high-voltage composite insulators for Eskom Holdings SOC Ltd. This tender will run for a period of four years. Vexila is the only manufacturer of high voltage composite insulators in Africa. The high-voltage composite insulators are long rods and line posts between 220kV and 400kV for Eskom’s transmission division.
Rondebosch Fountain replication update
The iconic Rondebosch Fountain has returned to Cape Town’s Southern Suburbs. Construction workers have installed a new replica of the original fountain on the corner of Belmont and Main Road, five years after it was destroyed, and dogs are already lapping from the fresh water. The restoration of the Rondebosch Fountain was undertaken by Heritage Castings.
ArcelorMittal restarts Blast Furnace C at Vanderbijlpark Works
Africa’s biggest primary steel producer, which is majority-owned by Luxembourg-based ArcelorMittal SA MT.LU, ArcelorMittal South Africa (AMSA) has said in a SENS announcement that the company has decided to restart Blast Furnace C at its Vanderbijlpark Works operations since steel demand has progressively recovered in the last two months. This follows after the company had put the furnace and its Vereeniging Electric Arc Furnace on idle in July 2020 amid low demand.
DataProphet raises US$6 million funding
South African startup DataProphet, which uses artificial intelligence (AI) to help manufacturers autonomise their operations, is to focus on expansion in the European Union (EU) and the United States (US) following its US$6 million Series A funding round. The company felt securing more capital was important for the company in order to realise its international growth ambitions.
Transport Minister after illegal scrap metal dealers
Government has developed an integrated plan, incorporating all law enforcement and prosecution authorities, to police and secure the Passenger Rail Agency of South Africa’s rail infrastructure. After months of talk, they are finally here, the bumped-up security detail being put in place to protect the infrastructure and trains of South Africa’s railways. There will be at least 3 100 of them in identified hotspots, according to reports.
Death of my Super Potjie number 12
A potjie – traditionally a three legged cast iron pot but frequently a flat bottomed one too – is manufactured of cast iron. A heavy lid is needed to create a slight pressure cooker effect inside the pot but you could actually use a normal pot as well. These pots become like a spouse, and sometimes more important, to many South African men and should last a lifetime. It was therefore distressing to receive the following message via the Castings SA website. “The best kitchen item I have bought in my life shows a crack of about 50% of the length of the potjie.”
Record production at Hillside smelter despite increased loadshedding
The unlocking of the potential and stability across operations benefited the energy-intensive business. South32’s energy-intensive Hillside aluminium smelter in Richards Bay delivered a record production performance despite unprecedented loadshedding over the past financial year. The global diversified miner reported that saleable production from the smelter increased by three kilotons (kt) to produce a record 718kt in the financial year to end-June 2020.
Foseco uses novel video links to make their products more visible
Click on the links to take you to a short video on new products: Feedex NF1 sleeves, Semco FD coatings and Kalpur feeder sleeves. In this age of the COVID-19 pandemic and the “wired world” that we live in, people have had to be creative and find solutions to communicate and to continue with life as though there were no restrictions placed on us by governments worldwide.
PMT vs CMOS The paradigm shift in metal analyser detector technologies
The photomultiplier tube (PMT) used in some metal analysers, for high-end applications, is one of the few vacuum tube technologies still manufactured for industrial use. However, an analyser based on PMTs suffers from inherent shortcomings. For example, it’s sharply limited in the number of elements it can detect. And its design makes it difficult or sometimes impossible to add new elements.
Dycer Engineering and Foundry graduates
Any organisation that is faced with the need to change things wrestles with the questions of what to change and how to sustain that change. What to change will obviously vary from company to company and industry to industry. Often, the answer to this question is presented to us by external forces. For example, changes in products will typically be dictated by customers.
NFTN supports Gauteng Foundry Training Centre
The Gauteng Foundry Training Centre (GFTC) was officially launched and opened in September 2013. The foundry industry in South Africa had for years been envious of what a number of its international counterparts were offered by their industry bodies in terms of training and research. The South African Institute of Foundrymen (SAIF) and its members had explored numerous options but there was always a financial constraint.
Atlantis Foundries welcomes Pieter du Plessis back to the helm as CEO
The Head of the Daimler Truck engine plant in Mannheim, southwest Germany, Andreas Moch, made the announcement in a recent statement issued to employees. He confirmed that after rounds of productive negotiations that Pieter du Plessis would once again take charge of the foundry as its CEO. “We are really happy to have du Plessis back in the family.”
Aluminium foundry doyen Charles Rowe passes away
It is with deep regret and sadness that we announce the passing of Charles Rowe (75) in June 2020. He was a doyen of the aluminium foundry industry prior to his retirement from Ajax Manufacturing. Charles was Managing Director of Ajax Manufacturing, one of the largest and oldest aluminium foundries in the Western Cape, retiring after 42 years with the company in 2011.
SAIF and AFSA submit application to Department of Environmental Affairs to exclude spent foundry sand as a hazardous waste product
Spent foundry sand may be a liability or an asset depending on how it’s handled. We live in a world of increasing scarcity. There is limited raw natural resources, financial resources are often not enough, and acquiring land for waste disposal is getting even more difficult and costly.
Denel PMP assets up for sale
A joint meeting of the South African Parliament’s Standing Committee on Finance and Select Committee on Finance, held on 3 July 2020, has heard how the country’s bleak financial outlook as a result of the COVID-19 pandemic is requiring significant action to reduce the economic effect of the disease and associated lockdown, including major reform within state-owned enterprises such as local defence company Denel.
South Africa bans all scrap metal exports for two months
Government commences urgent investigation into the supply of scrap to the metals industry in response to COVID-19. Ban put in place to safeguard employment at domestic metal production sites. At the beginning of July 2020 the Minister of Trade, Industry and Competition (the DTIC), Ebrahim Patel, issued a trade policy directive to the International Trade Administration Commission of South Africa (ITAC).
ArcelorMittal South Africa decides to idle blast furnace C at Vanderbijlpark, and the Vereeniging electric arc furnace until demand recovers
Steel producer ArcelorMittal South Africa (AMSA) will idle two blast furnaces in the country’s economic heartland to curb the effects of a collapse in global demand and forecasts it will record more than one billion rand in interim losses.
China’s manganese ore imports rise by 39% month-on-month in June
Our raw materials continue to be exploited. China imported approximately 2.18 million tons of manganese ore in June, a rise of around 39.3% from about 1.57 million tons in May 2020, according to the latest available Chinese customs data, reported recently in MetalBulletin. June’s volume is also 7.3% higher than the 2.03 million tons imported in the same month of 2019, the data showed.
Historic Saarbrücken Gusswerke finally shuts down
The fact that the last shift has been carried out at the casting works in Saarbrücken, Germany after 270 years may have to do with the reality that Volkswagen Group Germany (VW) had terminated its contracts with Bosnian supplier Prevent Group, who had only acquired the Neue Halberg-Guss company in 2018, and VW were not about to renew the contracts. It was reported that 70% of castings orders came from the automotive OEM.
The 5-inch high bargain ‘brass ornament’ that turned out to be a Susini masterpiece
Christie’s specialist Milo Dickinson reveals the extraordinary tale of a lost Renaissance bronze found in a $15 box of bric-à-brac in South Africa. “It is rare that something of this quality appears from out of nowhere. That it was found in a box of odds and ends in South Africa is a lesson to us all that there are still many great works hidden away, ready to be discovered,” says Christie’s Old Masters specialist Milo Dickinson.
The strange tale of Nelson Mandela’s gold-cast hands
Danielle Bochove of Bloomberg Businessweek writes that in May 2003, Nelson Mandela – the late former South African president, winner of the Nobel Peace Prize, and hero to millions – sat down at the dinner table of his house in Johannesburg and laid his right hand, palm side down, into a lump of cold dental putty. A team of technicians from the precision-casting division of Harmony Gold Mining Co. was present to supervise, and Mandela chatted amiably with them as they worked.
Technology empowered and people driven – ChemSystems Foundry unit
ChemSystems has been a fixture of the chemicals industry for over six decades. ChemSystems is one of the many companies belonging to the AECI Limited Group (African Explosives and Chemical Industries), which is listed on the Johannesburg Stock Exchange (JSE). AECI is a diversified Group of 16 companies that was registered in South Africa in 1924 and was listed on the JSE in 1966.
Three South African foundries accredited with PED 2014/68/EU certification standard, which enables them to supply castings with internationally recognised CE marking
NFTN supports initiative to get Kimberley Engineering Works, RelyIntracast and Vestcast audit ready. As a result of the TUV accreditation the local content pump and valve initiative gets clout and SOCs loophole is closed.
Endeco Omega Sinto ready to ship its first international order
Local fabricating and foundry equipment manufacturer Endeco Omega Sinto is getting ready to ship its first international order to a foundry that manufactures a range of small to large castings that meets the needs of companies in the mining, minerals, oil, gas, power and industrial markets. The equipment manufactured locally will be assembled at the foundry site once it arrives and will be incorporated into a very large project that the foundry is currently incorporating into its current location.
ProActively looking after its future – Active Foundry
Equipment investment cuts cycle times and improves quality. The increasing need to improve the quality standards for castings are not likely to be met by existing systems that are as old as the foundry in many cases. Increasing output also requires the foundry to consider process stability and repeatability. At the same time, production costs need to be contained in any change to equipment processes.
New owners of Schmidt Industries look to broaden scope of business
Significant change in culture within the business is showing positive signs. There comes a time when all of us must face the grim yet daunting task of divesting ourselves of a friendship, once unassailable, in favour of a new and invigorating relationship ignited with passion and endless, yet-to-be-determined possibilities. This is no easy choice, and there is no unequivocally guaranteed outcome.
IMP Scientific and Precision rebrands to Scientific and Precision Solutions
Following the approval of the competition authorities, FLSmidth announced in May 2019 that it had acquired the IMP Automation Group, which included the Mining and Minerals Automation division in South Africa. The IMP Scientific and Precision and associated services companies did not form part of the acquisition.
New steel mill denies bribes for jobs claim
United Steel condemns unnecessary protest at old Metso foundry. International metals and minerals company United Steel, a division of United Heavy Industries, has disassociated itself from allegations that jobs are up for sale at its steel mill, and condemned the protest action at the site, in Mandeni, KwaZulu-Natal, on June 1. The company recently acquired the business of Metso Minerals at the Isithebe industrial estate.
Tesla files another casting patent application
Invents new aluminium alloys for die-casting electric car parts. The “high-performance die-castable aluminium alloys” described by Tesla also have “a high flowability and low susceptibility to hot tearing when die-cast.” Tesla has filed another patent application to do with a metalcasting invention, this time for aluminium die-casting alloys. Last summer, the company had filed a patent application for a multidirectional unibody casting machine for a vehicle frame and associated methods.
74th World Foundry Congress postponed until 2022
The event was due to be held in October of this year in Busan, South Korea, but the organising committee, the Korea Foundry Society and the World Foundry Organisation (WFO) have decided to postpone due to the current COVID-19 coronavirus pandemic. The new date for the 74th WFC will be 16-20th October 2022, at the same venue of the former programme – Bexco, Busan, Korea.
The XRF principle – Spectro Analytical Instruments
The Fundamentals of Energy Dispersive X-ray Fluorescence Technology. The traditional use of X-ray fluorescence analysis (XRF) has its roots in geology. Solid samples were the first sample types analysed by X-rays. Over the years the applications have expanded and nowadays cover the analysis of alloys, various types of powder samples to liquid samples and filter material.
Foseco positions itself for the future of the foundry industry in Africa
2019 has been a tough year for all industries in South Africa. From political uncertainty, labour uncertainty, to an unreliable power provider, all resulting in a declining economy bordering on another recession. Everyone has been affected. It is in these times, that bold decisions need to be made and it is from this that Foseco South Africa has taken the opportunity amidst all the doom and gloom, to revitalise itself.
New owners for JC Impellers
After initially concluding a B-BBEE economic empowerment investment, partners agree to acquire 100% shareholding of jobbing foundry. JC Impellers has announced that the company has now been purchased in full by its B-BBEE partner Gabadela Investment Corporation, a Witbank-based holding company that already owns Witbank Foundry. JC Impellers, based in Wadeville, Gauteng, was established in 2001 and has been owned and run by Greg Smith since 2006.
Refractory and Metallurgical Solutions concludes B-BBEE deal and lifts shareholding to 40.82%
Refractory and Metallurgical Solutions (RMS) has announced that the company had concluded a B-BBEE deal that will see its partner increase its shareholding in the company from 12.5 per cent to 40.82 per cent. With this deal, RMS becomes one of the only South African refractory manufacturers of brick and monolithics that will comply with the new B-BBEE codes of the Department of Trade and Industry and the Department of Minerals and Energy.
Export tax on scrap metal under the spotlight
Publication notice of the proposal on export taxes on scrap metal for public comment. The effective date of implementation of the envisaged Export Tax on Scrap Metal will depend on the parliamentary tax process during 2020. This follows the announcement made by the Minister of Finance in the 2020 Budget Review regarding the introduction of export taxes on scrap metal and the publication by National Treasury on the 6th March 2020 for consultation to be the basic approach for such tax.
Solidworx Engineering and Fabcast Alloys combine talents and expertise
I was warned before visiting Solidworx Engineering to not to attempt to visit using my sedan vehicle. The reason given was because there had been plenty of rain in the area and the gravel roads leading to the company were in bad condition. Gravel roads should give you a clue as to the location of the company – not in your normal industrial area that has tarred roads and other good infrastructure.
Daimler Trucks AG set to acquire Atlantis Foundries
Germany’s and one of the world’s largest commercial vehicle manufacturers has entered into a transaction to acquire control over Ukuvela Holdings and its subsidiaries Atlantis Foundries Pty Ltd and Ukuvela Properties Pty Ltd. It is no April Fools joke but Atlantis Foundries is about to go through another ownership change – the fifth one in the last five years – and the purchasing company is part of the Daimler AG Group.
SI Group announces termination of agreement to sell industrial resin business
The SI Group, a leading global developer and manufacturer of performance additives, process solutions, pharmaceuticals and chemical intermediates has announced that its agreement to sell the majority of its global Industrial Resin businesses and its Brazilian Specialty business to ASK Chemicals has been terminated. The company previously announced the signing of the agreement in July 2019.
HA Group and SI Group to continue long-term partnership in Brazil and South Africa
Hüttenes-Albertus (HA), one of the world’s leading manufacturers of chemical products for the foundry industry, has announced that the company will continue its partnerships with the US-American specialty chemicals company SI Group in both Brazil and South Africa, following the termination of the agreement between ASK Chemicals and SI Group in terms of the intended disposal of SI Group’s Industrial Resin business to ASK Chemicals.
Machine Tools Africa 2020 postponed – new date still to be decided
Like many exhibitions worldwide the Machine Tools Africa 2020 exhibition has been postponed to a new date in the future. The exhibition, which was last held in 2017, has been designed to showcase the very latest technology developments, machinery, products, services and solutions in this innovative sector, was scheduled to take place from 12 to 15 May 2020.
Papenfus calls for steel industry businesses to resign from Seifsa
Gerhard Papenfus, CEO of the National Employers Association of South Africa (Neasa) has called for businesses involved in the metal and steel industry in South Africa to resign from Seifsa and escape the Seifsa/Numsa stranglehold on the industry. In an open letter Papenfus says: “Avoid being bound by the Seifsa/Numsa agreement. Resign now! Negotiations in the Metal and Engineering Sector are upon us once again.”
Melting capacity allows Sarco to expand their casting product base
South African Roll Company (Sarco) has long been recognised as one of the leading international manufacturers of castings used in the steel and non-ferrous manufacturing industries. Producing castings weighing up to 65 tons requires the foundry to have large melting capacity and the machine shop to have custom-built CNC equipment. All the processes in between pouring of the metal and final machining have to match and accommodate the size and weight of the castings – no mean feat.
Notice in response to current COVID-19 status in South Africa – SAIF activities
The content relates to the current COVID-19 virus situation. “Following the announcement made by President Cyril Ramaphosa on Sunday, 15 March 2020 in regards to the current outbreak of COVID-19 status in South Africa, the SAIF Board of Directors have taken the following decisions to support various precautionary measures in combating the spread of the virus within the SAIF community.”
Isuzu’s manufacturing plant in Port Elizabeth gears up for production of the next generation Isuzu D-MAX
Upgrades and modifications to the Isuzu Motors South Africa (IMSAf) production plant in Port Elizabeth are currently underway, gearing up for the production of the seventh generation Isuzu D-MAX bakkie. Late last year Isuzu Motors Limited of Japan confirmed that the company would be investing R1.2 billion in the next generation bakkie programme in South Africa.
Move to new factory positive for Endeco Omega Sinto
“The move was part of our restructuring plan to grow the business organically and externally. While the previous factory served its purpose while we were there, in the end it began to hinder our ambition to grow the business by expanding our penetration into the South African market and to be able to participate in Group manufacturing activities,” said Roy Dias, Managing Director of Endeco Omega Sinto.
Breathing new life into Nicast Foundry and Engineering
The risks associated with starting a new business are inherent. We have all heard the statistics that a high percentage of new businesses fail within the first year of operation. In addition, manufacturing is an especially tough business, with competition from both domestic and international sources. Many once successful manufacturing companies have folded in recent years, often because of situations beyond their control.
Norican partners with DataProphet to accelerate adoption of artificial intelligence in the foundry industry
Norican Global A/S, a leading metallic parts enhancement company, has entered an industry-exclusive partnership with DataProphet, a global leader in artificial intelligence (AI) for manufacturing, to bring meaningful AI applications into real-life foundry environments.
Mineral Zone accredited with ISO 9001:2015
“I am sure many individuals and companies debate hard about whether to get an ISO accreditation or not, especially as it is a relatively expensive exercise. How will it benefit my company? Will it give me an advantage over my competitors? These are just a couple of the myriad questions that will be asked,” mused Mineral Zone’s CEO, Brendan Homann.
Quality AND quantity? Yes, both are easily achievable through hard work
Based in Epping, in Cape Town, Gear Pump Manufacturing (GPM), part of the Hudaco Industries group, has always been a leader in the manufacture and assembly of SAE mounted hydraulic pumps and associated components right since its inception in 1985. This is evident through its worldwide recognition as a preferred supplier to various markets in the US and Europe, as well as Australasia.
Managing your mechanical and metallurgical testing is Vaal Metallurgical Laboratory’s metal
When Dries Saayman found himself ‘wandering the streets’ nearly 20 years ago after being retrenched as Foundry Manager of what was then known as Iscor Foundry in Vanderbijlpark, he was angry. He had studied hard to become a metallurgist and then worked long hours for the state-owned company and through his endeavours had been promoted to various senior positions.
The date for the Bright World of Metals 2023 has been set
The next date for GIFA, METEC, THERMPROCESS and NEWCAST has been set. The international leading trade fairs for metallurgy and foundry technology will be open to an expert audience in Düsseldorf, Germany from 12 to 16 June 2023. “I am delighted that we have once again found a date in the early summer. This timeline has proved to work perfectly,” says Friedrich-Georg Kehrer, Global Portfolio Director Metals and Flow Technologies at Messe Düsseldorf GmbH.
Globen Engineering Services and Supplies appointed agent for O.M.LER s.r.l.
Italian manufacturer of pneumatic decoring hammers O.M.LER s.r.l. has appointed local foundry equipment and services provider Globen Engineering Services and Supplies as its agent to market its products in South Africa. O.M.LER’s distribution network includes countries like China, USA, Mexico, South Korea and India, amongst others. The company has embarked on a strategy to penetrate more countries and foundry markets outside of Europe, including South Africa.
Atlantis Foundries receives sustainability award
“This is an award to Atlantis Foundries employees and in recognition of our continuing investment in the company and drive towards a sustainable future,” said Christoph Ewers, Director, Atlantis Foundries. “We understand this also to be in recognition of all the other automotive component manufacturers in South Africa who are not all large companies, but together consistently create enormous value in South Africa and essentially contribute to South African exports and GDP,” added Ewers.
Samancor Chrome looking at shedding nearly 2 500 jobs
South African miner Samancor Chrome said it could cut close to 2 500 jobs in response to weak chrome prices and power supply problems, according to a letter sent to unions and seen by Reuters. The warning follows a separate notification about 599 potential job cuts at its smelting operations and corporate offices, and highlights how the struggles of state power utility Eskom are dragging on the economy.
Trading statement by ArcelorMittal South Africa says the more than 1 000 job cuts had been finalised
ArcelorMittal South Africa, the largest steel company in Africa, has said in a SENS announcement to shareholders said that it had finalised job cuts affecting more than 1 000 employees as it attempted to cut costs. The company had previously announced the large-scale employee reorganisation in July 2019.
Denel’s Pretoria Metal Pressings under pressure
Company looking to exit business. Denel’s Chief Financial Officer is cautiously optimistic that the defence conglomerate is turning around and headed for financial sustainability, with major restructuring underway at the group. Carmen Le Grange was speaking at the sixth annual Aerospace, Maritime and Defence (AMD) Conference.
ABP Induction introduces MyABP
Foundry 4.0 and digitisation are buzzwords that, nowadays, play a role in every industry. And rightly so because the opportunities afforded by networking offer invaluable potential when it comes to raising productivity to an unprecedented level. ABP Induction has developed the MyABP portal for this very purpose – it supports their customers in raising this potential.
ITAC proposes export duty on ferrous and non-ferrous waste and scrap
The International Trade Administration Commission of South Africa (ITAC) has initiated a proposal to implement an export duty on ferrous and non-ferrous waste and scrap. The notice (568 of 2019) was published in the Government Gazette of 18 October 2019.
More efficient furnaces drive significant energy, cost and time savings at PDC
“Like every business and manufacturing operation in South Africa we were experiencing frustrating times when confronted with Eskom’s power outages and planned load shedding that have been haunting us for several years now. But it is not just the inconvenience of trying to work in the dark that raises temperatures,” explains Mike Wolhuter.
Allied Mineral Products opens precast shapes manufacturing facility
Allied Mineral Products has opened the doors to its newest precast shapes manufacturing facility in Gosforth Business Park in Germiston, Johannesburg. This marks Allied’s sixth precast shapes location worldwide. Allied’s engineering capabilities include designing and manufacturing complex shapes in virtually any size. Precast shapes can also be created from existing drawings or shapes.
Metal Casting Technology Station accredited as an ISO/IEC 17025 testing and calibration laboratory
The Metal Casting Technology Station (MCTS) at the University of Johannesburg (UJ) has announced that they have been accredited as an ISO/IEC 17025 testing and calibration laboratory for metallurgical and mechanical testing with a specific emphasis in the foundry industry.
Malleable Castings boosts productivity with new investments
“When I joined the company in 2011, I was given a challenging task to improve productivity, improve quality, reduce costs and scrap rates in a foundry that was operating in the 19th century. This was especially so as the foundry had not made any major capital equipment investments since the 1980s and there was a reluctance to provide funds for expenditure on modern foundry manufacturing equipment,” explained Divisional Managing Director Ben Dyson.
Duvha Foundry installs new equipment to reduce scrap, Improve shot blasting and optimise sand usage
Duvha Foundry, based in the Chamdor industrial area of Krugersdorp, Gauteng has recently installed and commissioned a new Endeco Omega mixer in its sand department and a new shot blasting machine in its finishing department. “The existing equipment that we had was old and did not meet our quality requirements,” said Stanley Tshivhase, director and owner of Duvha Foundry.
Insimbi – Resilience during tough economic conditions
Despite a very challenging local and global economic environment, exacerbated by the impact of the terrible floods and labour unrest that affected Transnet operations in Durban earlier in the financial year which created a backlog at Durban port that continues to hamper the Group’s export of recycled metals, Insimbi has achieved decent growth on the back of the acquisition of Group Wreck in November 2018.
Closure of the Saldanha steel plant by ArcelorMittal SA will have ripple effects
ArcelorMittal South Africa (AMSA), the domestic unit of the global steelmaker, has said that it was winding its Saldanha plant down and that it would be put on care and maintenance by the first quarter of 2020. The closure of ArcelorMittal South Africa’s Saldanha Steel plant will affect roughly 900 workers – 550 of whom are directly employed by the company, with the remainder sub-contracted.
SAIF 2019 Annual Golf Day
The South African Institute of Foundrymens’ Annual Golf Day took place on Thursday 14th November 2019. The event was held at the Reading Country Club. The competition on the day was four ball alliance with two scores to count. First on the day with 88 points were Arthur Spires, Gabriel Sekgwele, Bettie Knoessen and Seun Potgieter. Second on 84 points were Divan Kapp, Danny Muller, Willie Groenewald and Johan Pullen.
MCI Foundry concentrates on stainless steel castings
Although conceptualised in 2015 it is only now in 2019 that MCI Foundry has begun to melt metal and produce castings. “We registered the company four years ago with the idea of establishing a foundry that would be dedicated to manufacturing stainless steel castings only. We did not have a deadline to begin operating and we only began working on the implementation of the logistical requirements required to run a foundry in 2018,” said Gladys Tshivhase, a Director of MCI Foundry.
Job losses in the metal and engineering industry to continue
Numerous reports have been published in recent years about the extent of job losses and high levels of unemployment in South Africa. Many of these point to the fact that a major cause of this is unsustainably high wage levels, particularly for unskilled positions. Legislated high entry level wages in some sectors also prevent many companies from taking on young inexperienced workers and offering them the opportunity of acquiring vital on-the-job skills and experience.
Silica Quartz mine now offers AFS specification foundry sand
The Silica Quartz mine, situated outside Delmas, on the border of Mpumalanga and Gauteng, has been supplying high-grade silica sand and grit to the glass, industrial, mining, filtration and leisure industries. Extensively used in water purification, filtration, separation and the glass industry, the product is dried and sized to meet the specific needs of customers.
KPL Die Casting comes of age
The month of August marked a significant milestone in the history of KPL Die Casting, an aluminium and zinc high-pressure die-casting foundry located in Germiston South, Gauteng. “We have been in business for a full 21 years now so you could say we have come of age,” said owner Sally Marengo, who runs the company with her husband Guiseppe.
Carrol Boyes: Artist and designer
We learned recently of the sad passing of Carol Boyes, a renowned South African artist and designer that skillfully combined the science of engineering with art to produce creative and highly-sought-after tableware. Products are made of aluminium, stainless steel and pewter and are either cast in the foundry or processed via stamping or pressing.
Environmentally friendly Ecosafe Plus biologically degradable hydraulic fluid gaining momentum
Two years ago, Silca South Africa introduced Ecosafe Plus to the South African market with a mission to educate the local manufacturing industry about the benefits of the product and its environmentally friendly properties that had been accepted worldwide.
What comes next for Allied Mineral Products South Africa: Manufacture of precast refractory shapes
The primary function of the South African operation is to design and manufacture monolithic refractories for the foundry, aluminium, steel, cement, power, minerals processing, boiler, heat treating, forging and industrial markets. Allied Mineral Products, Inc. has designed, manufactured and sold monolithic refractories for the foundry industry since 1961.
Metso confirms closure of foundry – 200 jobs impacted
Mining OEM specialist Metso, which recently announced a merger with Outotec, will discontinue its Isithebe foundry by the end of September 2019 resulting in the loss of approximately 200 employees. The foundry is located in KwaZulu-Natal half-way between Durban and Richards Bay. It follows consultations in which it evaluated the closure or other alternatives.
Can South Africa afford AMSA any longer?
Gerhard Papenfus has also called for the scrapping of steel import duties, which he says are negatively impacting on South Africa’s downstream steel sector. “According to ArcelorMittalSA (AMSA), consumption of its steel has slumped to a ten-year low – falling to 70% of the consumption level achieved in 2008,” says Gerhard Papenfus, the CE of The National Employers’ Association of South Africa (Neasa).
Hulamin acquires remaining aluminium rolling slab business of Isizinda Aluminium
The Competition Commission has recommended that the Competition Tribunal approve the proposed transaction whereby Hulamin Systems intends to acquire the slab business of Isizinda Aluminium without conditions. The Commission found that the proposed transaction is unlikely to result in a substantial prevention or lessening of competition in any relevant markets.
ZF starts production in East London, South Africa
ZF Lemförder SA (PTY) Ltd opened a new plant in East London in May 2019. Only nine months after the nomination, the new Plant commenced production of front and rear axles for its customer, Mercedes-Benz South Africa. “We are expanding our global footprint by opening our new plant in East London. Additionally we are strengthening the relationship with one of our strategic customers and with the region,” states Dr. Peter Holdmann.
Important enabling factors for meaningful localisation in the automotive industry
“Manufacturing, and the automotive industry, is often seen as a gateway to inclusive economic growth. A well-developed manufacturing sector creates embedded jobs, deepens and broadens local value chains, advances technology, and supports local skills development,” says Dr. Martyn Davies, Africa Automotive Leader, Deloitte Africa.
Sub-Saharan Africa Workshop at METEC 2019
African and German delegates discuss market potential in Africa. The METEC Sub-Saharan Africa Workshop took place for the first time on June 26th, 2019 during the METEC/GMTN trade fair in Düsseldorf, Germany. Key players from Africa and Germany exchanged ideas on how to do business in Africa. The workshop focused on the challenges and opportunities of the African metallurgy market.
Spectro introduces Spectrolab S – A high-end OES analyser for process control and research metal analysis
Features proprietary CMOS+T technology; Delivers fastest measurements, lowest limits of detection, longest uptime in its class. Spectro Analytical Instruments has introduced the Spectrolab S high-performance arc/spark optical emission spectrometry (OES) analyser for the analysis of metal in process control and research applications.
Important developments emerge from GIFA/GMTN 2019
Those that did not attend will have to catch up as the industry moves full throttle ahead towards Industry 4.0, the Internet of Things, artificial intelligence, robotics as well as a common language for machines to operate. Speaking to some foundry owners before GIFA/GMTN 2019 to find out whether they would be attending the exhibition it was astounding to hear them utter that they would not learn anything new by attending.
Atlantis Foundries recognised at inaugural ‘Factory of the Year’ award
South Africa’s first ‘Factory of the Year’ award has been presented to Eberspächer South Africa based on an assessment of customer satisfaction, product quality, value creation, economics, agility and innovation. Judges said Eberspächer, which manufactures exhaust systems, was a highly efficient producer with a balanced score across all dimensions, falling within the top quintile of global benchmarks in terms of quality.
Patel promises support programme for new plant and equipment for foundries and steel mini-mills
The new Trade and Industry and Economic Development Minister Ebrahim Patel has promised to launch a support programme for new plant and equipment, specifically mentioning the development of foundries and steel mills. The promise came during his first budget speech to the National Assembly as the new minister.
Breaking the mould with robotic sand milling to generate patternless castings
Omega Sinto robotic milling cell creates waves at GIFA 2019. Mould making lead times drastically reduced by combining a robot with a sand milling solution. The technology used in modern parts manufacturing has come a long way during the past few decades.
McWade Productions continues on its growth path and diversifies outside of just being a foundry
Recent acquisition of Babcock Ntuthuko Powerlines introduces forging into its service offerings. Nine years ago, McWade Productions decided to take stock of its foundry facility in Olifantsfontein, Gauteng and have hard look at its operational and manufacturing procedures and equipment with a view to improving productivity, yields and increasing capacity.
Metso looks to close Isithebe foundry
Word has it that the parent company has had enough of the militant unproductive workforce and the power blackouts. In a recent press release that internationally recognised Metso released it stated: “As part of a global supply footprint development strategy in its Minerals Consumables business area, Metso is initiating consultations to evaluate the potential closure or other alternatives for its foundry operation in Isithebe, South Africa.”
Insimbi moves further into scrap metal recycling with the acquisition of the Treppo Group for R109 million
JSE-listed Insimbi Industrial Holdings (ISB) has informed shareholders that in terms of Section 9 of the JSE Limited Listings Requirements, Insimbi has extended an offer to the shareholder of Treppo, being Texiflash Proprietary Limited (the Vendor), who has agreed to the key terms of the proposed transaction, which will see ISB acquiring control of Treppo.
SAIF’s 56th Annual Awards Dinner
The South African Institute of Foundrymen’s 56th Annual Awards Dinner was held at the Emperors Palace (Boksburg), Gauteng on Friday 7 June 2019. This year’s event saw 225 foundrymen, guests, wives and award winners attend. The dinner was well supported by sponsors in the form of prizes for the award winners, ticket sponsors for the award winners and VIP guests invited by the Institute.
Hands on advice for successful sand reclamation
Sand reclamation has become a necessity in no-bake operations, particularly given the current challenges regarding the cost and availability of new sand. Foundries can no longer afford to operate with new sand alone and most are exploring how best to economically integrate sand reclamation systems into their processes.
Maxion Wheels plant in South Africa recognised as among the best in the group
The Maxion Wheels aluminium wheel manufacturing plant in South Africa was recently recognised as being one of the most technically advanced in the international group when senior executives, including Marcos Oliveira, President and CEO of Iochpe Maxion, Pieter Klinkers, CEO Maxion Wheels and Juan Lorenzo, President, Europe, Africa, Asia, visited the plant in Alrode, Gauteng to see the recent developments at the plant and to hold executive meetings.
Extension 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 (ITAC) 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.
RAPDASA 20th Annual International Conference
The Rapid Product Development Association of South Africa (RAPDASA) will hold its 20th Annual International Conference from 6 to 8 November 2019. The conference will be hosted by Central University of Technology, Free State (CUT) and will be held at the Emoya Estate, Bloemfontein in the Free State province. Additive Manufacturing (AM), better known as “3D Printing”, has matured from a prototyping technology into a fully-fledged manufacturing technology.
Insimbi’s voluntary performance update and trading statement looking positive
More acquisitions in the metal recycling industry being negotiated. The Insimbi Group’s results for the year ended 28 February 2019 will be published on or before 29 May 2019 (too late for this publication). However, management considers it appropriate to provide shareholders with a brief voluntary performance update on the business.
DataProphet launches Artificial Intelligence computer vision system for quality control in manufacturing
DataProphet Inspect uses machine learning and Artificial Intelligence (AI) to significantly improve quality control for Industry 4.0. DataProphet, a global leader in Artificial Intelligence (AI) for manufacturing has announced the launch of DataProphet Inspect, a cutting-edge machine vision system to enhance the effectiveness of human quality control operators.
Changes to board at SAIF
Following the South African Institute of Foundrymen’s 55th AGM held on Tuesday, 14th May 2019 at Reading Country Club no new directors were elected to serve on the board of the SAIF for the following year (2019/2020) as no proposals or nominations had been received. Continuing on as Chairperson will be Glen Dikgale and Janley Kotze as Deputy Chairperson. Other Directors include Enno Krueger, Nigel Pardoe and Didier Nyembwe.
Maxion Wheels to reduce the cost of non-quality with DataProphet’s Artificial Intelligence solution
DataProphet, a global leader in Artificial Intelligence (AI) for manufacturing, and Maxion Wheels, a leading wheel manufacturer, are working together to significantly reduce the cost of non-quality in the production of aluminium wheels. DataProphet’s AI solution aims to achieve a substantial reduction in non-quality incurred at casting.
GIFA, METEC, THERMPROCESS and NEWCAST (GMTN 2019) to be held in Düsseldorf, Germany
From 25 June to 29 June 2019, the Düsseldorf Trade Fair Center will play host to the trade fair quartet comprising GIFA 2019, International Foundry Trade Fair with WFO Technical Forum, METEC 2019, 10th International Exhibition for Metallurgical Technology with Congress, THERMPROCESS 2019, 12th International Trade Fair and Symposium for Thermic Production Processes, and NEWCAST 2019, the 5th International Trade Fair for cast products.
South African exhibitors at GIFA / GMTN 2019
Here you will find a list of companies involved in the metal casting industry in South Africa that will be exhibiting at GIFA / GMTN 2019. Listed are the personnel from the company that will be attending and the details of the companies that they represent, including hall and stand numbers for easy location.
GIFA / GMTN 2019 South African participation
Here you will find a list of companies involved in the metal casting industry in South Africa that will have representation at the exhibition. Listed are the personnel from the company that will be attending and the details of the international companies that they represent, including hall and stand numbers for easy location.
Foseco to launch a host of new products at GIFA 2019
As a primary innovator in the foundry industry globally, Foseco regularly publishes information on new products and enhancements, process developments and new techniques, and state-of-the-art papers on new thinking in foundry practice. With the commencement of the international GIFA 2019 exhibition scheduled to begin in little over two months, Foseco have released a number of new products that will be on display for the first time.
Pressure Die Castings faces up to the challenge of modernising and automating its die-casting operations
Austrian company Meltec chooses PDC to trial its brass vacuum dosing furnace on high pressure die-casting. This is one of the first of its kind trials in the world to be carried out. Continuing with its strategic decision to move further up the value chain, with an emphasis on product delivery and quality, Pressure Die Castings (PDC) has now invested in a further two new high pressure die-casting machines.
Pfisterer fronting up to global energy requirements
Global energy requirements are growing at an ever-increasing speed. Revolutions are underway all over our planet, causing the demand for electrical energy to increase even further. Be it a growing number of megacities, the boost to the international transport industry, the development of information technology, or the closer relationship between societies and industry, the direct result is the same. The world needs future-ready power grids to guarantee a safe and efficient supply of energy.
2019 Castings Industries Directory
Make sure your company is listed by sending in your details. The deadline for your free listing is 03 May 2019. The publishers of castings sa will be publishing The 2019 Castings Industries Directory in May 2019. This is the fifth edition of this popular specialised buying and contact guide of Southern African foundries and suppliers to the industry.
Elmacast Engineering invests R134 million into upgrades in foundry
Elmacast Engineering, a foundry based in Springs, Gauteng, has recently completed phase one of its expansion project that entailed the installation of four new induction furnaces, an automated continuous caster and a fully integrated double line heat treatment plant. The cost of the project totalled R134 million, which increased the foundry’s capacity to produce in excess of 2 500 tons a month of grinding media comprising high chrome balls.
Localisation of the South Africa automotive value chain
“The South African automotive manufacturing sector is the most dynamic manufacturing sector in the country and a major driver of economic development for the country,” says Renai Moothilal, the Executive Director of the National Association of Automotive Component and Allied Manufacturers in an opinion piece. This is due in part to a supportive auto industrial policy framework that has been sustained over the last three decades.
Olde World Foundry transforms into a ferrous jobbing foundry
Hammarsdale is an industrial estate some 45 kilometres west of Durban. The area is surrounded by the beautiful rolling hills and open countryside of Mpumalanga (place of the rising sun and not to be confused with the province of the same name) and geographically forms part of the well-known Valley of a Thousand Hills, KwaZulu-Natal.
ASK Chemicals celebrates the 10th anniversary of its foundry pilot plant
Together with customers, partners and employees ASK Chemicals celebrated the 10th anniversary of its foundry pilot plant at the company headquarters in Hilden, Germany. The festivities were rounded off by a lecture colloquium held the following day, at which representatives from the academic world as well as customers, partners and employees of ASK Chemicals gave lectures that focused on the importance of networking for innovation and success.
At GIFA 2019, HA will be showcasing the exciting possibilities of its Center of Competence
Many internal and external customers have already made use of the facility in Baddeckenstedt, Germany, located at approximately 50kms from Hannover. Looking ahead to GIFA 2019 HA will show that a comprehensive range of advanced chemical casting products is just one part of the success story.
Endeco Omega Sinto looks forward to busy year
35 years after being established initially as a design and details company before expanding into designing and manufacturing its own equipment for the foundry industry, Endeco Omega Sinto has notched up another significant milestone on its timeline. “We always outsourced our fabrication requirements but this changed in 1994 when we purchased our own premises in Alberton, Gauteng,” said Roy Dias, Managing Director of Endeco Omega Sinto.
Carbon International (a Durrans Group company) is opening a calcination plant in Sasolburg
“The Durrans Group purchases green coke from Sasol Secunda refinery and currently calcines the product in China. The Group approached Sasol with the view to beneficiating the product in South Africa for the obvious reason of eliminating the extended logistics and process costs,” said Chris Durrans, Managing Director of Sheffield, UK-headquatered James Durrans & Sons Limited.
Atvantz Patterns embraces modern technology
Additive manufacturing, 3D printing and simulation software may be amongst the fastest evolving areas of metalworking and casting technology. Even more impressive are the real changes that these technologies makes possible for foundries. Foundries and manufacturing operations are constantly re-evaluating their manufacturing processes, especially in this era where costs, accuracy, quality and on time delivery are more likely to be discussed before the actual manufacturing process.
Smelters will not survive 15% Eskom tariff hike, industry warns
As hearings into Eskom’s proposed tariff increase kicked off, the ferroalloy industry has warned it will not survive a double-digit increase in electricity prices. Eskom has applied for a 15% annual hike in the power price for the next three years but the national energy regulator of South Africa will only take a decision after three weeks of public hearings that began in Cape Town in January, according to a Business Day report.
Trade Fair Tours and Castings SA tour to GIFA, METEC, THERMPROCESS and NEWCAST 2019
More hotel options added – now 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.
Who benefits from erecting bronze statues as symbols?
For centuries, statues have been used as symbols of appreciation for the life and work of the person they seek to honour. Stone, cement, wood, ceramics, marble, bronze and other types of metal such as stainless steel are all materials used to manufacture these statues. In the case of Madame Tussauds Attractions worldwide wax is the preferred material.
Advanced Laboratory Solutions presents Struer’s The Professional Materialographer training course
The course covers the theory of metallographic sample preparation from cutting, hot mounting, grinding/polishing through to inspection and analysis. Through their experience in supplying materialographic preparation equipment Struers, one of the leaders in the field of materialographic sample preparation, have developed a training course known as The Professional Materialographer.
Joerg Foundry now in the BMG stable
In the middle of 2018 the Bearing Man Group added Rustenburg Engineering and Joerg Foundry to its long list of acquisitions that it has made in recent years. This is the first time that the Bearing Man Group, which forms part of the Engineering Solutions Group (ESG) business segment of Invicta Holdings Limited – an investment holding and management company that is listed on the JSE, has ventured directly into the foundry industry.
Neue Halberg Guss has new owners … again!
It has been widely reported in Germany that AVIR Guß Holding GmbH has acquired the business operations of Neue Halberg Guss GmbH together with all the major assets. The deal lifts the threat of job losses for the time being and was structured through AVIR’s affiliated companies Gußwerke Saarbrücken GmbH and Gußwerke Leipzig GmbH. The transaction is still subject to closing conditions, which should be fulfilled soon.
What can you expect from GIFA 2019?
In an interview with the German Giesserei magazine, GIFA and NEWCAST President Heinz Nelissen is optimistic that foundries will face future challenges and solve the problems together with their customers and suppliers. The megatrend of the moment and the topic of the future in production technology is additive manufacturing. Also the digital transformation is an issue for foundries. 3D printing has been gaining in importance alongside traditional manufacturing techniques.
Castings SA’s coverage of all the latest events, open houses, demonstrations, discussions, seminars and more keeps you up-to-date with vital industry developments. Whether lowering the cost of production with innovative new machine tools or hearing first-hand from experts about solving measurement challenges, Castings SA will ensure that you are always informed about the events vital to your business.