2 ria c12 1repro - metalworking news sa june...magma; an “app” that every engineer should have!;...

castings sa vol 12 no 1 June 2011 1

castings saA specialised journal covering the technology,

processors and materials field for castings

vo lume 12 number 1June 2011

cover storyLauds looking forward to GIFA 2011

industry newsAirtech riser sleeves;ArcelorMittal; Applied Casting Solutionsand ASK Chemicals;Endeco;Transnet foundry;2011 Castings IndustriesDirectory published;Foundries Engineering Centre;Local content of new locos;Copper Cables & Connectors;Coega; Recruitment;McWade Productions

international newsGIFA, METEC, THERMPROCESS and NEWCAST:AFSA; ASC; Lauds Foundry Equipment;Nimag; Pressure Die Castings;Rand York Minerals; RelyIntraCast;Scaw Metals; Solidworx Engineering; SAIF;Thos Begbie; Vestcast; Itshe Resources

product reviewMAGMA;An “App” that every engineer should have!;10% higher productivity;Oxford instruments; Control for extruding aluminium;Birkenmayer and Eirich;Hardness testing

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4Castings SAvol 12 no 1ISSN 1605-7589

Publishing EditorBruce Crawford

Editorial BoardMarc Hindle

Technical ArticlesReprinted with permission fromInstitute of Cast Metals Engineersjournal – Foundryman and FoundryTrade Journal published by dmgBusiness Media Ltd, UK.

Production ManagerWendy Crawford

ReproductionJericho Graphic Design

Printed ByMasterpack

Advertising Bruce Crawford/Wendy CrawfordTel: +27 11 463 0489Cell: + 27 83 628 7654E-mail: [email protected]

castings sa is published by BA Crawford SpecialisedPublications (Pty) Ltd. PO Box 69 299, Bryanston,South Africa, 202141 Arklow Road, Bryanston, South Africa, 2021Tel: + 27 11 463 0489E-mail: [email protected]

SubscriptionsAnnual – Local: R130.00 (incl. VAT)International: On application

CopyrightAll rights reserved. No editorial matterpublished in Castings SA may be reproduced in any form or languagewithout written permission of the publishers. While every effort is madeto ensure accurate reproduction theeditor, authors, publishers and theiremployees or agents shall not beresponsible or in any way liable for anyerrors, omissions or inaccuracies in thepublication whether arising from negligence or otherwise or for any consequences arising therefrom. Theinclusion or exclusion of any productdoes not mean that the publisher oreditorial board advocates or rejects itsuse either generally or in any particularfield or fields.

castings sa is the official journal of the South African Instituteof Foundrymen (SAIF)

Printed on:

2 castings sa vol 12 no 1 June 2011

EDITOR’S COMMENT

GIFA 2011 provides an ideal platform to network and learn

On the eve of the mostimportant internationalexhibition for the foundry

industry - GIFA/NEWCAST/ METEC/THERMPROCESS 2011 - which takesplace in Düsseldorf, Germany fromthe 28th June to the 2nd July 2011it's encouraging to note that the exhibition will again be well attendedby South Africans. To date I havecompiled a list of 128 names that Iknow of who have committed toattend. In comparison to the exhibition four years ago, this is

more than the 125 names that were on the list compiled then.There will also be a number of names that will surface in the nextmonth and there will be others that you will bump into while atthe exhibition, that are not on the list. I estimate that there willeventually be over 150 visitors from South Africa, which is veryencouraging if you consider that the economy is not as boisterousas it was a few years ago.

Again there will be a South African National Pavilion wherethe local companies can exhibit. In total there are 11 companiesexhibiting, down on previous exhibitions, and two industry representative bodies being the SAIF and AFSA.

The pavilion is located in Hall 13 Stand 22 and I encouragethose visiting GIFA to drop by the pavilion while you are there. It always fascinates me as to how much networking and businesstakes place between the South Africans while at exhibitions suchas GIFA. Generally speaking there is never time to make contactwhile back in South Africa or we are too busy to make that time.But when we are 'forced' to make contact we realise that we dohave something in common and we can help each other in some way, whether it is a business transaction or learning fromeach other.

For those companies that are presently exporting, their profitmargins are probably being squeezed at the moment because ofthe recent strengthening of the rand, but where would thesecompanies be if they did not have this business.

But out of a negative there is always a positive and thestrengthening of the rand will afford South African companiesand others an opportunity to invest in new equipment andimprove production and quality at a far more attractive price thanwas the case a few years ago.

If we are going to be competitive with the rest of the world weneed to invest in our manufacturing capabilities and companiesneed to understand they must be much better at what they do inthe future. Poor business practices and efficiencies and poorquality castings are not tolerated internationally.

With this in mind the GIFA/NEWCAST/METEC/THERMPROCESS 2011 exhibition provides an ideal opportunityfor visitors to see and hear first hand how the industry in the restof the world is progressing and of course, to compare ourselvesand hopefully learn.

The mammoth task of compiling and collating the 2011Castings Industries Directory has finally come to an end with thedirectory being published just in time to ship to Germany for theexhibition. The comprehensive listing of the foundries activitiesand contact details, including the data such as production figures,has been updated since the last directory was published in 2007.

If you would like a copy of the directoryplease contact the publishers - see story further on in the magazine for an order form.

The aim of the SAIF is to promote and develop withinSouthern Africa the science, technology and application offounding for individuals and involved industries.

Individual Member (local) – R575.00 Individual Membership (country) – R350.00 Junior Member – R100.00 – must be enrolled as a fullschedule student, in an accredited educational institutionin the Metals Industry as a trainee, and who has notreached his 23rd birthday.Retired Member – R250.00 Company Member (local) – 1 to 150 foundry relatedemployees – R2 350.00 Company Member (local) – more than 150 foundry relatedemployees – R4 850.00Company Membership (country) 1 to 150 foundry relatedemployees – R1 400.00 Company Membership (country) more than 150 foundryrelated employees – R2 850.00 Overseas Membership – R1 100.00 per annumAll of the above fees exclude VAT and are per annum

President – Luis DiasVice President – Enno Krueger

Immediate Past President – Bruce Crawford Previous Immediate Past President – Richard Seymore-WrightTreasurer – Wessel Watt

Bruce Crawford Nigel PardoePeter van Wyk John Davies Grant Estman Takalani MadzivhandilaMpho Mabotja Wouter Retief Grant Estman

President - Willy PolisTraining Coordinator – Anthony O’ BrienFinancial & Technical Speakers – Dean Horne & Sean StadlerAdministration – Kevin MissenheimerSocial Co-ordinator & Technical Speakers –Mike Killain

University of JohannesburgMetal Casting Technology Station - MetallurgyRoom G101, John Orr Building, Corner Siemert and Beit Street, Doornfontein,Johannesburg, Gauteng.Postal Address: P.O. Box 14863, Wadeville, 1422.John Davies - Tel: 011 559 6468; Cell: 083 630 2809;Email: [email protected]

Website: www.foundries.org.za

Contact details for Western Cape: Tel: 021 573 7311; Fax: 021 573 7296; Cell: 072 313 8375

Address Details

Western Cape

Elected Members

Constitutional Members

Council Appointments for 2010/2011

Fees

south african institute of foundrymen


cover story

Local foundry, industrial and mining equipment manufacturer and distributor of international equipment,Lauds Foundry Equipment is looking forward to

participating on the South African National Pavilion at thisyear's GIFA 2011 exhibition which takes place in Dusseldorf,Germany at the end of June.

"When we exhibited in 2007 it was our first time at GIFAitself and also our first at an international exhibition so wewere very inexperienced. However we learnt from that first exhibition and are now going to the 2011 version with a lotmore knowledge and know-how" said owner Kevin van Niekerk.

"This year we will be exhibiting a new range of our locallydeveloped material handling equipment. This includes a 15 tonan hour pneumatic conveyor, a 15 ton an hour hot/cold castingfeeding line and a pulse jet ventilation unit" said van Niekerk.

Richards Mining Equipment acquisitionHowever the company has expanded appreciably since

2007. The latest of these developments is the acquisition ofRichards Mining Equipment.

"In 2006 we signed an agreement with Omega FoundryMachinery to not only act as distributors for their equipment inSouth Africa but also to be a supplier to them of core blowingequipment. Omega specialise in the design and manufacture of sand mixers, mould handling systems, sand reclamation systems and turnkey installations."

"Omega acquired the business andassets of RichardsEngineering Inc in 2008.Richards manufacturesthermal reclamation systems, sand driers,chromite separation,shell sand coatingplants along with theirown range of sandmixers, mechanicalreclamation plantsas well as a rangeof mining equipment, whichnow all falls underour umbrella of products" explainedvan Niekerk,

"The foundry related side of the business has now beenincorporated into Omega with the company deciding to divesttheir interests completely in the mining business and as aresult from the beginning of May 2011 we (Lauds FoundryEquipment) have acquired the mining business, wholly ownedand will begin manufacturing the equipment locally. The product range will fall under our umbrella but be marketed as

Richards Mining Equipment."

Richards MiningEquipment manufacture a fullrange of mobile and portablemineral processing plant forthe extraction and concentration and beneficiation of a wide rangeof minerals, gem stones, precious metal and basemetal ores.

The units can be suppliedmounted on mobile wheeledchassis or portable skid bases,and are manufactured in unitsizes up to 100 tons an hour.

Simpson Technologies"Towards the end of last

year we were also appointeddistributors for SimpsonTechnologies, a US group thatmanufactures a range of greensand foundry equipment.

Lauds looking forwardto GIFA 2011

Product portfolio increased.

A Simpson Hartleycontroller

An overview of the Lauds factory


This appointment is significant in that we areonly one of two distributors worldwide, asagainst being agents. The distributorshipentitles us to do the complete supply,installation, commissioning and servicing of the Simpson products,carrying all guarantees backed bySimpson through Lauds FoundryEquipment."

Simpson Technologies, founded in 1912, is a five generation family business concentrated on the design and manufacture of technology and services for theworldwide metal casting and chemical process industries.Primary products include green sand batch and continuousmixing equipment, molding green sand coolers, on-line mixercontrols, core sand preparation systems, shell sand preparation plants, green sand reclamation systems, sand laboratory equipment and foundry system design, engineering and automation systems. Simpson Technologieshas operations in Aurora, IL USA; Steinhausen, Switzerland;Calcutta, India and Changzhou, China.

Other representationLauds also represents Koins Foundry Technology, a

manufacturer of automatic pouring systems, inoculation systems and crusher equipment designed for the continuouscrushing of ductile and grey iron scrap.

"Lauds has also adapted to the changing markets and wehave diversified our manufacturing base in the last few years.

Although foundry is still our main focuswe have also completed projects in the

general industrial market and the miningindustry. Full ranges of heat treatment furnaces

have been introduced as well as a range of shotblast equipment, giving the client a wider range of

choice, with quality, durability and price being our number one priority."

"ABB electrical have signed as our channel partners for allelectronic supplies including high and low voltage, instrumentation and high efficiency electric motors and controls. With this agreement we have the full support of theABB technical support and design team, thus enabling us toventure into sectors of the markets knowing we are backedwith the best."

Recent projects"Some examples I can give you include the manufacture of

an electrically heated oven used for baking the coatings on piping, some in line mixers and agitators, screens for the copper and coal mines and the automation of a packagingline."

"One of the bigger projects in the company history has beenthe recent completion of a 30 ton an hour chrome sand drying

plant, which is fullySCADA operated, for amine in Rustenburg,North West Province."

"We have alsoinstalled a Koins autopouring mapping system at AtlantisFoundries. The systemcontrols the sprewcup level with a constant level via 3D laser technology,resulting in no over orunder pours. Thissame system will alsobe installed in one ofthe bigger foundrygroups in South Africa."

"We have also supplied a one tothree ton an hour continuous mixer forthe WCIF trainingfoundry. Other equipment suppliedfor this no-bake plantis a dosing system, avent unit and a oneton filling hopper."A Lauds heat treatment oven

Although foundry is still our main focus we have also completed projectsin the general industrial market and the mining industry

Above: Simpson laboratory equipmentLeft: A Simpson multi cooler


"Currently we are also upgrading the reclamation plant andbag house at Weir Minerals Africa. The plant is being upgradedfrom six ton an hour to 12 ton an hour. Other equipment beinginstalled at Weir includes a 25 ton lump hopper, a 12 low levelvator, a 12 low level cooler and a 12 low level gammareclaimer."

Spare parts"As an OE manufacturer we keep all our

replacement parts for Lauds, Simpson, Omega andKoins equipment on our shelves, ready for installation. Three service teams are available 24 hours, 365 days of the year. We also stock allother foundry, industrial and mining spares,whether it be mechanical, electrical or hydraulic."

Other developments"We have appointed Jaco Grobler as our

Engineering Director and he has taken control ofour design department as well as overseeing theimplementation of a quality system throughout thecompany. As result we have attained SABS9001:2008 status and are due to be awarded ourcertification end of May 2011."

"Melvin Bircher has joined the company on thesales and service side and he will look after theWestern and Eastern Cape area. He is well knownin the industry and has exceptional knowledge withregards to green sand systems, core making andmelting practices. We are very excited with him

joining our team and he can be contact on 072 418 2341 or email [email protected]" concluded Van Niekerk.

For further details contact Lauds Foundry Equipment on TEL: 011 824 1238, cell 082 895 2871, email [email protected]/[email protected] or visit www.laudsfe.com.

A Lauds crusher unit


In an area that saw rapid developments last century,there has not been any ground-breaking advancement inrecent years. This is until Applied Casting Solutions, a

business unit in the Chemserve Division of listed chemicals and explosives firm AECI, together with Airtech Sleeves PTY Ltd developed a new and novel method of producing insulating and exothermic sleeves.

"Foundry men are constantly being confronted withchallenges to improve their operations and lower costswhile at the same time producing higher quality castings.One of the ways to achieve lower costs and improve thesoundness of a casting is to incorporate the use of risersleeves. This can lead to improved yield while solvingshrinkage problems", said Neville Sanders, National Sales Manager of Applied Casting Solutions.

The riser sleeves or exothermic orinsulating sleeves as they arereferred to today, provide the foundryindustry with a reliable cost effectiveapproach for optimizing feeding efficiency, improving quality and lowering costs.

"Riser sleeves are strategicallyinstalled around the casting mouldcavity to provide liquid feeder metalto the solidifying casting", explainedSanders.

"Risers or feeders are reservoirsthat contain excess molten metal.The excess molten metal is neededto compensate for contractions orvoids of metal that occur during thecasting process. Metal from the riserfills such voids in the casting whenthe casting metal contracts.

Thus the metal from the riser needs to remain in a liquidstate for a longer period of time, so it can provide metal tothe casting as it cools and solidifies. Sleeves are used tosurround or encapsulate the riser and other parts of thecasting assembly in order to keep the molten metal in theriser hot and maintain it in the liquid state for a longertime" Sanders continued.

"In order to serve their function, sleeves have exothermic and/or insulating properties. Exothermicsleeves function by liberating heat. This liberated heat satisfies some or all of the specific heat requirements ofthe riser and limits the temperature loss of the moltenmetal in the riser, thereby keeping the metal hotter and liquid longer. Insulating sleeves on the other hand,

maintain the heat of the molten metal in theriser by insulating it from the surrounding mouldassembly material" Sanders continued toexplain.

"For years sleeves were produced by"Ramming", "vacuuming" and "blowing or shooting" methods, well known in the industry.Traditionally the sleeves were made of fibrousrefractory materials combined with a blend ofmaterials that produce an exothermic reactionmore commonly known as a thermic reaction.The most common fuel material is aluminium.When mixed with an oxidizer and an iniator / fluxing material and then exposed toextreme heat, the aluminium is oxidized,

Revolutionary Airtechriser sleeves developed locally

industry news


giving off heat as the reaction proceeds"."More recently, it was discovered that sleeves could

be made by chemically curing a shaped sleeve mix with a curing catalyst by the no-bake and cold-box process.These processes provided sleeves with improved dimensional accuracy".

New development - a green process"However Applied Chemical Solutions and

Airtech Sleeves (Pty) Ltd have taken the technology to anew level with the development of the revolutionary Airtech insulating and exothermic sleeves".

"The company Genrick Technical has developed andpatented a method of producing synthetic beads in therange of one to three mm diameter. These beads are inert and made from what can be called "green" materials".

"Genrick Technical have licenced Applied CastingSolutions and Airtech Sleeves (Pty) Ltd. exclusively, to produce products for the foundry industry, by usingthese beads which have excellent insulating properties".

"Sleeves produced come in various sizes, shapes andangles including domed, straight, closed, with and withoutbreaker core and round neck down variations, to name afew. All these are commonly used in the foundry industry".

"The sleeves are manufactured in a cold box processand exhibit very good dimensional accuracy and consistency. The excellent insulating properties of ourinsulating sleeves and beads can result in replacing many exothermic products currently used, thus reducingcosts".

"The development has taken three years and many trials, and results are showing that the Airtech insulatingand exothermic sleeves performance is appreciably betterthan the sleeves currently in the market place".

"More importantly, in this modern age whereby environmental standards have to be strictly adhered to,Airtech Sleeves being manufactured in a "green" processusing "green" materials, will emit appreciably less undesirable fumes when coming into contact with moltenmetal. This affords foundries to operate in a more userfriendly environment".

Prospects"The local industry is said to be in the region of

R30 million annual sales of sleeves and we are looking totake a sizeable portion of the market" continued Sanders.

Applied Casting Solutions, a business unit operating inChemserve Systems is a specialty resin producer servingthe Foundry and Timber industries. The company has manufacturing facilities in Chloorkop, Durban and Cape Town and manufactures foundry products underlicense to A.S.K., a world leader in Foundry products whichis based worldwide with the head office in Hilden Germany.

The company continually introduces new technologyproducts into industry, has a well trained and qualifiedtechnical representative and strives to keep supplying thefoundries with world class technology and service at alltimes.

For further details, contact Neville Sanders of Applied Casting Solutions on TEL: 011 922 1600.


During a conference call to brief the media and analysts on the first-quarter results, a confidentArcelorMittal SA chief executive Nonkululeko

Nyembezi-Heita said the company would not divulge details yet, but had appointed a team to investigate theresources.

"We will be able to update the market in six months'time regarding the resource. We will acquire the propertyand will mine on our own account in the area," she said.

The subsidiary of ArcelorMittal, the world's biggest steel maker, was expecting the 2011 financial year to bestronger than the last financial year.

The giant's near-monopoly in South Africa's steel industry has meant that steel prices remain high, an issue the government is trying to intervene in as theresource is strategic.

The Department of Trade and Industry was last yearadvocating for the introduction of a "developmental steel

price" which would protect buyers and the downstreamindustries.

Nyembezi-Heita said her firm had yet to receive the government's steel pricing report. It has been reported that the company would increase steel prices by 4.5 percent.

She was confident the costs could be borne byArcelorMittal SA's consumers, among them the construction sector, which had made a comeback in 2010 after the World Cup and was growing due to maintenance needs.

"The automotive sector is robust, and looks set to havea strong performance in 2011. The packaging industry isfairly consistent," she said.

Evan Dold, the vice-president for global purchasing and supply chain at General Motors South Africa, said the company had dealt with price increases in the steel

industry by trying to negotiate lower price increases withArcelorMittal SA and considering alternative sources atlower costs.

He said there had been total cost management, forexample attempting to offset steel price increases throughprice reductions on other materials, absorbing increasesand also partly offsetting steel price increases throughvehicle price increases. Higher steel prices had a negative financial impact if these increases could not berecovered or offset, and would potentially reduce local content.

According to a Kumba Iron Ore report entitled The South African Iron and Steel Value Chain, more than 85 percent of South African steel was consumed in industry sectors for which steel's share of the productvalue was typically lower than 5 percent. Therefore, ironore typically contributed less than 1 percent to the costs of these end products and was largely insignificant in its impact on overall costs of

downstream industries. ArcelorMittal SA managed to make a turnaround after

reporting that the bottom line profit was R184 million inthe first quarter, compared with a loss of R496 million inthe previous quarter. Because of an increase in production volumes of both flat and long steel products, domesticsales volumes had increased 36 percent, the cost of steelsales slumped 7 percent, and steel production hadincreased by 20 percent.

However, the attributable earnings were 75 percentlower due to a 20 percent increase in the cash cost ofsteel sales coupled with a 7 percent drop in liquid steelproduction. The company also said that the sales volumeswere flat.

Revenue increased 14 percent quarter on quarter onthe back of improved domestic sales and 6 percent higher average realised prices.

ArcelorMittalto mine own ore

ArcelorMittal South Africa, the biggest steel maker in Africa, is respondingto procurement problems that have plagued it since August last year

by acquiring its own iron ore property in the Northern Cape.This will supply it with up to 3 million tons a year.

ArcelorMittal SA managed to make a turnaround after reportingthat the bottom line profit was R184 million in the first quarter, compared with

a loss of R496 million in the previous quarter. Because of an increasein production volumes of both flat and long steel products, domestic sales volumes

had increased 36 percent, the cost of steel sales slumped 7 percent,and steel production had increased by 20 percent


ASK Chemicals, one of the world's largest suppliers offoundry chemicals, active in 24 countries with 30 locations,16 production plants and a total of approximately

1,600 employees, has recently signed a distributorship agreement with South African company Applied CastingSolutions. ASK Chemicals provides foundries with products andservices for adding value to the entire casting process - from thecore shop all the way to the melting department.

"Applied Casting Solutions has been supplying the foundrymarket in South Africa for more than 20 years and has been thedistributor of Ashland products for a long time. Therefore it wasnatural to enter into discussion with the new company which hastaken over the heritage of Ashland Casting Solutions. Now we arehappy to announce that the agreement has been completed andwe can join forces" said Morne Cloete, Business Unit Manager,

Applied CastingSolutions

Whenaskedwhatdoes thismean toAppliedCastingSolutions'and ASK

Chemicals'customers in

South Africa, ASKChemicals CEO Stefan

Sommer said: "ASK Chemicals and AppliedCasting Solutions are partners in the marketplace. ASKChemicals is already serving customers in South Africa. In futurethese customers can continue to buy directly from ASK Chemicals if they wish. This means that all customers canbuy from Applied Casting Solutions but also from ASK Chemicalsdirectly. However, Applied Casting Solutions' customers now haveaccess to the latest technology developed within ASK Chemicals.This development is driven by the work of the company'sresearch and development centers, now present on three continents, with more than 90 chemists, engineers and technicians."

"Since ASK Chemicals is a one stop shop for all products thatare needed by a foundry, the new company offers the entirerange of foundry chemicals and services, across the whole valuechain in a foundry - from core shop through moulding line all theway to the melting process. The new company's extensive expertise comes from the development facilities, experience andproduct knowledge of the incorporated companies. Many ofthese products e.g. water based coatings, resins, risers, HiTechfilters for steel and investment casting as well as metallurgicalproducts can be sourced through Applied Casting Solutions now"continued Sommer.

Environmental considerationsThe foundry industry is assumed as an industry having

considerable environmental problems. Will there be products andprocess know how available to support our industry here inSouth Africa in improving these problems, I asked?

Cloete explained: "Applied now also has access to newlydeveloped product lines of ASK Chemicals. ASK Chemicals hastaken the responsibility to support foundry processes with efficient new product lines and solutions. This includes innovative product lines such as the INOTEC inorganic binder system, which has already proven its suitability for series production at BMW in Germany, for example. The use of highlyefficient cold box binder systems also helps to reduce emissionssignificantly through a reduction in the use of binders. Such products are essential, especially for high-technology customerswhich, as manufacturers, must present their sustainability credentials. Alongside the enormous reduction in pollutants anda significant improvement in the quality of castings, these product developments make an essential contribution to improving manufacturers' productivity by means of reduced costsfor maintenance and emissions provisions. Newly developedwater based coatings for serial castings complement the rangeof sustainable products. ASK Chemicals believes that thefoundries in South Africa are increasingly interested in thesekinds of advanced products. The alliance between AppliedCasting Solutions and ASK Chemicals will therefore benefit themarket and enable additional growth potentials for the partners."

ASK Chemicals consists of the following companies:• Ashland-Südchemie-Kernfest GmbH, based in Hilden,

Germany, together with its subsidiaries, has been a successfulbusiness since 1970 with operations mainly in Europe.

• The global foundry chemicals business unit owned byAshland Inc., Ashland Casting Solutions, Dublin/Ohio.

• Süd-Chemie's other companies supplying to the foundryindustry: SKW Giesserei GmbH based in Unterneukirchen,Germany; WD-Giesserei-Technik GmbH based in Fuldabrück,Germany; Tecpro Corporation Inc. based in Atlanta/USA; Süd-Chemie Hi-Tech Ceramics Inc. based in Alfred Station/USA;Ajay Metachem Süd-Chemie Pvt. Ltd. based in Pune/India and parts of Jiangsu Süd-Chemie Chemical Materials Co., Ltd.based in Zhenjiang/China.

Applied Casting Solutions are based in Chloorkop, KemptonPark, Gauteng have five technical sales people in South Africa,with offices and warehouse facilities in Cape Town, Durban, Port Elizabeth and Johannesburg.

For further details contact Applied Casting Solutions on TEL: 011 922 1600 or Stefan Schreckenberg, the ASK Chemicals' representative who is based in South Africa and will look after the Western Cape region on 078 075 44 24

Applied Casting Solutions and ASK Chemicalsagree on an exclusive distributorship for South Africa

Johannesburg based Applied Casting Solutions, a division of Chemserve Systems(Pty) Ltd, the former distributor of Ashland Casting Solutions, signed a distributorship

agreement with ASK Chemicals, Hilden, Germany, the newly formed global joint venturebetween Ashland Inc. Dublin / USA and Süd-Chemie AG / Munich / Germany in April.


South African foundry equipment manufacturer Endeco cchas appointed RCF Suppliers cc to represent the companyin the Western Cape. The appointment is effective

immediately.Managing member of Endeco Luis Dias said "We have never

had any representation in the Western Cape area and we neededsomeone on the ground rather than the long distance that wehave been trying to deal with."

"RCF Suppliers has beenestablished in the WesternCape for over 10 years, primarily supplying thefoundries with consumablesfrom well known companiesFoseco South Africa andGFE Alloys" continued Dias.

"RCF Suppliers is headed up by Dean Horne,who is a Past President andcurrent committee memberof the WCIF. Dean also runsa fabricating company andhas a vast amount of experience in the foundryfield having started hiscareer off working in afoundry" explained Dias.

"I am delighted to begiven this opportunity toexpand our product portfolioand now be able to offer thefoundries a quality range ofcapital equipment. As youknow Endeco have beeninvolved in supplying equipment for most of themajor foundry projects inSouth Africa and are currentlydealing with some blue chipcompanies" said Horne.

The range of sand plantand equipment that Endecodesigns and manufacturesconsists of all the necessaryequipment used in bothgreen sand and chemicalbonded sand projects, froma small ferrous or non-ferrous foundry to thelargest semi-automatic orautomatic complex, and forvirtually any type, size, quality or quantity of casting.The equipment includesreclamation plant, continuous and batch mixers, rotary drums, coolerclassifiers, conveying systems, compaction tables,vibrating feeders and shake-outs, rollover units,rotary screens, aerators,weighing devices and

additive screw feeders. Other equipment that Endeco has designed and

manufactured includes chromite sand separators, ladles, bucketelevators, dust extractors, moulding boxes, pneumatic conveyingsystems, degassing units, rotary sand dryers and mould dryingand coating units.

For further details contact Endeco on TEL: 011 907 6111 orRCF Supplies on TEL: 021 551 0582

Endeco appoints RCF Suppliers as its Western Cape agent

Transnet foundry continueswith its upgrade programme

Just under two years ago the Transnetfoundry in Koedoespoort, Tshwanebegan a major upgrade programme with

the commissioning of two 2750 kilowatt six ton induction furnaces, manufacturedand installed by Solid State InductionHeating (Pty) Ltd.

It was the beginning of a programmethat will see the foundry invest close to R15 million on new and refurbished equipment and is part of the foundry'sstrategy to supply the castings for its ownrail engineering consumption which are currently being imported.

"The foundry now has the ability to castup to 12 tons per casting, a factor that

limited the foundry in the past because of the size of theold furnaces" said the Business Manager of the foundrydivision in Koedoespoort Joel Reddy.

"We knew from the outset that with the extra meltingcapacity we would be limited on the sand side. We also hada number of other factors to consider when deciding to purchase the R5 million sand reclamation plant" continuedReddy.

"The foundry was operating under a very non greenfriendly environment, both for the employees and the environment itself. Added to this was a cost factor. We were not reclaiming any of our sand, which resulted inhuge input costs, and the costs for dumping of our wastesand were rising as well as becoming more of a legislationissue."

"Included in our strategy was to change our processfrom a foundry that was operating entirely as a green sandfoundry to one that would in the future be predominantlyreliant on resin sand and ultimately give us the opportunityto reclaim our sand. It is a gradual change and currentlywe operate a 70 percent green sand and 30 percent resinsand basis but it is our intention to swing these numbersaround as soon as possible" said Reddy.

"These compelling reasons led us to include the investment in a fully automated sand reclamation plantwhen we embarked on our upgrade programme. The reclamation plant, which is in the process of being

A fully automated sand reclamation plant is manufactured, installedand commissioned by local foundry equipment manufacturer Endeco.

The Endeco vibrating shakeout that is built over a six by five metreand 4.5 metre deep pit that houses a 5 ton sand hopper


The hopper incorporates a vibrating feeder which discharges thereturn sand via a belt conveyor to a 25 ton return sand hopper

that is located outside the foundry

The Business Manager of the Transnet foundry division inKoedoespoort Joel Reddy with Operations Manager Geloep Snyman

commissioned, incorporates two dust extraction units andwill be fully operational by the end of May 2011" explainedReddy.

"The sand reclamation plant includes a vibrating shakeout that is built over a six by five metre and 4.5 metre deep pit that houses a 5 ton sand hopper. The hopper incorporates a vibrating feeder which discharges the return sand via a belt conveyor to a 25 tonreturn sand hopper that is located outside the foundry.

Halfway along the belt conveyor we have installed an overband magnet to remove the tramp metal from thereturn sand. The first of the dust extraction units is locatedin the shakeout area."

"The sand is discharged from the return sand hoppervia a vibrating dosing feeder into the reclamation mill,where the lumps and sand is scrubbed and transported tothe cooler classifier. Sand is discharged from the coolerclassifier and a 10 ton an hour pneumatic conveyor pumps


Halfway along the belt conveyor an overband magnet has beeninstalled to remove the tramp metal from the return sand

The overband magnet to remove the tramp metal from the returnsand is clearly doing what it is supposed to do


the cooled, classified sand into an 80 ton storage silolocated above a continuous mixer. Reclaimed sand isblended with new sand before entering the mixer. A dustextractor has also been incorporated into the system."

"The plant is controlled via PLC with all the functionsdisplayed by a touch screen. The PLC enables us to keephistorical data for maintenance purposes."

"With the installation of the new plant it will not onlybring us up to speed in the sand department but we estimate that we will be making a 90 percent saving in new sand purchases and in the costs for dumping. Small savings will also be made on the chemical side."

On the green sand plant side a 50 ton an hourSpeedmüller batch mixer, which was manufactured in1953, has been refurbished by Endeco tomeet the requirements of amodern foundry. There arealso plans to install a dustextraction plant.

Other investmentsmade so far to improve theefficiencies of theKoedoespoort foundryinclude four new 11 tonladles. The heating ofthese ladles is being converted to a gas pre-heating system withcustom built jigs manufactured so as tomaximize energy management and production time.

Future investment"It made no sense to

just invest in the production side of thefoundry. Therefore we willbe shortly ordering a newspectrograph, a new heattreatment furnace and anumber of pieces of laboratory equipment whichincludes sand testing

equipment" said Reddy. "One of the main reasons for this upgrade programme

is to put the foundry in a position so that it can supply thecastings for its own rail engineering consumption which arecurrently being imported. This strategy has already seenthe foundry win orders for the manufacturing of an estimated amount of R35 million of knuckles and drawgears that were previously being imported from Brazil" concluded Reddy.

Transnet foundry divisionThe foundry division of Transnet is a leader in

South Africa's castings industry in that it possesses themost modern, efficient production equipment which is currently being upgraded to meet the requirements of thebusiness strategy.

Transnet Rail Engineering's foundry business has a longhistory dating back some 50 years. At one time, the business employed some 2000 people with immensecapacity to serve both the internal and external market.

The business's main objectives included casting of allthe components for the former South African Railways andHarbours. This product portfolio is made up of bogies,frames, bolsters, wedges, side frames, couplers and draw-gears. In fact, every casting needed on rolling stocki.e. locomotives, coaches and wagons. Today, the foundrybusiness is being further upgraded in all aspects to resumeits vital role in the South African rail industry.

Currently, the foundry business employs 175 people.With its low staff turnover, the division has the advantagethat many of its staff has extensive experience and knowledge within their field. However, the business is alsorecruiting new employees to strengthen its core of expertise.This allows the foundry division to advise its customers onthe best solutions for their castings requirements.

Other investments made so far to improve the efficiencies of theKoedoespoort foundry include four new 11 ton ladles.

The heating of these ladles is being converted to a gas pre-heatingsystem with custom built jigs manufactured so as to maximize

energy management and production time

The sand is discharged from the return sand hoppervia a vibrating dosing feeder into the

reclamation mill, where the lumps and sand isscrubbed and transported to the cooler classifier

Sand is discharged from the cooler classifier anda 10 ton an hour pneumatic conveyor pumps thecooled, classified sand into an 80 ton storage silo

located above a continuous mixer


The foundries business operates to the highest levels ofefficiency, ensuring that its customers receive an extremelycost-competitive service.

The business operates from two sites, one in Tshwaneat Koedoespoort and a much larger facility in Bloemfontein.The facilities are both ISO 9001/2008 accredited. The twofacilities have the ability to produce any casting a customercould require.

In terms of the materials it uses in its castings,

Transnet Foundries has expertise in casting all types ofmetals. Common metals that it uses are steel, brass, copper, white metal, spheroid graphite (SG) and cast iron.

Currently, the major clients that the foundries businessserves are Transnet Rail Engineering's wagon business, itslocomotive business and its rolling stock equipment business. External to Transnet, it also makes componentsfor VAE Perway. The business also serves a number ofsmaller clients such as NLPI, an Israeli company that ownsand operates the Zambian railways.

Apart from the railway industry, Transnet Foundriesserves a number of other industry sectors such as mining,automotive, and to a lesser extent marine.

The Foundry business has access to Transnet's RailEngineering's top quality product development facilities.This includes a range of engineers and designers who that use technologically advanced computerised computer aided design stations, and who are fully conversant with techniques such as finite elementanalysis. This service also includes pre-development surveys and feasibility studies.

At Koedoespoort, the foundry is equipped with two energy-efficient induction furnaces and a semi-automatedCT3 moulding machine for producing greensand moulds.The facility is also able to produce moulds from chemicallybonded sand. In addition, the foundry has a full suite ofequipment for fettling, shot blasting, finishing, machiningand heat treatment ovens. There are also copper and brassfurnaces and ingot making machines.

The foundry has all necessary ancillary equipment suchas cooling towers and overhead cranes and is currently producing in the region of 340 tons a month of steel castings.

The Bloemfontein foundry has four 30-ton furnaces andis one of the largest facilities in South Africa. There are twoother five-ton BBC furnaces for smaller production runs anda new 10 ton induction furnace will be installed this year.

Bloemfontein's foundry has three Disamatic automaticcasting machines, one of them installed just over two yearsago. These machines allow the business to turn out castingswith a maximum size of 500 mm x 300 mm x 120 mm.

There is also a patternshop fully equipped to producepatterns and core boxes, a rail breaker for shearing steelfor furnace feedstock and a sand plant for the milling andpreparation of green sand.

The Bloemfontein facility manufactures approximately350 tons of grey iron, 180 tons of SG and 130 tons of

The 80 ton storage silo that houses the reclaimed sand.All of the fully automated sand reclamation plant has been

manufactured, installed and commissioned bylocal foundry equipment manufacturer Endeco

Fettling A pour taking place


steel castings every month forthe railways and other transportindustries.

Quality control is integral toall production processes.Although the early steel castingswere prone to failure, quality control processes havenow nearly eliminated these. The facility routinely carries outspectrographic analysis to ensurethe metals it uses are of the correct quality. Stress and porosity tests can also be rapidlycarried out.

The two foundries are both onmajor rail sidings, which ensure asmooth supply local and exportsupply chain.

Transnet Rail Engineering also offers a very efficientreclaim service. It is able to takescrap copper and brass and rapidly convert this material into highly saleable ingots. This ensures that its customersget a quick return on their scrap. Buyers of copper andbrass can also be assured thatwith the foundry's advanced lab facilities, they are able to purchase metals of unquestionedpurity.

For further detailscontact Transnet Foundrieson TEL: 012 842 5328or Endeco on TEL: 011 907 6111Castings before shot blasting has taken place

“With the installation of the new plantit will not only bring us up to speed in the

sand department but we estimate that we willbe making a 90 percent saving in new

sand purchases and in the costs for dumping.”


Just published by the publishers of castings sa, the 2011Directory of Southern African Foundries & Suppliers to theindustry is now available. The directory provides a valuable

resource for the manufacturing and design engineer, procurement officer and buyer alike.

New foundries (new and existing) and suppliers have beenlisted since the last Directory was published in 2007.

Colour coded by sections for easy reference the Directoryis divided into the following sections:

• Useful Addresses - Local and International• Foundry Company details including address details,

personnel and what type of foundry it is• Details on whether the foundry is ferrous and

non-ferrous • Figures on metals cast by each individual foundry• Art Foundries• Alloy & Ingot Suppliers• Patternmakers• Heat Treatment Companies

• Spin Casting Companies• Supplier details

The foundries have also been listed according to whatmetal they melt including aluminium, brass, bronzes, copper,irons, stainless steel, SG/ductile, steels, zinc and mixed metaland whether they are production, jobbing, production and jobbing, in-house, or special foundries.

The foundries have in addition been divided into whichprovince/area they are in and production figures of eachfoundry have been given.

A comprehensive listing of supplier's company details andsupplier's activity details is also given. The suppliers have alsobeen categorised according to what they supply under theheadings Equipment; Consumables; Raw Materials and Metals and Services.

The 2011 Castings Industries Directory is available atR300.00 a copy including VAT and postage within South Africa.

For further details contact the publishers on TEL: 011 463 0489 or email [email protected]

2011 Castings Industries Directorypublished

We realised the engineering centre's competenciesneeded to be elevated if it wanted to offer the industry such services as prototype and production

tooling" says Adrian Sands, the FEC Manager.In 2008, with a relatively small team FEC started to

deliver replacement tooling to foundries in Germany. After thesuccess of this initial tooling project it was seen as an idealopportunity to offer the expertise to local and European customers on a bigger scale" continued Adrian.

"After visiting various tool rooms and patternshops inGermany, a strategic decision was made to increase the FEC's capabilities. The FEC then went through an expansionprogram, which doubled up the capacity in all aspects of thebusiness. This also included the introduction of the latestinnovations in various areas."

"Now the FEC can offer design, including part optimisationand analysis, casting simulation, tooling design and processdesign with runner systems. Coupled with the tool manufacturing capabilities, the FEC now offers a unique service to foundries and the industry here in South Africa, aswell as internationally" continued Adrian.

"In the design office, for example, we have a host of

software packages including all the required OEM preferredapplications such as Pro Engineer, Unigraphix, Ideas as wellas those required for machining in the tool room. These packages are complimented with a full Iron module Magma Soft station."

"Once the design work is complete our CNC programmersget to work on generating cutter paths using MasterCam andEukid."

"All machining is done on our Haas CNC milling machines.After machining and intermediate quality checks, where weuse a CMM, we then assemble and prepare the tools in our assembly area."

"The tooling is then verified using our GOM optical measuring system. Delivery to the foundry is not the last stepbut a part of the verification process. Our toolmakers form anintegral part of the trial phase so as to ensure that not onlydoes the tooling perform correctly but also if any practicalchanges are required they are there to assist the process."

"Once the first parts are cast they are then verifiedagainst the CAD or nominal data using the GOM system. Only when the customer is happy with the dimensions and

"

FoundriesEngineering Centre

develops into aworld class facility

Foundries Engineering Centre (FEC) was set up initially as a small tool roomto manufacture and repair tooling for the Groups' internal requirements in 1991.

However it became clear in the early 2000's that a tool roomneeds to offer a turnkey solution if it wanted to offer a service to the

foundry industry in general and, be effective.


tooling performance do we sign off the project" said Adrian.

The FEC unit is one of four divisions within the South African Group, the others being a nodular iron and aluminium plant in Port Elizabeth and the other a grey ironplant in Brits.

The Group is mainly involved in the production of automotive cast iron and aluminium power train components, including engine blocks, bearing caps, crankshafts, heads, manifolds, catalytic converter flangesand associated exhaust components.

The Port Elizabeth plant's material competences includeSG‚ SiMo and Grey iron with a total annual melting capacityof 75,000 tons.

The plant in Brits‚ built in 1977, produces castings in grey iron with an annual capacity in grey iron of 54,000 tons.

The Greenfield aluminium operation was first established in 1991 to produce castings for Volkswagen andAudi and subsequently another greenfield operation wasestablished during 2002, in order to be a key-supplier to Ford for the cylinder heads project.

All facilities are environmentally and quality rated ISO 14001, VDA 6 and TS 16949.

"In order to capitalise on market opportunities, the group has recentlyundergone an extensive redefining exercise to ensure global ompetitiveness and world-classquality products" says BernardBrussow, Group Executive.

"In line with this restructuring theFoundries Group hasadopted a strategy offocusing on customerneeds, core competencies andtechnologicaladvancement. Inaddition, focusedmanufacturing centres

of excellence havebeen createdencompassing specific productsand competencies" saysDavid Mertens,Technical Director.

"The FoundriesEngineering Centre'svision is to be a supplier to foundriesaround the worldand offer a qualityservice" saidBernard Brussow.

For furtherdetails contactFoundriesEngineering Centreon TEL: 041 402 [email protected]


South Africa's State-owned freight logistics group Transnet,which plans to materially expand and modernise its dieseland electric locomotive fleet over the next 15 years, has

been set a target of more than doubling the level of local contentin these vehicles - hitherto, the local content levels for locomotiveprocurement projects has been modest at between 20% and 40%.

Public Enterprises Minister Malusi Gigaba foresees particularopportunity for partnerships with suppliers of heavy-haul electriclocomotives and says Transnet, which has a R110-billion capitalexpenditure programme for the coming five years (much of whichwill be directed towards rail), will enter dialogue with originalequipment manufacturers (OEM) to explore localisation prospects.

"Our plan is to partner with the relevant OEMs to build South Africa's own locomotive manufacturing capability," Gigabasaid in an address to the South African Chamber of Commerceand Industry. "Our aim is to more than double the quantity of localcontent embodied in the locomotives."

He has highlighted the recent R2,4-billion deal betweenTransnet and General Electric (GE), whereby Transnet RailEngineering (TRE) will assemble 90 of the 100 diesel locomotivesbeing purchased in South Africa.

The first locomotives are to be delivered this year and the last during 2012.The GE deal is also the biggest commitment by Transnet under the government-led Competitive SupplierDevelopment Programme.

The idea will be to position South Africa as a niche engineering hub for specialised rail solutions and as a globalmanufacturing centre for OEM locomotive components.

There is also a near-term prospect of offering these productsand services to other African countries that are also looking toexpand their rail infrastructure. Further, there is potential to transform TRE, which currently mainly services Transnet FreightRail, into a maintenance and repair centre for African rail utilities,as well as private operators.

Gigaba reveals that there will also be a concerted programmeto unlock new sources of finance for the expansion of the country's freight rail network, particularly those corridors thatcould stimulate mining investment and expansions.

He acknowledges that Transnet's balance sheet presents anobstacle to tapping the post-crisis commodity revival, and reaffirmsthat a task team has been established to find ways to liberatedevelopmental and commercial finance, as well as to enable miners themselves to share project risk as coinvestors. The teamincludes directors-general from the Departments of MineralResources and Public Enterprises, as well as representatives fromthe State-owned enterprises and the Chamber of Mines.

"We need new sources of finance to enable a quantum jumpin the rate of investment in the capacity of these [iron-ore andcoal] export corridors," he asserts, adding that equity and quasi-equity arrangements are being explored.

The immediate thrust, however, is on lowering the averageage of Transnet's locomotives from over 33 years, as well asensuring that sufficient locomotives and wagons are available toraise daily train movements from 680 to the network's potential of1 700 trains a day.

No private sector participation deals have been struck, withthe Minister indicating that these are still in the "planning" phase.He also indicates that the initial developments will probably focuson branch lines, partnerships designed to shift freight from roadto rail and initiatives to reduce congestion around South Africa'skey ports.

Private sector & powerGigaba also stresses that localisation, as well as private sector

participation will increasingly feature in the electricity milieu, stilldominated by State-owned Eskom, which is spending R549-billionon generation, transmission and distribution investments.

Private participation will initially be focused on the deploymentof renewable-energy solutions and Gigaba assures that government is committed to ramping up the role of independentpower producers (IPPs).

At present, there are only five IPPs operating in South Africa,but South Africa's stated policy is for 30% of all new generationcapacity to be delivered by private developers.

However, there are still several regulatory and legislativeimpediments, notwithstanding the recent publication of the integrated resource plan for electricity, which outlines a substantial role for IPPs in the roll-out of 37 300 MW of newcapacity between 2010 and 2030.

Gigaba assures that the National Treasury and the NationalEnergy Regulator are making independent progress on dealingwith the constraints to investment, while work is also advancing inthe creation of an independent system and market operator,which will evolve over time and will eventually be separated entirely from Eskom.

Government wants Transnet to morethan double local content of new locos


The company specialises in the design, manufacture,supply and repair of copper related cables and connectors for a number of different industries that

are reliant on their products.The extensive product range includes water-cooled

furnace cables, air-cooled furnace cables, water-cooledresistance welding cables, flexible connectors, industrialbattery connectors, copper braid, earth sock, cotton covered strand and other copper related products. Copper lugs and crimping ferrules are also part of theproduct range offered.

"Our products are used in the foundry, steel making,smelting, mining, power generation and automotive industries to name a few" said Copper Cables & Connectors MD Basil Cherry.

"Romans in the 6th through 3rd centuries BC used copper lumps as money. However it has evolved over timeto be used as a major application in industry and can befound to be a part of our everyday life."

"The major applications of copper are in electrical wires (60%), roofing and plumbing (20%) and industrialmachinery (15%). Copper is mostly used as a metal, butwhen a higher hardness is required it is combined withother elements to make an alloy (5% of total use) such asbrass and bronze. A small part of copper supply is used inproduction of compounds for nutritional supplements andfungicides in agriculture. Machining of copper is possible,although it is usually necessary to use an alloy for intricateparts to get good machinability characteristics" explainedCherry.

"Copper, like aluminium, is 100% recyclable without anyloss of quality whether in a raw state or contained in amanufactured product. In volume, copper is the third mostrecycled metal after iron and aluminium. It is estimatedthat 80% of the copper ever mined is still in use today"said Cherry.

"Our company has evolved over the years to be one of the leading manufacturers and suppliers of products for electrical engineering applications" continuedCherry.

"Today we operate from a 3500 m² factory in Boksburg North, Gauteng with over 60 staff. To show ourcommitment to the industry we have recently been awarded with ISO 9001:2008 certification and have aLevel 4 BEE status."

For further details contact Copper Cables & Connectors on TEL: 011 914 4127 or visit www.coppercablesafrica.com

CopperCables & Connectors

comes of ageCopper Cables & Connectors (Pty) Ltd,

established in 1990, celebrates 21 years in business

this year.


The spending related to the construction of the smelterwould result in direct, indirect and induced output ofR7.3 billion in the Eastern Cape.

It is expected that about 1000 jobs in the EasternCape Province would be required during the constructionphase of the project. It is also estimated that the smelterplant will create approximately 400 permanent jobs. Theshare of jobs sustained by the project would be semi-skilled and unskilled jobs (28%), informal jobs (36%),skilled jobs (28%) and high-skilled jobs (8%).

This capital injection is expected to stimulate output inthe construction industry due to the expenditure on building equipment. As a consequence of these expenditures and because of the indirect effects associated with them, other industries such as paper andpaper products, machinery and equipment, furniture, plastic products, basic iron and steel, coking coal, business services, catering and accommodation services,security, wholesale and retail trade would also see relatively large increases in output.

The economy-wide GDP impact in Eastern CapeProvince is expected to be in the region of R2.7 billionwhile the total economy-wide GDP impact is estimated atR2.8 billion for South Africa. This represents about 3.0 percent of Eastern Cape's 2007 GDP.

The construction of the smelter is expected to start inthe third quarter of 2011.

"Kalagadi Manganese is excited about building thesmelter in the Coega Industrial Development Zone in partnership with the government of the Eastern Capethrough the Coega Development Corporation and otherstakeholders, and contributing to the creation of the muchneeded jobs in the province. We believe the investment willfurther contribute towards the stimulation of the secondarysector in the Eastern Cape."

"We are also encouraged by the enthusiasm of allstakeholders and the superior infrastructure that is alreadyin place to facilitate this project. Kalagadi Manganese ismaking a significant investment in the Coega IDZ and thisalso affirms the reason for the construction of the Port ofNgqura at Coega," said the Executive Chair of KalagadiManganese, Mrs Daphne Mashile-Nkosi.

The national government's IPAP2 and New Growth Pathhave a focus on mining and beneficiation activities. Thisinvestment in the Coega IDZ by Kalagadi Manganese givessubstance to that focus and will further stimulate efforts inthe mining sector.

For the Eastern Cape Government the announcement of the construction of the Smelter plant confirms theirbelief in the Coega IDZ as the key strategic driver of industrialisation in the province. The investment will boost investor confidence in the Nelson Mandela BayMunicipality and the province in general. The production of Ferromanganese will be a catalyst for the development of the metals beneficiation cluster in Coega.

Manganese is a critical ingredient in metal alloy production including stainless steel and other steels andaluminium. This investment therefore will kick start theplanned development of the heavy metals cluster atCOEGA. The benefits for manufacturing in general and theauto sector in particular are obvious. Manganese is also afoundation for dry cell battery manufacturing, which supports our strategic focus on the green economy. All ofthis fits neatly within the Provincial Industrial DevelopmentStrategy.

The Eastern Cape government is pleased with the implications of the proposed investment by KalagadiManganese. This investment will stimulate additionalinvestment from State Owned Enterprises in the form ofincreased infrastructure capacity in electricity; in improvedand efficient logistics (primarily in rail and harbour) systems. In addition, it expects to see benefits accrue tothe SMME sector in the form of additional work and investment opportunities in downstream and supportingactivities.

Smelter plant to be constructed at CoegaKalagadi Manganese is investing R4.2 billion for the construction

of a smelter plant with an annual production capacity of 320 000 tons ofHigh Carbon Ferromanganese (HC FeMn) in the Coega IDZ, Eastern Cape.



Recruitment goes globalSouth African companies and individuals

operating within the foundry industry can now casttheir job-search net across every continent

thanks to industry recruitment specialists de Belder Associates Ltd.

de Belder Associates are a UK based, metals industriesspecialist search and selection recruitment service, and unlike most other organisations within this sector they can boast what are truly worldwide connections. They have worked closely with a number of leading South African organisations since the 1980s and managing director, Philip de Belder, has personally visited clients in South Africa on several occasions withinthe past year.

The company specialises exclusively in fulfilling permanent and interim contracts for a broad spread of roles, including: Directors, Senior Managers, Project Management, Technical, Metallurgy, Operationaland Quality Management, plus a full catalogue of production positions.

de Belder Associates also acts for individuals looking to change or advance their own personal career opportunities.

Thanks to their unique global network of contacts, deBelder Associates are able to locate and introduce the specialist talent that companies are looking for from literally anywhere in the world. While at the same time,for anyone who is looking for a new career challenge,the world literally is their oyster.

de Belder Associates enjoys an unsurpassed international reputation, which is why they have becomethe 'first call' for so many companies and individualsacross every continent.

For further information about de Belder Associates Ltd,together with full details regarding its specialist metals industries recruitment services, you should visit the company's website: www.debelder.co.uk where in addition to extensive information regarding the company's background and facilities, you can also access a list of the latest recruitment opportunities.

Alternatively, if you wish to discuss your corporate or personal requirements in greater detail, you are always welcome to contact the company by telephoning: 44 1625 523 731, or email: [email protected].


Ihate to admit it but we hadnot invested in the foundryside of the business for

years" Marc Hindle, OperationsDirector of McWadeProductions tried to whisper.

"But this all started tochange last year" he said in amore audible tone.

"The foundry side of thebusiness had been growingsteadily compared to the otherunits in the company whichhave seen relatively rapidgrowth and form a much biggerpercentage of our annualturnover" continued Marc.

"However the foundry is anintegral operation within the company especially when you look at the number of proprietary products that the companymarkets, and the foundry supplies castings to make up theseproducts."

"The biggest drawback in the foundry was how its layoutand workflow had evolved over the years. You could say it wasthrown together. But because of production demands the

overhaul of this area wasalways put on hold. This wasuntil we took a strategic decision to increase our production levels as well asactively seek outside work"explained Marc.

"The majority of the production in the foundry waspreviously dedicated to supplying our own consumptionso we could hide the inefficiencies. The furnaceswere old and all over the place,the two mixers was barely coping and in the middle of thefoundry and there was just toomuch non productive handling

of the metal, the moulds and the castings.""We decided to get in an outside consultant who, in

conjunction with ourselves, could look at a new layout. It isalways good to get an independent view, no matter who it is,because to quote an old cliché you sometimes operate withtunnel vision."

"Shortly after we had appointed the consultant there were

McWade Productions has progressed in line with the growth of theelectrical transmission industry in Southern Africa and is today a prime supplier of

electrical components and accessory equipment to the African and internationaltransmission and distribution electrical industry.

Streamlining of workflowat McWade Productions starts

to show results

The four tilting furnaces and one pit furnace ranging between 250 and 500 Kgs

On the handling side McWade Productions have manufactureda number of roller tracks and an overhead rail track and put them

in place so that they fit in with the new design. This is alreadyeliminating bottlenecks and wasted downtime

Foundry Manager James Rossouw withOperations Director Marc Hindle

"


a number of benchmarking exercises offered to thefoundry industry and we took part in all of them.The results from these benchmarking exercises certainly highlighted our highly non productive situation."

"With all this information we could devise a planto take the foundry forward into a situation wherewe would start to see real benefits on the production side as well as the bottom line."

"Critical to the whole exercise was that it had tobe implemented without losing any production timeso you can see what we were in for."

"Before we started the change of the layout weacquired two tilting furnaces on the Kolbenco auction. Thisenabled us toget rid of someof the existing pitfurnaces as wellas kick start theoperation withthe repositioningof all the furnaces to oneside of thefoundry, whichnow comprisesof four tilting furnaces andone pit furnaceranging between250 and 500 Kgs. At thesame time wepurchased fivenew gas firedburners. This has improved the quality of metal tremendouslyas well as reduced the wastage."

"Simultaneously we had to begin work so that we couldrelocate the sand plant to the end of the foundry."

"The foundations have been laid for this equipment andultimately it will be housed outside the sand foundry facility. Itwill include a reclamation plant, new shakeout and knockoutplant, a cooler classifier and a blender. We are also in theprocess of ordering a third mixer and once this is operationalwe will be able to move our existing mixers, thus more thandoubling our capacity."

"On the handling side we have already manufactured a number of roller tracks and an overhead rail track and put

them in place so that they fit in with the new design. This isalready eliminating bottlenecks and wasted downtime."

"We are looking at purchasing a new shot blasting machineas well."

Founded in 1961, McWade Productions has progressed inline with the growth of the electrical transmission industry inSouthern Africa and is today a prime supplier of electrical components and accessory equipment to the African and international transmission and distribution electrical industry.

The company has developed over the years a substantialmanufacturing operation based in Olifantsfontein, Gauteng,operating to the requirements of ISO 9001:2008 and in accordance with local and international specifications. On sitefacilities include the non-ferrous sand and gravity diecastingfoundry, a machine shop as well as tool and die-making facilities.

The company manufactures and offers a comprehensiverange of equipment to meet both the market and customer'sspecific requirements. The numerous different products offeredare summarised in the following product ranges:

• High voltage sub station inter connecting clamps up to 765kN

• Insulators

The patternshop A section of the fettling shop

The picture above shows the mould for the turbine bladeswhile the cast and fettled product is in the picture on the left.

The turbine blades have a nett weight of up to 70 Kgs.Galsi 9 material is used to manufacture the turbine blades,

they are die penetrant tested and heat treatedbefore delivery to the client

• Isolators • Compression tooling • Transmission and distribution line

hardware

The company was family owned until the1970s before being sold to the then CullinanGroup.

The late Basil Burnett, a director at theCullinan Group responsible for the operationsat McWade Productions and father-in-law ofcurrent operations director Marc Hindle, decided to purchase the company in 1976.

The company was sold to the BatemanGroup in 1988 before a management buyouttook place in 2005. Hindle, a MechanicalEngineer, has been with the company since1981 and his partner sales and marketingdirector Dessen Naidoo joined the company in1978.

Over the years McWade Productions hasacquired various companies that manufactured similar or complimentary components. These included Burcon Engineering, B Karg Engineering, Elbroc and CCL. The most recent acquisition, Linegear 2000, took place in 2005.

Today both directors have a 30 percent share in the business having sold 40 percent of the company to a divisionof the Royal Bafokeng Holding Company in 2008.

"This tie up has opened up new doors and markets for us.

We fall into the Mining, Oil and Gas ServicesDivision of the Royal Bafokeng HoldingCompany. Although we have always exported,we are now exporting to the Middle East including Kuwait, Saudi Arabia and Oman aswell as a result of our tie up" said Marc.

The company employs 180 staff in totalwith 30 of these operating in the sand foundryand another 8 in the gravity diecasting foundry.The foundries produce 15 tons of aluminiumcastings a month and two tons of copper basedcastings. On an average the foundries will cast28 500 castings in a month comprising 300different components. On any one day 30 different components in various amountscan be cast.

Auxiliary services include patternmaking,fettling, tool design and manufacture, weldingand machining.

The mix of castings between the sand andthe gravity diecasting foundry is 50/50 and currently the foundry casts 70 percent of itsproduction for the company's own consumption.

"By the end of this exercise of organizing the foundries intomore productive units with new and modern equipment we willcertainly be running hard to fill the capacity" said Marc who is aPast President of the South African Institute of Foundrymenand is on the Editorial Board of Castings SA.

For further details contact McWade Productions on TEL: 011 316 2262 or visit www.mcwade.co.za


The machine shop on the foundry side has a number of CNC lathes as well as a Doosan DNM 650 machining centre

and a Dah Lih MCV 720 machining centre

An overview of the assembly section

Final product One of the three welding stations

Clamps that will be used on theproprietary products

From 28 June to 2 July 2011, the Düsseldorf Trade FairCenter will play host to the trade fair quartet comprisingGIFA 2011, International Foundry Trade Fair with WFO

Technical Forum, METEC 2011, 8th International Exhibition forMetallurgical Technology with Congress, THERMPROCESS2011, 10th International Trade Fair and Symposium forThermic Production Processes, and NEWCAST 2011, the 3rd International Trade Fair for Cast Products.

It is very encouraging that a number of South African companies will again be participating this year both on theSouth African National Pavilion in Hall 13 - Stand B 22 and asindividual companies such as Itshe Resources (Pty) Ltd who will have their own stand in Hall 13 Stand No. C61.

Full details of the companies participating are listed below. Planners of GIFA and its companion trade shows

acknowledge that the global industrial marketplace haschanged in the four years since the last staging of theInternational Foundry Trade Fair, but they're counting on that

fact to heighten interest. Exhibitors have ideas and informationto convey, and metalcasters have a pent-up need to invest inand improve their operations.

Early data suggests this may be true. Bookings for GIFA2011, the 12th International Foundry Trade Fair, along withMetec, Thermprocess, and Newcast 2011, are on track to setnew records. There is a trend towards larger stands, accordingto organiser Messe Düsseldorf: 77,230 m²of net exhibit spacehas been reserved, compared to 72 698 m² at the last stagingin 2007.

"We didn't expect this," according to project directorFriedrich-Georg Kehrer. "Everyone in our industry thought thatthe exhibitors would come, but with substantially smallerstands. However, the bookings to date reveal that the tradefairs have grown considerably, by almost 5 000 m²."

A high-quality side programme An extensive, attractive side programme with numerous

seminars and trade symposia, special shows and technicalforums as well as international congresses and lecture series isbeing organised again for the "Bright World of Metals" this year,which is being held in Düsseldorf from 28 June to 2 July 2011.

The focus is on information about current developments inresearch projects, with particular emphasis on energy efficiency and resource minimisation. This means that the fourmetal trade fairs have excellent additional benefits to offertrade visitors: alongside the comprehensive demonstration bythe exhibitors of their particular achievements, GIFA, METEC,THERMPROCESS and NEWCAST are providing the best possiblebasis for constructive dialogue between industry professionals.

GIFA: "GIFA-Treff" and WFO Technical Forum The "GIFA-Treff" organised by the National Association of

the German Foundry Industry (bdguss) will again be invitingexperts to come and exchange ideas and information right atthe heart of the trade fair in Hall 13. Thematic displays will beproviding detailed information about such subjects as the energy-efficient production of castings or the use of dischargedheat in the context of a special exhibition about "energy-efficient foundries".

The WFO (World Foundrymen Organization) Technical Forumin Hall 13 from 28 June to 1 July will once again be acting as asource of ideas and an opportunity to discuss trends when theinternational experts analyse the progress made in castingtechnology and indicate how foundry engineering can be optimised. The focus throughout the lecture programme is onenergy efficiency and the responsible use of resources.Specialists from Brazil, Denmark, Germany, Finland, France,Great Britain, India, Italy, Japan, Canada, Austria, theNetherlands, Switzerland and South Africa will be demonstrating impressively how practical applications know-how can be transferred internationally.

Star billing for South African companies atGIFA, METEC, THERMPROCESS and NEWCAST

in Düsseldorf, Germany this year

Participants look forward to export enquiries.

international news


METEC: InSteelCon 2011 and EMCMETEC InSteelCon 2011 that is being organised by the

Steel Institute VDeH, combines no fewer than four differenttrade congresses for the international steel industry at onelocation from 27 June to 1 July: ECIC (6th European Coke andIronmaking Congress), ECCC (7th European Continuous CastingConference), STEELSIM (4th International Conference onModelling and Simulation of Metallurgical Processes inSteelmaking) and EECRsteel (1st International Conference onEnergy Efficiency and CO2 Reduction in the Steel Industry). Theevents are being held at the Düsseldorf Congress Centre,directly on the exhibition site. More than 600 presentations - all of them in English - underline the outstanding global significance of this occasion. The European MetallurgicalConference (EMC) 2011 promises to be excellent too. Theorganiser, the Society for Mining, Metallurgy, Resource andEnvironmental Technology (GDMB), has chosen "Optimisationand improvement of resource efficiency in the nonferrous metalsindustry" as the issue to focus on in the high-quality event this year.

THERMPROCESS: Symposium, special show and conference

Optimisations and the latest findings from the industry - presented by experts with in-depth practical experience, all ofwhom are exhibitors at THERMPROCESS 2011 - will be the centreof attention at the THERMPROCESS Symposium organised byVDMA in Hall 9. Here, too, the emphasis will be on technicalinnovations relating to energy efficiency, heat recovery andburner technology. The special FOGI show organised by theIndustrial Furnace Manufacturing Research Association (VDMA)in Hall 7 will provide a unique overview of the current researchfindings in the thermo process technology field. More than tenwell-known German universities and private research

institutions are issuing an invitation to participate in an intensive exchange of information and experience this year.

The 4th conference organised by Deutsche GesellschaftFeuerfest-und Schornsteinbau e.V. in CCD.Ost is taking placeon 28 June too. Speakers from Germany, France and GreatBritain will be providing information about such subjects asnew material developments and innovations in the design,implementation and installation fields.

NEWCAST: Forum and AwardNEWCAST will be featuring the "NEWCAST Forum" that will

be presenting the latest casting developments in interestingpanel discussions and lectures by experts. The main subjectscovered here will again be material and energy efficiency aswell as innovative rapid manufacturing systems. The forum isbeing organised by bdguss.

For the second time after 2007, Messe Düsseldorf, bdgussand Verein Deutscher Gießereifachleute e.V. (VDG) are presentingthe prestigious NEWCAST Award for the most innovative andoutstanding castings in the following three categories: bestsubstitution of a different manufacturing process, best functionintegration, best casting solution (extending the boundaries ofcasting engineering). The winners are being announced shortlybefore the trade fair, so that the companies can already exhibittheir prizewinning products at the fair.

"Science Street"20 institutes from Germany and other countries will, on the

other hand, be demonstrating their comprehensive scientificcapabilities in the context of "Science Street" in Hall 7.Research facilities from such countries as Germany, Poland,Switzerland, Slovenia and South Africa will be presenting theirresearch and development findings and operations.


The Aluminium Federation ofSouth Africa is the voice of,and the gateway to, the South

African aluminium industry! AFSA'smembers are companies operating in any sector of the industry thatcovers the full range of activitiesfrom primary aluminium production, through secondarysmelting, semi-conversion, casting,fabrication, extrusion, distribution and surface finishing.

The South African aluminium industry is focused on:• Growing and developing a co-operative and outward

orientated industry;• Being well promoted both in terms of the material

(aluminium) and the industry; and• Adding downstream value

The purpose of AFSA is to promote the use of aluminium and the Southern African aluminium industry,both regionally and internationally and in doing so, to represent and defend the interests of its members.

The key roles of the Federation,and the sector Associations actingunder the aegis of AFSA, are to:

• Facilitate, assist and support growth initiatives (in an enabling climate for all stakeholders) both regionally andinternationally.

• Promote the awareness ofaluminium, its application and

promote the aluminium industry with input from the industry role players.

• Assist and participate in knowledge diffusion andtransfer:

- generic technology- product development- information and statisticsVia working linkages / synergies (often working

with champions).• Facilitate and advise in areas of education and

training at appropriate levels.• Make mandated representations for the industry on

relevant matters and especially key national issues.

Sector Associations - the corner stones of theFederation

AFSA's approximately 150 members are grouped intoone or more industry sector Associations. Associationmembers meet on a regular basis to discuss areas of common interest, within the limitations imposed by theCompetitions Act. Typical programs include marketresearch, sector promotion, marketing and education,workshops, seminars, standards' development and government liaison regarding trade practices, duties and incentives. Each Association has their own budgetand appoints a chairman who represents that Associationon the AFSA Executive Committee.

There are currently four active sector Associations inAFSA and these are:

• ACA - Aluminium Casters Association• AFA - Aluminium Fabricators Association• ASPA - Aluminium Sheet Products Association• ASFA - Aluminium Surface Finishers Association

AFSA has a well defined marketing strategy, the mainfocus of which covers generic promotion of aluminium - alongside co-ordinating the promotional activities of thevarious Associations, plus the development of commercialmaterial such as the Industry Directory, and training andeducation publications.

Mark Krieg will be on the stand.

The Aluminium Federation of South Africa,1st Floor, Helvetia House, Greenvale Road,Wilbart, Germiston, Gauteng;P O Box 423, Isando 1600, South Africa;TEL: +27 (0) 11 453 3339, FAX: + 27 (0) 11 453 3403,email: [email protected], website: www.afsa.org.za

Aluminium Federation of South Africa (AFSA)


Association members meeton a regular basis to discussareas of common interest,

within the limitations imposedby the Competitions Act

The following companies will be participating on theSouth African National Pavilion in Hall 13 - Stand B 22


ASC is an innovative niche supplier of aluminium castings to the local and international automotiveindustry. ASC is a division of Pressure Die Castings

(Pty) Ltd, a privately owned company based inPietermaritzburg, KwaZulu-Natal, South Africa which hasbeen in business since 1952.

ASC is a specialist die caster that has been in businesssince 1999 supplyingmachined aluminiumcastings and subassemblies to theindustry.

The company hasbeen built companycustomer by customer.ASC's approach is tostart from their customer's need,exploring variousdesign options untilthey identify the bestprocess solution. Thisapproach is valued bytheir customers whoare then confident thatthe process which isdesigned for them willbest meet their requirements.

ASC was the firstcompany in SouthAfrica to introduce thehigh speed milling of hardened steel for diesresulting in improvedaccuracy of die manufacture, speed ofproduction andrepeatability of quality.

The company's current product rangeincludes oil filter adaptors, air throttlebodies, bearing caps,engine mount brackets,electronic base platesand military components.

To meet the exacting standards ofthis industry, ASC iscertified with ISO 14001:2004, ISO TS 16949:2002and has been awardedthe Ford Q1 status.

ASC was audited bySABS in July 2010 andso retains its ISO TS 16949: 2002certification.

Mike Wolhuter and Lance Deysel will man the stand.

ASC Pty Ltd,P O Box 4009, Pietermaritzburg, 3200,KwaZulu-Natal, South Africa;4 Willowton Road, Pietermaritzburg,KwaZulu-Natal, South Africa; TEL: +27 (0)33 397 5500,email: [email protected], website: www.pdc.co.za

ASC - Aluminium Squeeze Casters


Lauds Foundry Equipment (Pty) Ltd is the distributor forOmega Foundry Ltd, Simpson Technologies and KoinsFoundry Technology equipment.

"Lauds have become one of the technology leaders in theaffiliation that we have with our global partners, introducingstate of the art equipment, into the foundry, industrial and

mining sector. This knowledgebecomes standardpractice whendesigning our ownsemi and fullyautomatic coreblowers from 1 litre to 150 litres,environmental dust control systems,

casting conveyors, shakeouts, heat treatment furnaces/ovens,dryers and all other unique customer requirements such asmaterial handling equipment, whether it be specific or generalto an application. We handle all aspects from design, manufacture and commissioning under one roof. We are a certified SABS ISO 9001:2008 company that puts quality and adding value to our clients first and foremost" says Kevin van Niekerk.

The company will be exhibiting a vent unit for dust control,a casting feed conveyor and a 15 tph pneumatic sand transporter.

Lauds will be represented by Kevin van Niekerk, Jaco Grobler and Francois Southey.

Lauds foundry Equipment (Pty) Ltd,Postnet Suite 139, Private Bag X1037,Germiston, 1400, South Africa;TEL: +27 11 8241238, email: [email protected], website: www.laudsfe.com

Lauds FoundryEquipment (Pty) Ltd

A 15 tph pneumaticsand transporter

A casting feed conveyor

Nimag (Pty) Limited, the Nimag Group's founding company, manufactures the "Metalloy" range of master alloys at its facility some 65 km north west

of Johannesburg. "Metalloy" master alloys are predominantlyused in processes requiring the efficient nodularisation ofcarbon to produce Spheriodal Graphite (SG) iron, as well asthe desulphurisation of iron. In many instances the masteralloy is beneficial to the final casting to improve machinability, resist heat and physical deformation.

Alloy production commenced on the existing site in1962 as Metallurgical Process (Pty) Ltd, becoming NimagLimited in 1995, subsequently in 2003 GVM Metal Ltd(quoted in Australia, London AIM and South Africa) purchased majority shares.

The "Metalloy" master alloy range includes NickelMagnesium, Ferro Nickel Magnesium, Copper Magnesium,Nickel Calcium and Ferro Nickel alloys. Custom or specialtyalloys are available on request.

"Metalloy" master alloys are exported worldwide throughan extensive network of distributors and the company wasthe proud winner of the Presidents Award for ExportAchievement; the Johannesburg Camber of Commerce andIndustry Exporter of the Year (SME) in 2001 and has beenawarded the BID-QC100 International Gold Star for QualityAward 2004 and Platinum Star for Quality Award 2005. Allproducts are made under strict quality controls and inaccordance with the company's ISO 9001:2000 certification.

Full details and specifications of the "Metalloy" range of master alloys will be available from the Technical Director, Ian Ball, on the Nimag Group stand.

Nimag (Pty) Ltd, P O Box 1401,Kelvin, 2054, South Africa;TEL: +27 (0) 11 803 8247,email: [email protected],website: www.nimaggroup.com

Nimag (Pty) Limited


Alloy production commenced on the existing site in 1962 as Metallurgical Process(Pty) Ltd, becoming Nimag Limited in 1995, subsequently in 2003 GVM Metal Ltd

(quoted in Australia, London AIM and South Africa) purchased majority shares


PDC is an innovative supplier of brass and aluminium castingsto local and international industry. The company is a specialistdie caster, who has been in business since 1952.

The company has been built customer by customer. PDC'sapproach is start from their customer's needs exploring variousdesign options until they identify the best process solution. Thisapproach is valued by their customers who are then confident thatthe process designed for them will best meet their requirements.

PDC's team of specialist engineers translates the concept intothe working steel dies that are used to repeatedly make qualitycomponents. The sophisticated tool room is an integral part of theprocess and critical to the successful manufacture of high qualityproducts. All tools and dies are made and serviced in the company's own toolroom.

The company has a fully integrated process line from sourcingraw materials, to tool making and manufacturing in house whichenables PDC to deliver a quality product, on time.

PDC has extensive experience in the manufacture of a rangeof components with weights from just a few grams to 800 g withcurrent production runs from 1 000 to millions of components perannum. The manufacturing process that a component followsvaries according to its complexity and sub-assemblies are madeaccording to the customer's brief. PDC is always open to increasing their capabilities to meet a customer's specific needs.

The company manufactures more than 100 components for anumber of industries, the primary ones being the architectural

and building hardware industry, the fire protection industry, thepower reticulation industry, the OE and aftermarket automotiveindustry and plumbing industry. Over fifty percent of production isexported.

PDC has been a certified ISO9001 company since 1997 and isaudited regularly to ensure conformity and continuous improvement.

PDC strives to always improve and spend time developing newideas that ensure their processes and systems stay at the cuttingedge of technology. The company is committed to improving productivity and equipment to ensure customers get quality product all the time.

The company is a full service supplier working with customersto provide a die casting solution that includes:• Component design • Tooling design• Material alloying and analysis • Testing and assembly• High pressure die casting • Fettling and CNC machining• Tool and die manufacture

Mike Wolhuter and Lance Deysel will man the stand.

Pressure Die Castings (Pty) Ltd,P O Box 4009, Pietermaritzburg, 3200,KwaZulu-Natal, South Africa;4 Willowton Road, Pietermaritzburg, KwaZulu-Natal, South Africa; TEL: +27 (0)33 397 5500,email: [email protected], website: www.pdc.co.za

Pressure Die Castings

Rand York Minerals(Pty) Ltd

Rand York Minerals is one of the world's leading suppliers of quality foundry chromite sand and havebeen supplying chromite sand to the world wide

foundry and refractory industry since 1992, and supplymaterial to all five continents.

Rand York Minerals has received the prestigiousSouth African President's award for export achievement in1998 (from President Nelson Mandela) and in 2000(from President Thabo Mbeki) and has been recognised as"a quality exporter that understands the requirements ofits customers both in terms of a consistent quality productand world class personal service."

Rand York Minerals exclusively processes and marketsfoundry chromite sand for the London listed Xstrata Groupand has various other suppliers in Southern Africa. Allmaterial is mined in the heart of the Bushveld Complex,the principal chromite deposit in South Africa. All materialis washed and processed under ISO 9000/2 standards orthe equivalent of these standards.

Rand York Minerals supplies material either in bulkquantities from Richards Bay or in dried and bagged onemetric ton bags. The chromite sand is dried and bagged atthe RYM processing and drying plant in Rustenburg. Thebagged material is transported to Durban.

A warehouse with sufficient stock to ensure "just-in-time stock management" is maintained in Durbanthat ensures efficient loading and shipment of the containerised material to more than 40 countries.

As Rand York Minerals strives together with their customers to achieve a defect free "as cast" castings forsome of the world's most demanding end-users, the company has developed a philosophy of "as cast, not aftercast". As the global foundry and refractory industry isextremely technical and specialised, Rand York Mineralshave entered into various joint venture agreements withleading international consulting engineers that are able toassist their customers to not only improve the quality ofthe castings, but to do so in a cost-effective manner.

Chief executive, Mrs Zelda du Preez with Mr RichardThomas and Mrs Michelle de Bruyn would like to meet withyou at their stand at GIFA 2011.

Rand York Minerals (Pty) Ltd,P O Box 650755, Benmore, 2010;63 Mount Street, Bryanston, Gauteng;TEL: +27 (0) 11 463- 9000, FAX: +27 (0) 11 463 7002, Cellular: +27 82 490 8155,email: [email protected], [email protected]

Rand York Mineralshas received the prestigious

South African President's awardfor export achievement in 1998

(from President Nelson Mandela) andin 2000 (from President Thabo Mbeki)


RelyIntraCast is a leading producer of investment castings and was formed in 2006 with the merger oftwo of the most respected names in investment

casting - IntraCast and Rely Precision Castings. This mergermakes RelyIntraCast the only BEE compliant precision casting enterprise in South Africa.

The company has two foundries, both internationallyknown for producing high integrity investment castings toexacting specifications. RelyIntraCast specialises in themanufacture of investment castings to individual customer's requirements in all air melted alloys includingstainless steels, speciality heat and wear resistant alloysand non ferrous alloys.

An ISO 9001:2000 accredited company, RelyIntraCastmeets and sustain the most exacting specifications.RelyIntraCast's experienced and qualified metallurgicalteam works from state-of-the-art spectrographic and laboratory facilities to provide quality control, design optimisation, testing and chemical analysis for consistentquality. Sales staff are qualified and experienced to assesscustomer's requirements and ensure that the process,material and design are appropriate to your needs.

The company has a strong R&D base with over 10 yearsexperience in Rapid Prototype (RP) Casting manufactureand has been the technical development partner in manyuniversity and research institute joint programs.

An in-depth knowledge of the investment castingprocess, combined with extensive application experienceand above average metallurgical applications expertise,has enabled RelyIntraCast to assist customers with designand material selection, ensuring a quality casting to meetthe application requirements.

A customer centric approach to business, coupled withan ongoing commitment to technology advancement hasseen RelyIntraCast establish a centre of service

excellence for customers. Rely IntraCast produce in volumes from single items up

to hundreds of thousands, and in weights from a few gramsup to 25 kilograms.

Rely IntraCast's investment castings are used in themining, petrochemical, pump, heat treatment, food preparation and general engineering industries.

Typical products include:• Coal borers and P- shank borers for mining, • scraper blades and scraper mounting systems

for cleaning of conveyor belting, • Cast conveyor links for heat treatment furnaces,• Switchgear parts,• Impellers for pumps,• Import replacement machine spares• Gears, ratchets and pawls

Mark Hughes and Carlos Palihos will man the stand.

RelyIntraCast,P O Box 222, Boksburg, 1460, Gauteng, South Africa;512 Commissioner Street, Boksburg, Gauteng;TEL: +27 (0) 11 914 1640, FAX: +27 (0) 11 914 3586,email: [email protected], website: www.rely.co.za

RelyIntraCast


An in-depth knowledge of the investment casting process,combined with extensive application experience and above averagemetallurgical applications expertise, has enabled RelyIntraCast to

assist customers with design and material selection, ensuring a quality castingto meet the application requirements

The company has two foundries,both internationally knownfor producing high integrity

investment castings toexacting specifications


The Scaw Metals Group is an international groupmanufacturing a diverse range of steel products. Its principaloperations are located in South Africa and Australia. Smaller

operations are in Namibia, Zimbabwe, Zambia and Europe.Scaw has its major operations in Germiston, Gauteng. Cast Products is one of the oldest and most important

manufacturing operations in the Scaw Group. The Scaw foundriesemploy approximately 2,500 people across its six foundry plants.Each plant specializes in specific products in terms of processcontrol and plant optimization, resulting in the best quality at thelowest cost of manufacture. Three large on-site machine shops,with extensive machining capabilities, allow Scaw to supplyfinished products which are ready to install.

Scaw's Germiston Foundry in South Africa is one of the largestfoundries in the southern hemisphere and produces castings infinished weights up to 30 tons. It is a leading supplier of single-piece, thin-walled locomotive and passenger frames, freight carcomponents and high integrity cast steel railway wheels. The foundryholds the American Association of Railroads' approval for themanufacture of freight-car side frames, bolsters and cast-steel wheels.

Other products include large gear segments, high-carbon,high-chromium, abrasion resisting coal grinding elements for coal-fired power stations, high-chromium iron mill liners andimpact crushing parts, stainless-steel coiler drums, and a range ofslag ladles for the metal processing industry. Arc furnace meltingunits and a 25 ton capacity ladle vacuum degassing unit serve

the foundry where steels can be produced with lower sulphur,nitrogen, oxygen and hydrogen contents, particularly necessary forthe manufacture of high strength, low-alloy steels.

Scaw's other foundry operations (Standard Foundry, BoksburgFoundry, Dimbaza Foundry, Eclipse East Foundry and EclipseWest Foundry) produce a vast range of cast wear parts from avariety of materials that can be custom designed according toindividual customer specifications. The product range includesmill liners, cone and gyratory crusher wear parts, jaw crusherwear parts, impact crusher wear parts, dragline and shovel parts,shredder wear parts, railway parts and mining spares.

International standardsScaw is an ISO 9000-series accredited organization

manufacturing products to meet the requirements of the appropriate international certification authorities. Scaw's safety,health and environmental management systems are aligned withthe international ISO 14001 and OSHAS 18001 standards.

Dion van Rooyen and Graeme Jardine will man the stand.

Scaw Metals Group (Scaw),P O Box 61721, Marshalltown, 2107 Gauteng, South Africa;Lower Germiston Road, Heriotdale, Johannesburg, Gauteng;TEL: +27 11 621 1555, FAX: +27 11 621 1590, email: [email protected], website: www.scaw.co.za

The Scaw Metals Group


Solidworx Engineering is a young dynamic company witha passion to design, create and deliver components andtooling for the manufacturing industry.

The founder of Solidworx, Anton Bezuidenhout is wellknown around the globe for his tool and die making capabilities in the alloy wheel industry and, was also thefounder of Wheelcraft Alloy Wheels. Through the years he hasfound that there is a huge demand by companies for themanufacture of medium sized aluminium die cast components (30g to 5kg) as well as companies that specialize in the tool and die making side for aluminium diecasting.

For most people the cost for die cast components has justbeen too high, simply because of the tooling aspect and sothey stick to the old fashioned sand cast method where thequality is not consistent but good enough for the job.

Recognising the need in the industry, Anton decided to startSolidworx Engineering, a company that offers new and moreaffordable ways to die cast components as well as offering acompetitive alternative to sand casting components with ahigher quality and consistency.

At this stage the company only does aluminium gravity die casting and can produce between 6000 and 9000 components monthly. This volume is based on components that vary from as light as 30 grams to 3kg. The company's melting holding furnaces vary from 50kg to400kg. Dies are cleaned by fine sandblasting after every run and are maintained in-house by our tool room.

Drawing office, tool room and fabrication facilities arealso offered.

Anton Bezuidenhout will man the stand.

Solidworx Engineering,P.O. Box 580, Derdepoort Park, 0035,Pretoria, South Africa;Portion 410 of Plot 269, Kameeldrift East, Pretoria, South Africa;Cellular: 082 901 0749, website: www.solidworx.co.za

Solidworx Engineering

The founder of Solidworx,Anton Bezuidenhout is well known

around the globe for his tooland die making capabilities in the

alloy wheel industry

The South African Institute of Foundrymen (SAIF) is a non-profit organisation that has been active within South Africa, initially as a branch of the Institute of

British Foundrymen since 1939, then as an independent institute since 1964.

Over the years, the Institute has taken great interest intechnology transfer and technical education. The Western CapeInstitute of Foundrymen (WCIF) established in 1982, by SAIF, isparticularly active in the field of education in the Cape area,and the Western Cape Training Centre for Metal Casting skillswas opened this year. Skills and apprentice training in theGauteng and other regions is being presented and a trainingcentre in Gauteng is under evaluation.

Aims of SAIFThe main aim of the SAIF is to promote and develop within

Southern Africa the science, technology and application ofmetal casting and foundry work for individuals and involvedindustries through:

• Appropriate education and training.• Dissemination of relevant information and knowledge.• Building cooperation and fellowship.• Developing and promoting career awareness.

In partnership with NFTN and other associations the

SAIF is active in assisting foundries to become more technologically aware and globally competitive. Projects aimedat energy saving and recycling, simulation modelling and leanmanufacturing are in progress. Joint projects are undertakenwith several government agencies to further the scope andopportunities to grow the foundry industry in the country.

Benefits offered to members of SAIFEducation and Training: Realising the need for both

operator / artisan and technical training for the Industry, theinstitute is committed to on-going development of operators'courses and seminars in conjunction with both local and overseas institutes and foundry technical courses are run inconjunction with the University of Johannesburg on a regularbasis. In addition skills development, in house - courses ondemand and other workshops are presented regularly at subsidised rates to Industry members.

Trends and Technology: You or your company can benefitby being kept up to date and familiar with local and international technology and trends relating to foundry activities.

castings SA: You will receive a free copy of castings SA, a bi - monthly publication which reaches decision makers at alllevels and sectors of the industry. The Journal covers topicallocal and international technology and applications in foundrypractice as well as news of the SAIF activities.

Technical Papers: Are presented to member and theirguests on a monthly basis, and cover all fields in the metalcasting industry.

Works Visits: Several times a year, the Institute organizesvisits to a foundry or allied interest works.

Annual SAIF Dinner: A purely social function to relax in goodcompany. Awards presented at this function include theMorganite Medal for best presentation paper of the year by anSAIF Member, Non-Members' Diplomas for best presentationpaper by non-members, Past President's Certificate andPlaque, and Honorary Membership.

Literature: The SAIF library, which forms a part of theUniversity of Johannesburg library, is open to any member,making both international publications and reference worksavailable.

Seminars: Are organized in conjunction with local or international developments as they occur. These one to threeday seminars cover foundry and related subjects.

South African Institute of Foundrymen,P O Box 14863, Wadeville, 1422, Gauteng;Sectretary: TEL: +27 (0)11 559 6455, e-mail: [email protected], CEO: TEL: +27 (0)11 559 6468, e-mail: [email protected], FAX: +27 (0)11 559 6526, website: www.foundries.org.za, email: [email protected]

The South African Institute of Foundrymen(SAIF)



Thos Begbie was established in Johannesburg in 1887 as aFoundry and General Engineering business and in 1907relocated to Middelburg, Mpumalanga. Today Thos Begbie

is one of the few fully integrated foundry and general engineering operations in the country, supplying all major sectors of industry.

Thos Begbie services include:Pyrometallurgical

Component ManufacturerThis division is

equipped to produce a comprehensive range ofCopper and Copper Alloycastings. The annualcapacity is in excess of1100 tons of finished product with a maximumcast mass of 7 000 kg.These products are supplemented by an extensive range of copperbased alloy components.

General Engineering The General

Engineering Division primarily provides foundrieswith machining capacity. Itincludes a CNC machiningcentre, grinding machines,milling machines, andpower saws. They also operate the largest horizontalfloor borer and Vertical Millin the region, which provides for machining ofabnormally sized components.It also provides services tothe local mining, power generation, paper processing, steel mills andferro alloy producers.

Technical ServicesThese include pattern

making facilities, a metallurgical analysis laboratory, technical customerliaison and, methoding - a computerised SolstarSolidification Modelling.

Quality AssuranceThos Begbie's quality

management system complies with the requirements of SABS ISO 9002, which wasawarded to them in 1990.

Thos Begbie is a privately owned company.

The exhibition stand will

be manned by Eugene Rossouw and Harry Mulller.

Thos Begbie, Tswelopele Street, Off Hendrina Road, Middelburg, Mpumalanga;P O Box 192 Middelburg, 1050, South Africa; TEL: + 27 (0) 13 246 9100, FAX + 27 (0) 13 246 1165; email: [email protected], website: www.thosbegbie.com

Thos Begbie & Company Pty (Ltd)

Vestcast is located within the Gautengprovince, the hub of South Africa's manufacturing industry. Located three

kilometres from O.R. Thambo International Airportand thus ensuring complete convenience of serviceto the customer and the supplier.

This ISO (9001:2008) accredited company is not only in a position to supply sound investment castings but can also provide clients with vastdesign inputs such as, selection of the correct materials, practical solutions, machining of castings, analysis of unknown metals with our spectrometer and many more. Vestcast is builtupon an extremely dedicated and capable management team which is supported by a worldclass manufacturing facility and a highly skilledworkforce.

Vestcast is one of the leading investment casting foundries in South Africa that does cast all opencast metals (alloys) as well as aluminium,SG Iron and closed impellers with waxes made fromthe rapid prototyping techniques.

Examples of castings used in the mining, petrochemical, pump and valves, medical and general engineering Industries will be on display at GIFA/NEWCAST.

The two Directors, Dave Barnes and FanieFouche as well as Marketing Manager David BarnesJnr. will man the stand.

Vestcast (Pty) Ltd,Cnr Kelly & Harold Flight Roads, Jet Park, Boksburg, Gauteng;P O Box 25005, East Rand, 1462;TEL: +27 11 397 4564, email: [email protected], website: www.vestcast.co.za


Vestcast (Pty) Ltd

Itshe Resources (Pty) Ltd was founded in 2006 to marketfoundry grade chrome sand from South Africa. The company serves the local and global foundry and

refractory markets with both wet bulk sand from RichardsBay, and containerised dried and bagged shipments fromDurban.

Chrome sands and concentrates are sourced from twomajor mines, one on the western side and one on the eastern side of the Bushveld mineral complex. Drying facilities are located in Durban for the export containerizedmarkets. Distribution of chrome sand is supported by theirwarehouses in Johannesburg and Durban and the longterm commitment from the mines to produce qualityfoundry sands and concentrates for industry.

Itshe Resources also distributes Metallurgical andRefractory grades of chromite ores which are used in themetallurgical, foundry, refractory and pigment applications.

Graham Evans and Ernest Mberi will be at GIFA onstand C61 in Hall 13.

Itshe Resources (Pty) Ltd,4 Arlington Road, Bryanston, Gauteng, South Africa;TEL: +27 (0) 11 706 0322,Graham Evans Cellular: +27 83 675 0299,FAX: +27 (0) 11 463 2475,email: [email protected], website: www.itsheresources.com

Itshe Resources (Pty) Ltd The following company will exhibit in Hall 13 - Stand C 61

MAGMA will show the newestversion MAGMA5 5.2 withextended capabilities for all

cast materials and processes, introduce its new software MAGMAC+M for the simulation of the core production processes, and provide aview into the future of autonomousoptimisation of casting processes atGIFA 2011.

MAGMA5 5.2 introduces severalnew simulation capabilities: new process modes forpermanent mould, low pressure sand and lowpressure die casting, as well both hot-chamberand cold-chamber die casting allow fordetailed process-specific definitions. Thesoftware also supports process designby controlling process parametersduring a simulation run. For gravitycasters, process modules forDISAMATIC and investment castingare now available.

At GIFA, MAGMA will alsopresent its newest developments forthe quantitative prediction of as-cast and heat treated localmicrostructures and properties in aluminium, iron and steel castings.MAGMA5 simulates sand and reoxidation inclusions during mould filling and predicts defects related tomoulding materials. MAGMAnon ferrous calculates the final microstructure and mechanical properties for aluminium alloys considering the metallurgy, inoculation,and hydrogen content of the melt.MAGMAiron predicts local microstructures for iron materials fromgraphite growth through to the distribution of phases making up thematrix. MAGMAsteel calculates macrosegregation in steel castings and the local microstructureresulting from heat treatment.

The stress module MAGMAstress for the first time offersthe option to calculate thermally induced casting stresses inpermanent moulds for all manufacturing steps, including heattreatment and finishing, in order to predict casting crack problems and distortion. The simulated distortion results canbe evaluated just as on a coordinate measuring machine andcompared directly with real measurements. For the first time,the new module MAGMAdielife facilitates the evaluation of theeffects of tooling design and thermal stresses on the durabilityof permanent molds.

MAGMA Core+Mold - transparencyin core production

With MAGMA C+M, MAGMA introduces an integrated tool for thesimulation of core production processes. MAGMA C+M simulatescore shooting, blowing, and hardeningof organic and inorganic cores.Processes where binder hardening isdriven by a catalyst gas as well as coreproduction with tempered core boxes

are supported. MAGMA C+M considers all aspects of

core production starting from the coreshooter, in order to calculate the flow ofthe air-sand mixture based on the realshot parameters. An integrated databaseprovides the ability to specify the characteristics of the sand and thebinder system as well as core box ventsand blow tubes. The program simulates

gassing, purging and the curing reaction of gas-hardened cores. The design and

control of core box tempering for heat-cured cores(hotbox, croning, inorganic) is effectively supported by

modelling of heating cartridges and oilchannels. For inorganic cores, MAGMAC+M calculates the drying of the corein the heated core box as well as dueto transport of water vapor by hot airduring gassing. MAGMA C+M takesadvantage of all the functionality ofMAGMA5 and is available as an add-on module to MAGMA5 or as astand-alone product.

Autonomous optimisation is thefuture

With autonomous optimisation,foundrymen can make use of simulation in order to pursue theirobjectives for quality and costs.

Autonomous optimisation makes proposals for the right castinglayout or the optimum process parameters. The virtual testfoundry in the computer enables variation of parameters andsystematic examination of influencing variables leading up tothe optimum configuration. Based on the fundamental physicsembedded in MAGMA5, the program finds the best possibledimensions and positions of ingates, as well as the location offeeders and chills including their optimum size. Using industrialexamples, MAGMA will present state-of-the-art capabilities andprovide a view into the future of optimisation.

For further details contact South Africa's sole registered re-seller Ametex on TEL: 011 914 2540


product review

The process orientation of MAGMA5illustrated using die casting

MAGMA presents the economic benefitsof casting process simulation:

MAGMA5 5.2 - optimised reality

With MAGMA C+M, the simulation of thecore shooting process is possible for complex tools,

shown here for three cores including blow tubesin a single core box

Autonomous optimization of casting processes andlayouts, shown here for gating optimization in diecasting, is the future of casting process simulation


These days everyone talks about great"Apps", whether it is calculating your fitness levels, keeping up-to-date with the

latest weather reports or even finding the bestlocal restaurant in an instant.Endress+Hauser has always believed in handyapplications to make life a little easier.

Their online Applicator tool(www.endress.com.applicator) is more thanjust a product selection tool offering convenient selection and design functionalityfor all your engineering processes. By enteringthe application parameters such as the measuring point specification, ambient conditions or approvals, Applicator identifies arange of suitable products and components.The products/applications are displayed with graphics and features on the screen.

Endress+Hauser is continuously, expanding Applicator'sfunctionality. Applicator offers a wealth of product selections,sizing and even industry-related help:

• Applicator selection will determine the appropriatemeasuring device

• Applicator Industry is useful in the Water andWastewater and Cement Industries

• Applicator Diaphragm Seal module offers extended helpwhen selecting the correct diaphragm seals for level, differential pressure and process pressure applications.

• Applicator Sizing Flow will calculate a suggested diameter of the flow device for the respective application.

• Applicator Sizing Gamma tool has been speciallydesigned to assist in sizing the correct Gamma device for theapplication area, whether continuous level, limit level, or density measurement is sought.

• Applicator Sizing Energy module supports the productselection of energy measuring points taking application parameters such as flow, pressure and temperature into consideration.

For further details contact Endress +Hauser on TEL: 011 262 8087 or visit the website: www.za.endress.com

An “App” that every engineer should have!

Numbers support the new "TF" Italpresse technology.Castings previously produced with a toggle machine ofthe same size are now produced on a new

toggle-free machine TF 1000 that guarantees a higher productive consistency and a very user-friendly operation.

Fratelli Lucco Borlera is a die casting foundry established in Rivoli, Turin, in 1949. At the beginning it wasa small workshop in the owners' garden, the classic example of the Italian industry and of its gradual andextraordinary development from the end of the Second World War.

Nowadays the company is ISO TS 16494 certified, andstands out for the delivery of castings to various fields suchas the automotive field. During the years, great care hasbeen given to automation and robotics, in order to optimise the working cycle and to reach high production levels, as well as to the process control and quality, in orderto guarantee controlled and conformable components.Furthermore, they also added various mechanical machining phases, in order to deliver finished castings,ready for the next cycle phase. Lucco Borlera's constant target is in fact to supply complex castings respecting thecustomer's tolerances and requirements.

The foundry is equipped with 22 cold chamber

die casting machines (from 300 to 1100 tons closing force)and three hot chamber machines. The latest machine is anItalpresse TF 1000. Supplied in June 2008 it was first purchased for its excellent closing force/volume ratio. Mr Massimo Lucco and his colleagues in the TechnicalDepartment had been impressed by the reduced mechanicaland hydraulic parts that would have limited the eventual failures (the toggle system is one of the most frequent failure causes) and above all the general maintenance.

After the machine start up, they could also appreciate its"hidden" advantages, especially the closing system and itssetting easiness. During the functioning the most importantquality came to light: a greater product consistency, quantifiable in an increase of 10%. "In the future we willsurely buy another toggle-free machine" announced Mr Massimo Lucco. "Its strength is above all the greater productive consistency."

While the foundries face more and more difficult challenges, often depending on the field and the final destination of the castings, the chance to count on a greaterproductive performance represents for Lucco Borlera animportant competitive plus.

For further details contact RGC Engineering on TEL: 011 887 0800

10% higher productivityby using a toggle free machine

Oxford Instrumentshas introduced thenew UVTouch OES

probe, an essential tool forPMI (Positive Material

Identification) work at high level.No more working with heavy items on ladders or

scaffolds. Just take the light weight 2 kg UVTouchprobe and leave the spectrometer on the floorlevel!

The PMI-MASTER PRO with the UVTouchprobe is the only analyser with an optional

10 m flexible connection cable. Fastanalysis, quick identification of

results and sorting of material isnow possible even on remote, difficult and hard to reach areas.

The probe's robust technologyallows continuous use in any

location, even in extreme conditions.The compact nose design allowseasy access to sample surfaces.Adapters are also available forthose irregular surfaces.

UVTouch has Argon purgedoptics in the probe. Using UVTouchuncompromised accuracy and

stability of analysis invarying environmentsis guaranteed. Thiseven includes theidentification of lowconcentrations of C,P, S, Sn, As and B insteel.

All data is available on theprobe, with no compromise in analytical precision or which elements need tobe determined. Control of the main PMI-MASTER PRO unit isalso possible by using the probe's advanced user interface. Anembedded PC at the UVTouch probe runs the most user-friendlyuser interface with large icons and virtual keyboard. It displayselement concentrations and grades.

The user can access the main functions of the spectrometer,change analytical programme, sample ID and grade library. Italso has store / print commands and many more valuable features. The touch screen display has optimal contrast propertiesto accommodate any lighting conditions inside and outside.

UVTouch gives reliable, repeatable, flexible analysis for allrequirements of the metals inspections industry.

More information on UVTouch probe and PMI-MASTER PROalloy analyser is available from Horst Klever on TEL: 011 678 1654or 082 964 9627 or visit www.oxford-instruments.com


Oxford instruments introducesthe new smarter UVTouch probe

Williamson Corporation's innovativeTemperature Process Control (TPC)System significantly improves quality

and productivity at aluminium extrusion plantsby automatically optimising process temperatures and press speeds.

The TPC System's closed-loop-control software makes presses operate more efficiently, thereby increasing recovery ratesand product consistency while reducing cycletimes and scrap rates. Its graphical interfaceand database of process "recipes" enable anyoperator to meet Best Practices Standards foreach die and order. Advanced utilities andreports identify and eliminate process bottlenecks for ongoingprocess improvement. A "Best Extrusion Analyzer" uses theaverage RAM speed and recovery rate to automatically capturethe "recipes" used for the best five extrusions of each die.

Unlike speed- and pressure-based control systems, whichuse temperature inputs only to select the appropriate controlmodel, the TPC System uses live temperature feedback toattain still greater improvements and maintain consistent quality. It continuously tunes the process, automatically adjusting billet temperature, profile temperature,

die temperature (optional), quench temperature (optional), etc. to compensate forvariations. System diagnostics monitor thenetwork and automatically switch the systemto manual control if communications are lost.

The system integrates Williamson ProSeries infrared temperature sensors, programmable logic controllers, and personalcomputers with the plant's existing furnace,press, and puller controls. An optional liquid-nitrogen cooling module typicallyincreases press speed by another 30%.Installation and training can be completed in less than seven days with little or

no downtime.Williamson Corporation manufacturers a complete line of

non contact temperature measurement and control systems forsteel, aluminium, glass, and petrochemical applications. AllWilliamson products are designed for high accuracy and longlife, even in hostile environments.

For further information please contact the SalesDepartment of Temperature Controls (Pty) Ltd on TEL: 011 7916000 or email: [email protected] or visit: www.tempcon.co.za

Innovative real-time temperature based systemprovides exceptional control for extruding aluminium

Birkenmayer along with Eirich, itstechnology partner, serves the metallurgical industry by making the

mineral beneficiation processes more efficient and environmentally conscious.Eirich mixers turn previously impermeableand unusable fine ore into permeable anduseable granulated pellets with the highspeed agitating mixer. This technologyallows for more efficient mineral extraction, lower energy requirements,and a reduction in overall process waste.

Louis Eksteen, Business DevelopmentManager at Birkenmayer explains: "Themetallurgical industry realised early in the20th century that sintered ore performsmuch better than natural, solid ore - because it is more permeable, porousand is easy to process."

He says: "Up to the end of the 20th century, the mixing and granulation of sinter mixes requiredthe use of large and cumbersome mixing and granulation drums.Since 1997, the mixing drums in new sinter plants have beenreplaced by Eirich high intensity mixers. Birkenmayer and Eirichare excited to be part of this technologically progressive step assuppliers of the integral Eirich mixers, without which, sinterpreparation is inefficient."

Eirich, a leader in industrial granulating and pelletising technology, has helped pioneer this step-change in the sinteringprocess. Typically, metallurgical processes require lumpy ores ofbetween five and 50 millimetres in diameter to allow enough permeability for gas movement during the reduction and smelting stages. About half of mined ore typically gets groundintentionally or unintentionally into fine dusts smaller than fivemillimetres in diameter through various processing steps. Thisdust is too fine for traditional metallurgical processing.

The Eirich high speed agitating mixer is used to turn this dustback into workable granules (or pellets) of around four or five millimetres in diameter. This helps eliminate unnecessarywastage of fine ore which still has potential for yielding minerals.

The extremely durable Eirich mixers are fed with fine ore, andthen mix the dust thoroughly with the required additives. Once

homogenised, the material is moved intoa second Eirich mixer where added moisture helps with granulation. G-forceand impact, created by the Eirich mixer,helps to compact the material into layeredpellets. This process can produce veryexact results since moisture content canbe precisely measured - as the material iswell homogenised inside the mixer.

The granular product is then put on asinter belt, where it is heated to between800°C and 1000°C. Surface meltingbinds these granules together and produces very workable chunks, whichare extremely permeable and, since itconsists of a lot of fine granules, are veryporous.

"This impact of this extra step in theprocess is significant as is evident in certain industries, like ferrochrome

processing, where it is applied to all ore - as 100% of it is intentionally ground to produce fine dust for sintering and leavesno wasted ore" says Eksteen.

Other benefits of having Eirich mixers as part of the sinteringprocess include the potential for saving space and reducing energy requirements. Typical mixing drums or pelletising discstake up vast amounts of space and are relegated to ground leveldue to their weight. Eirich mixers are much smaller and can beinstalled on supported structures. Compact, better designed mixing solutions also operate much more efficiently by requiringless power during the mixing process.

Also, as an intelligent mixing and pelletising solution, usingagitating arms and tilted drums, Eirich mixers still manage to produce higher output volumes than traditional sintering methods.

Mixing solutions from Birkenmayer are customised to meetparticular and unique mixing requirements. "We establish whattheir throughput is and suggest which mixer they should purchase, and then we can look at implementing a total mixingsolution," concludes Eksteen.

For further details contact Louis Eksteen Birkenmayer onTEL: 011 970 3880-8


Birkenmayer and Eirich enable sinter plant efficiency

The Eirich high-speed agitating mixer, with tilt, swivel door, and highly-durable design

Extended load range 1-250 kgf and 20-3000 kgf

Clever hardness testing made fast and simple

The new innovative load-cell basedDuraVision offers extremely fast andfully automatic hardness testing of

Brinell, Vickers, Rockwell and Knoop.Available with test load ranges from 1-250 kfg or 20-3000 kgf, the DuraVisioncovers the full spectrum of regular hardness testing.

The entire test cycle of load application, indentation, focusing, illumination adjustment andhardness evaluation is now carried out

fully automatically - without touching themachine -thereby ensuring 100% repeatability in testing fast, simple andunique!

For more information, contact yournearest IMP branch, Gauteng TEL: 011 916 5000, Kwazulu Natal TEL: 031 764 2821, Western Cape TEL: 021 852 6133, Eastern Cape TEL: 041 364 0159, Free State TEL: 018 293 3333 or email: [email protected]

2 ria c12 1repro - metalworking news sa june...magma; an “app” that every engineer should have!;...

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