vol 15 no 2 - castings sa › wp-content › uploads › 2014 › castings...6 castings sa vol 15 no...

castings sa vol 15 no 2 August 2014 1

Castings SAvol 15 no 2ISSN 1605-7589

Publishing EditorBruce Crawford

Online EditorDamon Crawford

Editorial BoardMarc Hindle

Production ManagerWendy Crawford

ReproductionJericho Graphic Design

Printed ByPaarl Media

Advertising Bruce Crawford/Wendy CrawfordTel: +27 11 463 0489Cell: + 27 83 628 7654E-mail: [email protected] Website: www.castingssa.co.za

castings sa is published by BA Crawford Specialised Publications (Pty) Ltd. PO Box 69 299, Bryanston, South Africa, 2021

41 Arklow Road, Bryanston, South Africa, 2021

Tel: + 27 11 463 0489E-mail: [email protected]

SubscriptionsAnnual – Local: R140.00 (incl. VAT)International: On application

CopyrightAll rights reserved. No editorial matter published in Castings SA may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

castings sa, published every second month, is the official journal of the South African Institute of Foundrymen (SAIF). The information and ideas presented in castings sa do not necessarily reflect the position of the SAIF staff, executive, advisors, sponsors or members.

4 cover storyIs your spectrometer producing the correct analysis?

8 industry newsCelebrating the life of Luis Dias; Scrap merchants; General Electric SA; Dawn forms JV with Grohe; Denel PMP; Hudaco; Grifo Foundry part of Scamont Group; 2015 Castings Industries Directory; Premier Valves; Air Products; SAIF’s 51st Annual Awards Dinner

34 international newsOmega celebrates 30th anniversary; Künkel Wagner files for bankruptcy; Lightweight design of GF Automotive; ASK Chemicals launches Casting Academy;3D printing supports casting

42 product review Selee IC™ aluminosilicate-based ceramic foam filters; RadEye PRD radiation meters; Ecocuretm Solventless cold-box technology; Struers’ new automatic and manual cut-off machines; Norton X-Treme flap grinding discs; The new Coriolis flow meter

castings saA specialised journal covering the technology,

processors and materials field for castings

volume 15 number 2August 2014

2 castings sa vol 15 no 2 August 2014

EditOR’S COMMEntIs Numsa pushing some unwanted buttons?

Below is a selection of headlines from news reports that I have seen in July. These

might have been taken in isolation but the contrasting messages give us a reality check when put together. They come soon after the Australian automotive industry was dealt a huge blow with the automotive OEMs deciding to pull out of Australia by 2017. Reading between the lines it is quite evident that the OEMs assessed the situation and costs, led by demanding Unions, which forced them to take this drastic

decision and re-shore or look elsewhere. We must not forget that it was only in August 2013 that 30 000 South African auto workers held a four-week strike. Numsa then called out members at automotive components suppliers, thereby denying assemblers the parts they needed to build vehicles. The dual strikes shut down the industry for seven weeks. BMW immediately put its South African expansion plans on hold.

International headlinesGM to invest $740 million in new Argentina factoryVW plans $250 million investment for IndiaBMW Group to build plant in MexicoJaguar Land Rover plans China engine plantPSA to start output in Nigeria this yearBMW will raise China capacity to 400 000 vehicles

South African headlinesGM shuts assembly plant as strike hampers component supplyNissan latest automaker to suspend South Africa productionamid strikeStrike-weary Ford hopes for quick resolution to labour situationToyota, Ford halt output in South Africa as strike spreadsAuto manufacturers start to feel Numsa strike impact71% year on year rise in May copper theft

So are foreign automotive investors on the point of losing patience with strike-prone South Africa? Or will militant trade unionists be proved right in their gamble that multinational motor companies are too deeply embedded in SA to walk away? These are the questions asked by David Furlonger for his cover story in a recent issue of Financial Mail.

Furlonger continues: “Though there appears to be no question at this stage of disinvestment by any of SA’s seven full-scale vehicle manufacturers — BMW, Ford, General Motors, Mercedes-Benz, Nissan, Toyota and Volkswagen — there is a sense that they may reconsider the scope of their presence here. BMW and Datsun, Nissan’s reinvented entry-level brand, admit that plans to build new cars in SA were put on hold because of the uncertain labour environment.”

“The cars would have been mainly for export but the companies say they can’t risk an unreliable workforce. Last month, Datsun’s global head, Vincent Cobee, expressed regret at having to bypass SA for the Go car, which is designed for emerging markets and will go on sale in SA in a few weeks. The first generation of the car will be imported from India.”

The impact of this strike could have far reaching implications and unions must accept that actions always have consequences. The South African and sub-Saharan Africa markets may have good long-term prospects but they are not so important to the OEMs, in world terms, that the usual rules of economics don’t apply.

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

Membership Fees for 2014Junior MemberR100.00 per annum

Individual MemberR700.00 per annum

Company Member - less than 150 employees R3 000.00 per annum

Company Member - more than 150 employeesR6 000.00 per annum

Retired Member R330.00 per annum

International Member R2 000.00 per annum

All prices include VAT

Council Appointments for 2014/2015President - Takalani Madzivhandila Vice President - Janley Kotze Treasurer - Justin de Beer Constitutional Members

Immediate Past President - Enno Krueger

Elected MembersAndrew McFarlane Adrie El Mohamadi David Mertens Colin Smit Bruce Crawford Cyprian KyaluJohn Davies Dalmari McQueenKevin van Niekerk Joshua van FlymanNigel Pardoe

Western CapePresident - Mike KillainFinancial & Technical Speakers - Dean Horne & Sean StadlerAdministration - Kevin MissenheimerSocial Co-ordinator & Technical Speakers - Mike Killain

Address detailsUniversity of Johannesburg Metal Casting Technology Station - Metallurgy Room G101, John Orr Building, Corner Siemert and Beit Street, Doornfontein, Johannesburg, Gauteng. Postal Address: P.O. Box 14863, Wadeville, 1422.

John Davies - Tel: +27 (11) 559 6468; Cell: 083 630 2809; email: [email protected]

Executive Secretary - Tel: +27 (11) 559 6455; Fax: +27 (11) 559 6526; email: [email protected]

Website: www.foundries.org.za

Contact details for Western Cape: Mike Killian - Cell: 082 442 3785

south african institute of foundrymen


cover story

Developing a best-in-class quality-control program demands a thorough understanding of processes, both in the methods and practices set by an operation’s

managers and in the minds of the metalcasting workers. To obtain the highest levels of quality control, it is important for modern foundries to be as well organised as possible, and developing a complete quality-control plan is the bedrock of any such endeavor.

Regular testing remains the cornerstone of any thorough quality-control process, but this cannot be a random practice, nor one that is focused simply on products exiting a production line. A company’s quality-control plan should explain exactly each step involved in the process, and the frequency with which it should take place, and define acceptable ranges of results. It also should set out the appropriate steps to be taken when a problem is identified.

Your spectrometer Incorrect results produced by your spectrometer can lead to

serious consequences, including high scrap rates and possible failure of castings in the field, to name but a few. The end result will always have financial implications. Huge savings can be achieved by ensuring that the chemical composition of your metal is according to the required specification.

Quality control in this area has become critical to a metalcasters’ customer service and cost containment initiatives. Quality engineers, laboratory managers and plant metallurgists have to understand and appreciate that the

recent developments and introductions, particularly in the field of spectrometers, will facilitate their quality-control program enormously.

Spectro Analytical Instruments is a manufacturer of elemental analysers using optical emission spectroscopy and x-ray fluorescence spectrometry. They do not only supply spectrometers, but also offer a complete solution for the determination of the chemical composition of your alloys from sample taking to reporting of the results. Experience has shown that incorrect results can be produced by all spectrometers, but

it is comforting to know that these can be alleviated by correct operation and practice. The main problematic areas, which contribute to incorrect analysis, are indicated below:• Sampletaking• Samplemouldtype• Samplepreparation– different preparation is required for different metals• Checkingthatthe

spectrometer is correctly calibrated prior to use• Theuseofcontrolsamplesandcertifiedreference

materials• Operatorsofthespectrometernotbeingproperly

trained

Spectro Analytical Instruments held a workshop recently to address problematic areas related to the results that are produced, with particular emphasis on sample taking and sample preparation.

Is your spectrometer producing the correct analysis?Operator and technician training is part of the solution.

Danie and Gareth Henning from Franktech Metallurgical Services with Allan Bruggerman of Matt Cast Supplies

John Taylor of Spectro Analytical, Chris Robbins of GE Patterns & Foundry and Peter Moatshe of WASA


The workshop included different types of sample moulds for the various metals, these being cast iron, steel, aluminium and copper base alloys. Various sample preparation methods were discussed, and available for practical demonstrations of the appropriate sample preparation for the various alloy groups was a cup wheel grinder, a disc “sander/grinder”, as well as a bench top milling machine.

The Spectromaxx, Spectro’s latest generation bench top spectrometer, was introduced to delegates as well as Spectro’s Spectrotest portable spectrometer and the Spectro xSort hand held XRF analyser.

The Spectromaxx stationary metal analyser has been among the most successful Spectro models in recent years.

The Spectromaxx is used mainly for material testing in foundries and for

incoming and outgoing inspections in the metal industry. With it, users are able to determine all of

the elements used in the metal industry, including trace analysis of carbon, phosphorous, sulfur and nitrogen. Calibration modules are available for base metals: iron, aluminium, copper, nickel, cobalt, titanium, magnesium, zinc, tin and lead.

The Spectromaxx fulfills the users’ need for simplification in several ways: The measurement is no longer controlled through the menu, but with symbols and toolbar buttons. Once a procedure has been started, only the functions that are logical at that point in time are active in the control software – all other commands are hidden.

The metal analyser also offers a user management system that permits rights for individual employees to be determined. Operators that have not been trained by qualified personnel from the spectrometer supplier will in all likelihood not be using the instrument correctly. This occurs when the properly trained

operators leave the company, with subsequent “hand me down” training being given to the new operator. As this can happen numerous times, it could end up with the current operator having very little idea of what is actually required. With each retrained operator the training becomes diluted

Now in its fifth generation, the Spectromaxx features a new argon-saving module that reduces gas consumption when the instrument is not in use, with substantial savings. When the spark generator is turned off at the end of the day, the argon saver reduces the flush to zero. The operator can set the time when the instrument is to be used the next morning, so that the spark stand and optical system starts automatically and are optimally supplied with argon. The instrument can be set on a timer for longer idle periods, and it can be pre-programmed, too.

The new integrated diagnosis system continuously informs operators and service technicians about the state of the system and its main components, making it possible to rectify malfunctions more quickly and favourably complete service calls.

For further details contact Spectro Analytical South Africa on TEL: 011 979 4241 or visit www.spectro.com

Andre Bezuidenhout of Sasol, Juane Mohr and Jean-Pierre Viviers, both of Frankwen Forge

Thys Redlinghuys of Heraeus and Reg Turton of MIS

Right: A cup wheel grinder used for the preparation of cast iron

and high chrome white cast iron, but also suited for the preparation

of all ferrous samples

Above: A bench top milling machine used for non ferrous samples

industry news

It is with great sadness that I have to report on the sudden and untimely passing of Luis Filipe Duate Dias in May at the tender age of 61. Luis was one of the most well respected

and liked personalities in the foundry industry, having worked in the industry for over 35 years. But more importantly he was a very proud man, a devoted husband and family man, lived afulfilledlifewiththemottoofthefirsttogiveandthelasttotake uppermost in his mind, and was happiest when he had the opportunity to babysit and entertain his two grandchildren Cassandra and Veronique.

Born in Lisbon, Portugal on the 10th October1952 to the lateManuelandBeatriz,LuislandedinAfricaforthefirsttimeat the age of four when his father decided to leave Portugal and seek better pastures in Beira, the second largest city in Mozambique. The family compliment was increased by two with the birth of sister Lena and brother Rui, during the family’s nine year period in Beira before ‘Vovo’ decided to move to South Africa and take up a position with Everite in Klipriver south of Johannesburg. This was where Luis would later meet his wife Rosemary and marry in November 1974.

Luis completed his schooling at General Smuts High School, Vereeniging, a remarkable achievement in that he could not speak English or Afrikaans when he arrived in South Africa and was assigned to the immigrant class.

AfterfinishingschoolLuiscontinuedhisstudiesandcompleted his draughting diploma through Wits Technikon. His

firstpositioninindustrywas in the draughting officeatBarnes-Birlec.Thereafter he took up a position as Production Manager at Boart International before venturing out on his own.

Luis was also a keen sailor for a period in his life and he excelled at roller hockey.

Luis had been a member of the South African Institute of Foundrymen (SAIF) since the 1980s and was voted in as a council member of the SAIF in the mid 1990s, a position he dedicatedmanyhoursofhistimeto.HewasfirstelectedVicePresident in 2009/2010 and then served as the SAIF President for two years – 2010/2011 and 2011/2012 – a position he held with distinction.

A devoted husband, son, father, brother, grandfather, uncle and in-law, Luis was known as the ‘godfather’ to the family – “always in control and sorting everything for all of us and no task was too great for him,” as his daughter Sylvia said.

The same could be said about Luis’ career in the foundry industry, having built up a reputation for going out of his way to make time and come up with a solution for anybody that phoned, visited or presented a problem. Luis was extremely committed to the foundry industry and gave up many a spare hour for the cause of the industry.

In 1984 Luis established design and details company Endeco, an acronym for Engineering Design Company. “30 years is a milestone in the history of most companies but it is even more so when you are in the business of design, manufacture and installation of foundry equipment in South Africa. The fact that Endeco achieved this milestone says something about the tenacity of the company,” said Luis earlier this year before his passing.

Thefirstmajorbreakthroughforthecompanycamein1987when Luis was contracted to design, supply and install a turnkey project for Rely Precision Castings. This included a reclamation plant, silos, a monorail system and spincasting equipment.

In the same year Luis was engaged by Scaw Metals to design,manufactureandinstallthatcompany’sfirstgrindingmedia high chrome ball casting plant. This was subsequently followed up with a second order for an exact replica, in 1992.

Over the years, under Luis’ leadership, the company has been involved in most major foundry projects in South Africa, either as turnkey projects, equipment manufacturers and suppliers or as designers and project managers. The company has steadily increased its market share in the South African foundry industry.

“The development of locally designed and tested equipment, and the policy of continually introducing new equipment, has enabled the company to remain in the forefront of the industry and essentially assist foundries in import replacement.AnaddedbenefittodayforfoundriesisthatEndeco are also prepared to handle all the civil engineering aspect that is involved in installing equipment,” said Luis in the same interview.

Initially Endeco outsourced all the fabrication work but since the purchase of their own premises in Alberton 20 years ago, all

Celebrating the life of Luis Dias



the manufacturing has been done in-house. One of Endeco's largest projects to date was the Eclipse

Foundries East Plant green sand high pressure moulding plant installed in 1999. This project was a turnkey project, which included the design, manufacture, supply and installation, as well as the full management of the project.

The legacy that Luis built is reinforced in the words of brother Rui, who joined the company in 1994 and Victor, Luis’ son, who joined 17 years ago.

“Luis we promise to make the business you started more than 30 years ago, which you were so proud and passionate about, and of which we have shared with you, flourishandgrowinhonour of you. We will not let you down. We will look after your “Endeco family” with pride as you did.”

“Your passing has left a huge void, not only in our lives but in the lives of everyone that you touched and came across, and we know you will be looking down at us with that special smile of yours and will be wondering what all the fuss is about, because you know that you have left a legacy that will be continued for generations to come and that we will never let you down.”

However, many will remember the principles that Luis lived by and those are trust, honesty, sincerity, integrity and faith. Luis’ wry sense of humour is expressed in daughter Sylvia’s tribute.

“Life is not measured by the number of breaths we take but by the moments that take our breath away. How does one begin to acknowledge and thank the very person who gave you life and who, as stubborn as he was, gave his all to his work, his family and the foundry industry. This year when I embarked on my MBA journeymyfirstprojectwas to identify why. The reason is simple. I was guided by the ambition and drive of my dad, my role model, my friend. I not only wanted to make him proud but I longed to be just like him. When arguing with him about something his response

was quite simple: Talk to me when your brain is as big as mine.”

“Simplicity, goodness and truthfulness – therein lays greatness. He added so much to others lives and expected so little in return. He was a humble man,” added brother Rui.

Rest in peace Luis. We will all miss you, especially your cheerful greeting of Comrade President. His lifetime of dedicationandself-sacrificeserveasamonumenttotheexemplary man he was. His humility, integrity, and hard work continue to inspire those who knew him.


Amendments unsettle smaller scrap merchants

Recent amendments to the published export guidelines for ferrous and

nonferrous waste and scrap have created uncertainty among small and medium-sized scrap merchants who fear that they could be forced out of the market because of the more stringent measures, according to a Business Day report.

The initial export guidelines published by the Department of Economic Development last year were aimed at making sure local scrap metal users in South Africa had sufficient material, yet since their publication several concerns have been raised about possible anticompetitive outcomes and effects on small merchants that are focused on the export market.

The amendments to the initial policy, published in May, have seen a flood of correspondence to the International Trade Administration Commission (Itac), which is responsible for the implementation of the policy.

Smaller scrap merchants say if amendments are implemented, dealers leasing yards will be excluded as only owners will be allowed to export. They say they will have less working capital because of the new seven-day payment period. They also say job losses may be unavoidable.

The department last year introduced measures through its published guidelines to allow foundries, mills and secondary scrap processors to buy scrap at a preferential rate of 20% below the international spot price that South African exporters can get for waste metal. Scrap merchants have to offer their waste to local buyers before applying for export permits.

South Africa exports about 1.5 million tons of scrap metal every year, which is 40% of the country’s collections.

Smaller scrap dealers claim the amended guidelines will entrench the position of bigger scrap merchants given their current relationship with foundries as their “authorised dealers”.

Economic Development director-general Jenny Schreiner said in response to concerns that South Africa could not allow scrap metal exports that took advantage of soaring global prices to undermine local producers and encourage the theft of cables, sewer lids and other important infrastructure elements.

“The new price-preference provisions seek to sustain local foundries that will increase

local value-add as well as jobs.”“The available evidence shows that the guidelines will

promote job creation. They are critical for future economic development, as they will assist local steel mills, secondary smelters and foundries to acquire affordable, quality scrap metal for local processing,” she said.

Smaller merchants — who did not want to be identified — said domestic users had already started “flexing their muscles” in terms of the proposed amendments and that a lot of “animosity and bad blood” was brewing between the scrap trade and domestic users.

One of the dealers said foundries traditionally did not buy directly from smaller dealers as they did not meet their requirements. They had the freedom to export what was not sold in the domestic market. Small dealers said in correspondence to the International Trade Administration Commission that they found themselves in the position where offers were made by local buyers, but they had no intention of buying it. It was merely a ploy to prevent them from getting an export permit.

Itac said it could not respond to the allegations. The amended guidelines stated that Itac would not issue an export permit where, prior to the expiry date of the circulation period (which is currently three weeks) — a valid offer had been made. If no agreement was reached, an export permit was issued

within three working days, Itac said.The Competition Commission has since

confirmed that it met the department and Itac to discuss concerns raised by industry bodies about anticompetitive provisions in the export guidelines. The Competition Commission said there had been allegations of collusion made by some of the industry players, but none of the allegations were backed up by a formal complaint that could be investigated by the Competition Commission.

Ms Schreiner said the export permit guidelines provided for a technical working group to discuss the administration and implementation of the price preference system. But the Competition Commission was concerned that the working group could be used to share price information.

“After we clarified that the group’s engagement would be limited to administration of the system, the commission was satisfied. It is well known that in its role overseeing the competition authorities, the Department of Economic Development has worked actively to stop price collusion, and we have no intention of changing this stance,” Ms Schreiner said.


General Electric (GE) SA is set to invest R500 million to create an engineering and development-focused Customer Innovation

Centre (CIC) that is geared towards critical skills development through innovation and technology transfer and a further R200 million investment in a supplier-development vehicle to provide technical, funding and business support to small and medium-sized enterprises (SMEs).

Tim Schweikert, GE SA President and CEO, said the investment was ultimately aimed at incorporating local approaches and innovation developed by South Africans into GE’s global product pipeline.

“The CIC will leverage South African talent to provide meaningful and dynamic solutions to this region and the world. It will become a technical resource centre and hub for suppliers and customers across GE’s business entities, as well as for the industry,” Schweikert said in a statement released recently.

The investment is also set to create jobs for around 100 technical professionals and engineers. Preference will be given to black graduates and graduates from rural areas who hold an engineering degree or the equivalent from a Further Education and Training college.

An additional R200 million has been earmarked to bolster black-owned small to medium sized enterprises’ (SME) capacity through funding, business and technical development services.

The end goal is for these SMEs to be absorbed into GE’s supply value chain to local and international multinational corporations.

Small business owners will be exposed to business development services that focus on sharpening their business acumen, operational and management skills, while the technical development services will include engineering and problem-solving support and technology transfer.

Schweikert said a possible incubation scheme for black-owned SMEs was also being considered.

GE Africa president and CEO Jay Ireland said the schemes

formed part of a larger R5 billion-worth of investments that the group was making across Africa, which he described as the “final growth frontier”.

Ireland said the intention was to foster in-country innovation and position South African enterprises to supply into GE, as well as other global supply chains. Globally eight jobs were generated in the GE supply chain for every one created internally, but the African ratio was still one-to-one, owing to inadequate skills and supply-side capacity.

He said GE’s relationship with Transnet Engineering was showing promise, with the Koedoespoort facility not only assembling locomotives for Transnet Freight Rail (TFR),

but now also for other African customers. The partnership had received orders for nearly 100 locomotives mostly for Mozambique.

“By creating new developing black industrialists, this initiative will grow existing and new businesses and provide products and services that are currently unavailable in the region, which will, in turn create long-term sustainability and economic growth,” he said.

In the first phase, eight black-owned industrial companies would be identified to supply components and services to GE as it delivered on a R7.1 billion order from TFR for 233 diesel locomotives. The order formed part of a larger R50 billion TFR order for 1 064 electric and diesel locomotives, which had been split between four suppliers.

Newly appointed Minister for Small Business Development Lindiwe Zulu applauded the investment and its potential to “unlock economic opportunities” that could drive inclusive economic growth and sustainable employment.

“Together, we must ensure that small entrepreneurs have abundant opportunities to grow and develop their enterprises in an environment that nurtures the development of these enterprises and enhances their job creation potential,” she said.

General Electric SA to invest R700 million in establishing an innovation and

technology development facility and supplier development vehicle

The programme is broken into two components and is closely aligned with government's increasing demand for localisation when awarding infrastructure contracts.

GE Africa president and CEO Jay Ireland


Stock exchange listed Distribution and Warehousing Network (Dawn) has announced that it had sold 51% of its Watertech companies for R880 million cash to

international group Grohe.Dawn CEO Derek Tod said the company had, for a number

of years, sought to globalise its manufacturing operations. However, to be globally competitive, it was necessary to have full access to global technology, manufacturing expertise and dispersion of manufactured product via established channels.

Grohe is Europe's largest and the world's "leading" single-brandmanufacturerandsupplierofsanitaryfittings.Theeffective date of the deal will be no later than 30 November.

The deal will be structured within a newly created JV entity named Grohe Dawn Watertech Holdings. It will be a holding company in Dawn, which will be 51% owned by Grohe and 49% by Dawn. Proceeds of the transaction will be used by Dawn to repay debt and acquire businesses in areas of the group's core competence.

The acquisition involves all Dawn's Watertech companies, which consist of Cobra Watertech, Apex Valves SA, Exipro Manufacturing, Vaal Sanitaryware, Isca and Libra Bathrooms. The acquisition price will be subject to a price adjustment as at the effective date in respect of 51% of the net debt and a 51% net working capital adjustment, should net working capital be less than R500 million on the effective date, or R450 million if the effective date occurs in December 2014.

Grohe will have a call option to increase its share in the JV to 75.1% after ten years, but before the end of the twelfth year and at a minimum price of R9 billion multiplied by the proportionate shareholding acquired. Should Grohe exercise its call option, Dawn will have the right to put its remaining shareholding in the JV to Grohe on the same terms as the call option.TheJVwilldistributeaminimumof33%ofnetprofitstoshareholdersannually,afterprovidingfinancialdebtservicing,should there by any.

The transaction is subject to a number of conditions precedent, including shareholders of Dawn approving the transaction at a meeting with the requisite majority and regulatory and competition commission approvals.

The management teams in the operating companies will remain unchanged, while the executive committee of the new company will be led by Tod and Julian Henco, previously VP emerging markets at Grohe.

As part of the transaction, Dawn and Grohe had entered into distribution and services agreements, which would start on the effective date.

These include exclusive distribution agreements that allow the Watertech companies to distribute Grohe’s products in agreed African territories, distribute Joyou's (a Grohe group company) products in agreed African territories and the distribution of the Watertech companies' products in all global territories other than the agreed African territories, as well as services agreements between the Watertech companies and Wholesale Housing Supplies (WHS), a Dawn group company, in terms of which WHS will provide certain operational and distribution and warehousing services to the Watertech companies and sell the Watertech companies’ products, which will include the Grohe and Joyou products, in the agreed African markets.

Further, Africa Saffer Trading (AST), a Dawn group company, will allow AST to sell the Watertech companies’ products, which will include the Grohe and Joyou products, in agreed African territories other than South Africa, Lesotho and Swaziland.

Theacquisitionisexpectedtocreateanunspecifiednumber of jobs in Dawn’s domestic manufacturing operations. The transaction is also expected to more than double the estimated R1.5 billion in annual revenue the JSE-listed manufacturer and distributor of local plumbing and hardware brands receives from exports.

Dawn chief executive Derek Tod said the transaction would not require the group to invest in expanding the manufacturing capacity of the Watertech companies.

Tod said most of the companies involved in the transaction

Dawn forms JV with Grohe R880 million deal to globalise manufacturing operations includes Cobra Watertech foundry operations.


had extra capacity, with Cobra, for instance, running at about 65 percent of capacity and bath manufacturers Libra and Plexicor operating at 50 percent.

Vaal Sanitaryware had in the past six months also invested R60 million in increasing its capacity and improving the quality of its products, he said.

Tod said the transaction would help the group to use its available capacity to the full irrespective of what happened to the building industry.

“But in the future, the business plans anticipate further investment in ceramic sanitaryware in about 2016/2017 because of the enormous opportunity Grohe sees for these products,” he said.

Tod said the transaction would help to create and sustain jobs, as it would definitelyresultinmorethroughputin Watertech’s factories, but it was difficultatthisstagetoquantifythenumber of jobs that would be created.

About GroheGrohe is German manufacturer of

sanitaryfittings,includingkitchenandbathroom faucets, and shower systems established by Friedrich Grohe in 1936. The Grohe Group comprises Grohe AG, Hemer, Joyou AG, Hamburg

and other subsidiaries in foreign markets. With its global Grohe brand, the Grohe Group relies on its

brand values of quality, technology, design and responsibility to deliver “Pure Freude an Wasser”. With the Joyou brand, the Group covers the fast growing Chinese market.

Spearheaded by Grohe Group S.à r.l., Luxembourg, the group has a global workforce of around 9 300 people worldwide (including some 3 500 at Joyou). There are about 2,400 employees working at Grohe in Germany. The Grohe Group generated consolidated sales of €1.45 billion in 2013.

The Grohe Group has nine proprietary production plants, of which six are located outside Germany, namely in Portugal, Thailand, Canada and China (Joyou). The company currently generates some 85% of its sales outside Germany.

The Grohe Group was taken over by the Japanese LIXIL Group and the Development Bank of Japan in January 2014. The LIXIL Group is the global leader in the building materials and housing equipment industry. Grohe and Joyou remain independent within the LIXIL Group.


Munitions manufacturer Denel PMP will double its turnover to more than R1 billion rand within the next fiveyearsinresponsetostrategicrequirementsinthe

local market and its growing presence in the rest of Africa.Insupportofthissettarget,theChiefExecutiveOfficerof

the Pretoria West-based manufacturer, Phaladi Petje, says the company will be embarking on a plant-renewal programme to modernise its machinery and production processes.

“We will also increase our research and development capacity. PMP is set to become the ammunition solution partner of choice both in South Africa, across the continent and in any of the markets we are targeting,” says Mr Petje.

The Defence Review, presented to Parliament, earlier thisyear,hashighlightedtheneedforself-sufficiencyinthe provision of ammunition not only to the SANDF, but the security cluster as a whole. “PMP is in an excellent position to meet all the SANDF’s current and future needs for small and medium calibre ammunition,” says Mr Petje.

“We have been in this business for more than 75 years and the experience gained over this period will enable us to meet the challenges emanating from the local defence community.”

The company has a very productive relationship with the SANDF and Armscor in a partnership that covers the entire technology assessment phases. This ranges from product developmentthroughtoproductspecifications,design,testing

andqualificationtotheultimateproductionanddeliveryaswellasaftersalesservice,proofinganddestruction.“Weofferour clients a complete life cycle management approach,” says Mr Petje.

The company intends to build a similar relationship with the SA Police Service, metro police forces and the private security industry. “We can meet almost the entire local demand for small calibre ammunition in the defence and security sectors,” he says.

MrPetjealsoforeseessignificantopportunitiesforbusiness growth on the rest of the African continent. The company now manufactures 7.62mm calibre ammunition for thewell-knownAK-47assaultrifleaswellas23mmrangeofammunition widely used by African defence forces. Denel PMP has formed strategic relationships with companies in Europe whilstsimilarmutuallybeneficialrelationshipsarebeingpursued in Africa and within the Brics partnership.

More than 40% of PMP’s current production of ammunition is destined for the export market. He says “innovation is at the core of the company’s future” and Denel is working together with Armscor, the CSIR and local universities on various research and new product developments.

For further information contact Vuyelwa Qinga on TEL: 012 671 2662 or Denel PMP on TEL: 012 380 0400 or visit www.pmp.co.za

Denel PMP set to strengthen its position in local ammunition manufacturing

Five years ago Denel PMP installed a six ton Inductotherm furnace An existing holding furnace

Interim results ‘disappointing but resilient’ as company says increased emphasis will be placed on sales into markets outside South Africa.

Hudaco Industries has delivered disappointing yet resilient resultsforthefirsthalfoftheyearreportedthegroupinitsinterim results report for H1 2014 ending 31 May.

The company stated that it has experienced one of the most challenging trading environments in recent time, mostly owing totherecentlyendedfive-monthlongplatinumstrike.

The results were released just prior to NUMSA's strike in the metals and engineering sector which would also hit the company. The mining and engineering sectors currently made up about 50% of Hudaco's sales, which meant that the company had "nowhere to hide" during strike periods in these sectors.

As part of JSE-listed Hudaco Industries’ key strategy to pursuetheaquisitionofnewbusinessesinsimilarfieldsofactivity, the company signed an agreement to acquire the Dunford Group of businesses, which comprised Dosco Precision Hydraulics, Gear Pump Manufacturers (an in-house foundry in Cape Town), Joseph Grieveson Foundry and Engineering Technology Services, for R154.3 million last year.

Contracted GDPThe South African group, which supplies engineering

consumables mainly to the mining and manufacturing

industries, reports that Q1 2014 mining GDP contracted 25%, while the manufacturing sector contracted 6%.

“There is no doubt that these depressed conditions continued into the Q2 2014. These two sectors of the economy account for about half of Hudaco’s sales. As a result, the engineering consumables segment faced very tough trading conditions particularly felt in those businesses serving the mines in the Rustenburg platinum belt,” stated the company.

Strike aftermathHudaco said that while the platinum strike may have ended,

itsaftermathwillcontinuetoimpactdemandinthefirstmonthsof the company’s second half in 2014. Sales at R2,1 billion were up 16% of which only 3% was from ongoing operations and 13% was from acquisitions.

“Activity in open cast mining was not as badly affected as in deep level mining by strikes. So, sales volumes held up reasonably well. There were also reasonable performances from businesses serving other markets; for example sales into neighbouringcountriesgrew33%inthefirsthalf,”reportsHudaco.

Comparable earningThe company says that comparable earnings held up well

against last year, until the end of March 2014, however they fell behind in April and May, ‘which is an indication that conditions are still deteriorating’.

Hudaco reports that December, January and April are traditionallydifficultperiodsforthecompanyowingtotheholiday season. However, April and May were particularly hard hit by the strike activity in the platinum mining sector, reports the company.

Demand for diesel engines and spares, electrical equipment, bearings and power transmission equipment and chemical piping was well down on last year, noted Hudaco in its interim results report.

“Acquisitionsoverthepastfewyearshavesignificantlystrengthened the sales base and market spread of this segment, and businesses with less exposure to the platinum mining sector performed reasonably well under the circumstances,” stated the company.

Opportunities outside of South AfricaAccording to Hudaco, the South African economy seems set

for a period of no or low growth. As a response, the company will place an increased emphasis on sales into markets outside South Africa.

Hudaco will look at neighbouring territories as a market for its complete basket of imported products and overseas markets for the company’s own brand locally manufactured gear pumps and electrical plugs and sockets.

Meanwhile, Hudaco chief executive, Stephen Connelly, was due to step down from his post effective 30 June 2014. Connelly will remain on the board of Hudaco Industries as a non-executive director. Graham Dunford will take over as chief executive with effect from 1 July 2014.

Hudaco looks abroad in ‘challenging’ times


The Scamont Group was founded when Luciano Sandri acquired Scamont Engineering in 1978, when the companywasoperatingasasmalljobbingfirmbased

in Jeppestown, Johannesburg.Over the next four years Scamont was strategically

repositioned as a manufacturer of positive displacement slurry pumps and in 1983 success in this market required the commissioning of increased production capacity. The launch of the Scamont SP-200 pump in 1984 signalled the company’s entry into the market as a major supplier of slurry pumps throughout the South African mining industry.

For the next decade, strong demand for Scamont’s high quality, well-priced products and expert technical support enabled the company to secure major contracts for the supply of products and repair services to all of the major gold and platinum mining houses in South Africa.

During 1994 Scamont developed the 3,500 m² manufacturing and engineering facilities that it occupies today. The facility was fully commissioned in May 1996 and remains one of the most advanced and efficientofitstypeinthecountry.Thisfacilityisbased on the West Rand and has been optimised for new product production and the repair of equipment. Scamont continues to invest in state-of-the-art manufacturing equipment, ensuring optimum productivity

and reliability of supply to its customer base.

Acquires Grifo Engineering and foundryIn 2013, Scamont acquired the entire business

of Grifo Engineering, which included the Grifo Foundry, a company founded by the late Gianni Fontanella. Grifo manufactures a range of multi-stage clear water pumps, which operate side-by-side with Scamont’s slurry pumps in many installations. The Grifo business has been fully integrated into the Scamont group, broadening the product offering whilst maintaining the highest standards of manufacture, service, and after-salessupport.Thisacquisitionre-affirmsthe company’s vision and commitment to its core competency of being an Original Equipment Manufacturer (OEM), supplying its own range of world-class products, and backing them up with readily available spares, repair capability, and strong technical support.

Scamont manufactures and supplies slurry and clear water pumps and rock drill machines to the South African and global mining industry.


Grifo Foundry part of Scamont Group

The publishers of castings sa will be publishing The 2015 Castings Industries Directory in February 2015. This is the fifth edition of this popular specialised buying and contact

guide of Southern African foundries and suppliers to the industry.The new directory will include offerings from all known

foundries and suppliers to the industry and will provide a valuable resource for the manufacturing, design and engineering industry.

The Directory is divided into various sections with the buyer's needs in mind. These include:

• UsefulAddresses–LocalandInternational• FoundryCompanyDetails• ArtFoundries• Alloy&IngotSuppliers• Patternmakers• HeatTreatmentCompanies• SpinCastingCompanies• FoundryAreaofActivityDetails

The foundries will also be listed according to what metal they melt (ferrous and non-ferrous) including aluminium, brass,

bronzes, copper, irons, stainless steel, SG/ductile, steels, zinc and mixed metal and whether they are production, jobbing, production and jobbing, in-house, or special foundries.

The foundries will in addition be divided into which province/area they are situated in and production figures of each foundry will be given.

Suppliers company details and suppliers activity detailsA comprehensive listing of supplier’s company details and

supplier’s activity details will also be given. The suppliers will be categorised according to what they supply under the headings Equipment; Consumables; Raw Materials and Metals and Services.

Free listingThere is no cost for a listing. The Castings Industries

Directory is published by BA Crawford Specialised Publications (Pty) Ltd and is distributed to the industry via the castings sa magazine - a specialised journal covering the technology, processes and materials field for castings – and Metalworking News - a specialised journal covering the technology, processors and materials field for forming, shaping and

2015 Castings Industries DirectoryMake sure your company is listed by sending in your details. The deadline for your free listing is the 2nd February 2015.


Foundry Details

Company Name: ________________________________Holding Company: _______________________________Postal Address: _________________________________Street Address: _________________________________ Tel: ____________________________________________ Fax: ___________________________________________ Email: _________________________________________ Website: _______________________________________

ContactsMD: ___________________________________________Sales & Marketing: ______________________________Foundry Contact: ________________________________Buyer: _________________________________________Number of Employees: ___________________________Number of Foundry Related Employees: _____________Type of Foundry: ________________________________Casting process: ________________________________Typical Castings Cast: ____________________________Size of Castings: ________________________________Weight of Castings: ______________________________Tons cast per month (Per metal): ___________________Net weight of castings per month: __________________Ancillary services (Machine shop etc.): ______________Speciality: _____________________________________Accreditation: __________________________________Association/Institute membership: _________________Countries exporting to: ___________________________

Supplier’s details

Company Name: ________________________________Postal Address: _________________________________Street Address: _________________________________Tel: ___________________________________________Fax: ___________________________________________Email: _________________________________________Website: _______________________________________

ContactsMD: ___________________________________________Sales: _________________________________________Marketing: _____________________________________Production: ____________________________________Company activity: _______________________________Speciality: _____________________________________Accreditation: __________________________________Association/Institute membership: _________________Countries exporting to: ___________________________

assembling in the metalworking engineering industry.

Entry deadlineThe basic entry

details are listed below. Please can you email these details back to the publisher by the 2nd February 2015 to ensure that your company details are listed.

Advertising in the Directory

With a shelf life of over two years The 2015 Castings Industries Directory presents an ideal opportunity to get your message across to prospective buyers, both local and abroad. Contact the publishers for further details.

The Directory will also be promoted at the South African Pavilion at GIFA/Newcast, which takes place in Düsseldorf, Germany in June 2015.

The 2015 Castings Industries Directory will be available after publication at R350.00 a copy including Vat and postage.

To ensure that you take advantage of the free listing in the 2015 Castings Industries Directory fill in your relevant company details below, and email them back to the publishers.


A majority stake in South Africa’s Premier Valves Group (PVG) has been acquired by AVK, one of the world’s leading valve manufacturers. The R100 million

investment will see AVK South Africa become compliant with the DTI’s new Designation Law, requiring State Owned Entities to buy locally manufactured products with a 70% local content.

PVG’s existing factory in Alrode Johannesburg will be upgraded with new machines, facilities and buildings, creating 80 new jobs. AVK will also set up a modern state-of-the-art resilient seal valve (RSV) manufacturing unit at the Alrode plant producing up to 80 000 RSV’s per year.

“Thisacquisitionrepresentsasubstantial,confidence-boosting, inward investment by one of the world’s leading valvemanufacturers.ThisatteststotheefficacyofDTIpolicy aimed at re-industrialising South Africa to meet the requirements of its state owned enterprises and infrastructure spend by providing large volumes of world-class, competitively priced valves locally, defraying concerns over quality, capacity and delivery time,” said Tjaart van der Walt, Director, AVK Holding Southern Africa.

PVG is one of South Africa’s largest and longest established valve manufacturers. Whilst PVG supplied many of the valves in South Africa’s major power stations and water

infrastructure projects, cheap imports from China prior to the DTI’s designation of valves for local content forced PVG to downsize and import valves to survive.

PVG is now in the process of re-building its productive capacity in support of the DTI’s policies. Selling a majority staketoAVKwillprovidePVGthefinanceandtechnicalsupport to meet the needs of South Africa’s state owned enterprises for local content procurement.

AVK is one of the world’s leading valve manufacturers with manufacturing operations in nine countries. The company has a net turnover of approximately ZAR 6.4 billion and is present in 80 countries.

“AVK is committed to making a substantive phased investment in commencing local manufacture of its range ofworld-classvalvesandflowcontrolfittings,and,atthesame time, expanding the manufacturing capacity of PVG’s products,” said van der Walt.

AVK’s investment will fund the creation of a new international standard for local production capacity in support of the DTI’s designation policy, creating new employment opportunities through the value chain. The AVK investment will also introduce the latest international production technology and green processes totheSouthAfricanindustry.Knock-onbenefitswill

include the acceleration of green technology as skills and high tech production and foundry capacity are made available to non-valve sub-suppliers and external customers.

Increased local production as a result of AVK’s investment is anticipated to have a, “sales value of up to R400 million per annum – being the value of import substitution plus additional exports delivered through AVK’s international sales network,” added van der Walt.

AVK is also considering the feasibility of establishing an advanced green foundry in South Africa. This offers the potential for a further R300 million investment in plant while introducing new skills to the industry and creating more jobs.

Peter Thomson, Managing Director of PVG for the past 10 years will remain as Managing Director of PVG. He will also be a Director of AVK Holding Southern Africa. PVG’s range of products will continue to be marketed under its own brand. Brian McGugen has been appointed as the new Managing Director of AVK Southern Africa, producing and marketing AVK branded products as AVK Valves Southern Africa. The two companies will work closely together to expand and strengthen the overall position of AVK in the Southern African market.

About AVK GroupThe AVK Group is a privately owned industrial group that

currently comprises 77 companies. AVK’s core business is the production of valves, hydrants and accessories for the water and gas distribution network, sewage treatment and fireprotection.Furthermore,AVKhasbuiltupstrongbrandssupplying valves and controls for water treatment, dams and reservoirs, HVAC, chemical processing, marine and other industrial sectors. AVK products are designed to international standards and are sold in more than 80 countries worldwide.

About Premier Valves GroupPremier Valves (Pty) Ltd is a privately owned

company that has grown over a period of more than 50 years to become one of the largest manufacturers and suppliers of valves for the water industry in Southern Africa. Premier’s 22,000 square meter factory premises in Alrode, Johannesburg obtained its ISO 9001 Accreditation in 1996, and is well known for both the manufacture and repair of large bore valves of up to DN3000.

For further details contact Premier Valves on TEL: 011 908 3760 or visit www.premiervalves.com

Premier Valves acquired by Denmark’s AVK

Global valve giant invests R100 million in local manufacturer.


AVK is also considering the feasibility of establishing an advanced green foundry in South Africa. This offers the potential for a further

R300 million investment in plant while introducing new skills to the industry and creating more jobs

Air Products is making an impact in the Eastern Cape and creating employment and business opportunities alongside economic advantages for local industry

withitsR300millioninvestmentintheprovince’sfirstairseparation unit (ASU).

Construction and installation of the plant in the Coega Industrial Development Zone (IDZ) will have created approximately 120 jobs by the time it is commissioned in the fourth quarter of 2014, said Air Products onsites project manager Robert du Pisanie.

The new plant will supply industrial gases, in particular oxygen and nitrogen, to Air Products’ established Eastern Cape customer base. It will also open up opportunities for entry into new markets with a series of new prospective clients showing increased interest in the company’s expanded – and more affordable – offering locally.

The reasons foundries use oxygen enrichment are not complicated. Blast air normally contains 78% nitrogen and 21%

oxygen, with the balance being other inert gases. Coke reacts with the oxygen in the blast air, creating heat that melts the charge material. However, the nitrogen representing more than 75% of the volume contributes nothing to the combustion reaction. In fact, nitrogen in the blast air reduces

theoverallefficiencyinthecupola since it takes heat away from the melting process and is exhausted through the flue.Byimplementingoxygenenriched air, as the oxygen percentage increases, the percentage of nitrogen decreases,theflametemperature and available heat increase, and the heat transfer rate increases.

Thefirstofitskindintheprovince, the ASU will bring security of supply to industry that previously relied on gas being trucked cross-country

by road. It will produce 110 tons of liquid nitrogen and oxygen per day and has been built with the capacity to scale-up production to meet market demand.

The project has also created opportunities for local small and medium enterprises (SMEs), consultants and contractors. Du Pisanie said the civil works were “100% implemented by Eastern Cape contractors”, with the lion’s share of the engineering and design work also done by local consultants.

He added the company was committed to pushing as much as possible of the Air Products investment into the Eastern Cape.

“An air separation unit is a highly specialised, technical operation and, out of necessity, most of the components have to be imported. However, in terms of construction materials, wehavesourcedasignificantproportionfromEasternCapesuppliers,” he said.

In addition to employment created during construction and the electrical and mechanical installation phases, the plant itself will employ between 10 and 15 people once operational.

“Thesignificantimpacthoweverisinthelocaland regional value chains where security of supply and the support of our world-class technologies enabling customers to improve processes and competitiveness, will unlock business opportunities and support employment,” Air Products managing director Mike Hellyar said.

He said Air Products had made a strategic decision to locate an air separation unit in the Coega IDZ based on promising economic and industrial growth in the Eastern Cape, particularly the pipeline for mega-projects at Coega, and growing demand for industrial gases in diverse sectors from automotive to agro-processing, food and beverage, renewable energy and pharmaceuticals.

The project is well on track for completion in the fourth quarterofthisyear,withgassettoflowtocustomersbeforethe end of 2014.

ForfurtherdetailscontactAirProductsheadofficeon TEL: 011 570 500 or visit www.airproductsafrica.co.za

Air Products to open Eastern Cape air separation unit



310 foundrymen, guests, wives and award winners attended this year’s event. Conrad Koch and his puppet Chester provided the entertainment for the evening.

The dinner was well supported by sponsors in the form of prizes for the award winners, wine on the tables and ticket sponsors for VIP guests invited by the Institute.

The SAIF would like to thank the following sponsors for their valuable contributions to help make the evening a success: Saveway Furnace Monitoring, Foseco South Africa, Insimbi Refractory and Alloy Supply, Sasol Synfuels Procurement and Marketing, Morgan Thermal Ceramics, LIL Sales,LaudsFoundryEquipment,SIGroupHA,IMPScientific,Thos Begbie and Kimberley Engineering Works.

Awards handed out on the evening were as follows:• PastPresident’sAward-EnnoKrueger• Non-MemberDiploma-DrMarkAinsworthforthe

best technical paper presented to the Institute

during 2013 by a non-member: “The Fundamentals of Lost Foam Process”

• ColinButlerAward-MikeWolhuterforthebest technical presentation presented by a SAIF member during 2013

• AHGuyAward-AdrieElMohamadi• HonoraryMemberAward-JohnBryson• InsimbiRefractoryandAlloySupplies/SasolSynfuels

Procurement & Marketing Award - Miteo Muzeu of Tshwane University of Technology for the highest marks achieved by a 1st year metallurgy student for 2013

• FosecoAward-NkutwaneMokoanaofUniversityof Johannesburg for the highest marks achieved by a finalyearmetallurgystudentfor2013

• SpecialAward-HelenDlaminiforcompletion of the required modules in the Diploma Course Programme

SAIF’s 51st Annual Awards DinnerThe South African Institute of Foundrymens’ 51st Annual Awards Dinner

was held at the Emperors Palace, Convention Centre, Kempton Park, Gauteng on Friday 30 May 2014.

Front row Ronel and Dennis Baker of Chemsystems, Delmari McQueen of Guestro, Anna and Paul Oliaro of

Chemsystems and back row Eric Mathiesson and Jacques Swanepoel, both of Chemsystems

Emile Timmins, Ronnie de Fin and Freek Viljoen, all of Scaw Metals

Angus Singleton and Graham Smith of Pressure Die Castings, David Makhafola of Pfisterer South Africa, Ash Roopchand

of Pressure Die Castings, Thergen Naidoo of Pfisterer South Africa, Mike Stephenson and

HRH Lance Deysel, both of Pressure Die Castings

Guarin Miles of Sulzer, Wilma Buys of KEW Foundries, Wendy and Rob Lolli of R.I.L. Hydraulics, Danie Steyn and Harry Hills,

both of Sulzer

Arrie Schriek of Volclay, Rui Dias of Endeco, Pat Riley of Scaw Metals and

Mike Holton

Damon Symondson of Scaw Metals, Nino Ciani of SI Group HA and Victor Dias

of Endeco

Terence van Niekerk of Saveway, Madelaine De Bruyn, Karien du Plooy of Saveway and Mart and Johan Potgieter of Tips Consultants

Desiree and Jan van Heerden of Fry’s Metals, Marie Samons of Insimbi Alloys, Frik Geyser of Copalcor with Len Hutton, Dudley De Beer

and Cornetta Rautenbach, all of Insimbi Alloys

Barry Keech of Keech Controllers with Phil Mehigan and Ian Gibson, both of Relyintracast

Byron and Rob van Niekerk of RC Systems with Neville Saunders of FP Speciality

Eddie Short and Marius and Mrs van Tonder, all of Morgan Advanced Materials

Ray van Rooyen of Insimbi Alloys, Jim Christopher of Auto Industrial Isando

and Greg Wurts of Insimbi Alloys

Current SAIF President Takalani Madzivhandila presenting Emile Timmins the Non-Member

Diploma for the best technical paper presented to the SAIF during 2013, by a non-member.

Emile accepted the award on behalf of Dr Mark Ainsworth of Scaw Metals

Current SAIF President Takalani Madzivhandila with Past President

Enno Krueger

Stephen O’Reilly and Andy Struppmann with Kevin and Nicolle van Niekerk, all of

Lauds Foundry Equipment


Left: Miteo Muzeu of Tshwane University of Technology received the Insimbi Refractory and Alloy Supplies / Sasol Synfuels Procurement and Marketing Award for the highest marks achieved by a 1st year Metallurgy Student for 2013. He is seen with Dudley de Beer of Insimbi Alloys

Right: Mark Wynn hands over the Foseco Award, for the highest marks achieved by a final year metallurgy student for 2013, to Nkutwane

Mokoana of University of Johannesburg

Eddie Short of Morgan Advanced Materials presented the Colin Butler Award to

Mike Wolhuter of Pressure Die Casting for the best technical presentation by a SAIF Member presented during 2013

Adrie El Mohamadi of Shareek Consulting Services was awarded

the AH Guy Award

Honorary Membership was awarded to John Bryson

of Kimberley Engineering Works



A special award was made to Helen Dlamini of Scaw Metals for the completion of the re-

quired modules in the Diploma Course Programme. She is seen with SAIF CEO

John Davies and Takalani Madzivhandila

Jan van Heerden of Fry’s Metals with his daughter Janley Kotze of Ceramic and Alloy Specialists. Janley is also the

current SAIF Vice President

Gordon McNeilage, Faan Roos, Colleen Boyce, Steve Pyke and Nino Ciani all of SI Group HA

Fubio Ciani and Derick Elliot both of Procor, Cobus van der Walt of Knights Sales and Stefan Strydom of Wanderers Engineering

Roxanna Cabaco, CJ Lindeque of Lauds Foundry Equipment, Garth and Angie Sinclair of Metlink, Grant and Greg Estman, both of Viking Foundry,

Colin Smit of MIS Engineering, Trevor and Jane Sinclair of Comproc

All the President’s men – past and present - Enno Krueger, Bruce Crawford, Takalani Madzivhandila, Marc Hindle

and John Davies

Rob Hallaby of Aluminium Copper Processors, Graham Hardisty and Gary Coull, both of Zealous Automotive Castings, Alex Saam

of Fochem and Jacques Smith of Henkel

Darren Brown of F&PS, Brian Clough and Wouter Retief, both of Ceramic and Alloy Specialists, John Taylor of Spectro Analytical, Peter Peyerl of

Scaw Metals with Brian and Gary Kimble, both of Windsor Metals

Eric Benvenuti of MIS, Colleen Boyce of SI Group HA and Peter Forbes

of Forbes Foundry


international news

Omega Foundry Machinery Ltd celebrated its 30th anniversary in June with 150 staff, clients and guests and agents from around the world. The

festivitiesbeganwithatourofthecompany’sheadofficefacility in Morley Way, Peterborough, which is situated in the county of Cambridgeshire in the east of England, followed by lunch. In the evening guests were invited to a medieval themed event at Belvoir Castle, north of Peterborough. For the evening event the international guests were asked to wear their national dress.

“The 31 countries represented at the 30th anniversary celebrations for a global no-bake equipment supplier are testament to what the company has achieved in just three decades,” said the company’s chairman Mark Fenyes.

The company was originally known as Baker Perkins and began to function independently in 1984 after a successful management buy-out, headed up by Fenyes. Since then, the company has continued to specialise in the manufacture of equipment for the ‘chemically bonded’ or ‘no-bake’ process in the foundry industry.

Feynes himself has been in the foundry industry for all of his working career, having started off as a sand technician at Renishaw Foundry in the UK.

“I left school at 16 and started work at the foundry in Sheffieldasametallurgicaltrainee.AtthesametimeIwenttonightschoolatthelocalcollegeandqualifiedasametallurgistafter six years.”

“I then left the foundry and joined a supplier to the industry and was based in Birmingham for some time before being sent totheUSAonayear’scontractthatlastedfive.”

“The opportunity to join Omega as MD then came up and I moved back to the UK. A year later I led a management buy-out to take over the company.”

So began a “long and happy relationship” he told clients, agents, staff and fellow foundry personnel gathered to celebrate the milestone anniversary of the company.

“Our desire within the company has always been to “be the best”. From an initial compliment of 12 staff the company now employs 230 people, manufacturing a range of mould handling, sand mixing and reclamation, core making and ancillary equipment.”

“In the last 30 years Omega has acquired or formed several strategic companies.

Besides Peterborough our equipment is also manufactured andservicedinfiveothercountries.TheseincludeRichardsEngineering Ltd (founded 1873), which was acquired in 2009 and is a manufacturer of thermal sand processing equipment, Tinker Omega, which is a USA based JV serving North and South America, Omega Sane Foundry Machinery PVT Ltd, an Indian based JV serving the local markets in and around India and WES Omega Foundry Machinery PTY, an Australian based JV serving the local and other markets in the region.”

Omega invested four million pounds to relocate to new premises in Woodston, Peterbourough, UK, which it moved into in June 2012. “It was really to consolidate the manufacturing. WehadfivelocationsaroundPeterboroughandIthinkit’sbetter for the workforce to combine into one area. That was the main reason, to get everyone under one roof,” said Fenyes.

In 2013 Omega, which has had strong ties with Japan-based metalcasting equipment maker Sintokogio Ltd. for more than seven years through a license agreement to manufacture and market the “USR” range of Sinto’s secondary reclamation units, announced an enhancement of the strategic alliance. The alliance is intended to increase the range of products manufactured under license by Omega, further penetrate nobake markets, and improve service and support.

“We have also sponsored Peterborough United Football Club, who are a professional English football side in the League One division, for eight seasons.”

Current World Foundry Organisation president Vinod Kapur, who has represented Omega in India for over 20 years, gave a keynote address.

“Mark is a man with a vision and a passion for the foundry industry. You have to love your work and he does. His strength is also that he gets involved with his head, heart and hands,” Kapur said.

“I am very fortunate to have a great team of people at Omega who have diligently worked to make the company what it is today,” said Fenyes.

For further details contact Mondeco Solutions on cell 079 448 1277 or email [email protected] or visit www.mondeco.co.za

Omega celebrates 30th anniversaryRepresentatives and guests from all over the world attend function in Peterborough (UK).

Chairman Mark Fenyes addressing clients, agents, guests and staff on the occasion of Omega Foundry Machinery Ltd’s 30th anniversary

Local agent Peter Petersen of Mondeco Solutions attended the celebrations

with current World Foundry Organisation president Vinod Kapur, who has represented

Omega in India for over 20 years


Individuals responsible for the Kunkel-Wagner process technology have applied for insolvency proceedings at the district court in Hildesheim. As provisional liquidator, the court

has ordered Attorney Christopher Seagon from Heidelberg. Seagon is currently engaged to assess the economic

situation and reorganizational possibilities for the company. "It’s still too early toreleasespecificinformation," said Seagon.Thefirstaimisfirsttokeepthebusiness running stable in order to ensure the process of existing contracts and projects.

Künkel-Wagner was established in 1907 as a mechanical engineering company specialising in foundry technology. Since then, the headquarters of the internationally operating company including administration, a

research and development division, fabrication division and project management has been located in Alfeld near Hanover, Germany.

Sincetheconstructionoftheveryfirsthandmouldingmachines in the year 1911, Künkel-Wagner has developed a wide range of foundry equipment.

In the late 1950s, Künkel-Wagner wasoneofthefirstcompanies offering fully automatic moulding plants. Innovative moulding techniques were developed and the firstalternativestojolt-squeeze moulding machines were presented, followed by integrated moulding sand preparation equipment, core sand separation, simple casting machines and automatic pouring equipment.

Künkel Wagner files for bankruptcy

Seagon is currently engaged to assess the economic situation and reorganizational

possibilities for the company

During the Metal + Metallurgy China fair, ASK Chemicals, international supplier of high-performance foundry consumables,launcheditsfirstChineseASKChemicals

Casting Academy with a comprehensive lecture program. In addition to the company’s own expertise in products and technologies, the one-day event featured lectures on core production at Mingzhi Technology and on supplier excellence in the automotive industry by the example of Audi AG. The opening event met with great response from customers. The global player ASK Chemicals is planning to establish the newly launched ASK Chemicals Casting Academy as a yearly platform for exchanging knowledge in China.

The experts at ASK Chemicals have many years of experience in all steps of the manufacturing processes in a modern foundry. This is why the company has long since established itself as a competent partner in process support and as process consultants. Another reason for sharing this knowledge in an appropriate setting is that technological progress and the development of high-performance castings depend on the intensive exchange of information about innovations and their applications.

ASK Chemicals is building this bridge with its new ASK Chemicals Casting Academy in China, which is planned to take place every year. The day’s program started with nine lectures on the application of coatings and additives, inorganic binders, no-bake binders, including experience reports, and the company’s design services. Dr. Roman Viets from Audi AG, Germany, gave a lecture on the topic of

“Audi engine castings – request for supplier excellence”, and Qiu He from Mingzhi Technology presented new possibilities for core production in his lecture entitled “Inorganic core making machine – opening the door to Chinese green casting”.

Jay Tang, Managing Director of ASK Chemicals China, emphasised the importance of this form of knowledge transfer for the Chinese foundry industry. “The goal of our academy is to promote networking between Chinese foundrymen, thereby actively exchanging current knowledge and making it tangible,” said Jay Tang.

ASK Chemicals launches Casting Academy at the Metal + Metallurgy China Fair in Beijing, China

The International Magnesium Association (IMA) recognized advances in magnesium technology, products and processes in the 2014 Awards of Excellence and

International Environmental Responsibility Award competitions during the 71st Annual World Magnesium Conference held in Munich, Germany in June.

The Awards of Excellence competition was open to all companies demonstrating outstanding examples of magnesium's use, as well as magnesium products and manufacturing technologies in three categories: Design, Process, and Application.

The Environmental Responsibility Award is based on the achieved and documented reduction of carbon dioxide equivalents (CO2eq), and is intended to include all aspects of the magnesium industry from primary production through to end-user industries. The IMA Awards of Excellence highlight how the magnesium industry is continually working to improve the manufacturing process and companies that provide innovative and improved products made from lightweight magnesium.

The Design Category includes subcategories for cast and wrought products and the competition seeks unique, novel and creative designs and product developments. The winning entries in this category demonstrate design and engineering thatisasignificantadvanceovercurrentpractice.

The Award of Excellence in the Design-Cast Product

Automotive Category was presented to Georg Fischer GmbH & Co KG in Altenmarkt, Austria for an oil conduit module used in the powertrain of the Porsche Panamera. The part made using the magnesium high-pressure die casting process was developed with partner GF Automotive AG in Schaffhausen, Switzerland.

"The oil conduct module is situated below the engine bloc of a combustion engine. It contains the oil reservoir and the attachmentpointsfortheoilfilterandoilcooler.Themoduleintegratesthebackandforwardflowofthelubricationoilofthe engine and ensures the degasing of the oil. The possibility to integrate many functions and attachment points and the chance to reduce weight [led] to the choice of a Magnesium die casting," noted the company in their entry.

Theoilconductmoduleisthefirstofitskindproducedwithcreep resistant magnesium alloy (MgAl4Re4), resulting in 1 kg of weight saving compared to the previous aluminium part. The magnesium design features 100% casted oil ducts, and a finishedcastedsealingcontourfortheoil-water-heatexchanger.The manufacturing process included casting, machining and assembly of the component. The supplier delivered the module completewithoil-water-heatexchanger,oilfilter,reductionpieceand other small parts to their customer, Porsche.

Lightweight design of GF Automotive wins the design award at the IMA Awards 2014

The first ASK Chemicals Casting Academy in China aroused great interest



No castle in the sand - 3D printing supports casting

But that most established and traditional of processes, sandcasting,isalsoabeneficiaryofthetechnology,although it is currently a very exclusive club.

One member is £35 million turnover Grainger & Worrall. Indeed, the installation at the company's Bridgnorth, Shropshire, UK headquarters of an Exone S-Print HHS (now renamed S-Print Phenol)wasthefirstcommercialinstallationinEurope,whenthe machine was delivered at the end of 2012. And today there are just four installations in Europe – two commercial; two non-commercial – for this £500,000 sand-printing equipment, which is used to rapidly produce sand cores, so avoiding the design and manufacture of hard tooling.

Established in 1946 as a pattern maker, by Vernon Grainger and Charles Worrall, under second generation Grainger family ownership (the Worralls exited early), the company, led by Pat Grainger (now chairman), moved into casting during the 1980s. Subsequently, the third generation of James, Matthew and Edward Grainger has driven further into the casting engineering, casting and casting machining total package area, targeting prototype and low volume series production at a global level. Today, the 500-employee company boasts representation in the USA, its largest export market, China, Italy and Germany.

"It was never a strategy to compete in the volume area. We had the opportunity to move into it, but didn't. It would have been a mistake, if we had. That work is best left to low-cost economies," offers executive manager, head of engineering, Keith Denholm, who, in underlining the nature of the company's work, adds: "For the most part, we're doing things that haven't beendonebefore."Andthemeasureofitsglobalsignificanceisthat it typically competes with just two or three other companies when bidding for work around the world, much of which now emanates from China.

Grainger&Worrall'sfieldofexpertisecentreson,butisnotexclusively, automotive powertrain activity, including high grade cast iron 6-cylinder truck engine blocks at the heavy end of its work spectrum (about 400 kg). Most work is in aluminium, but stainless steel and cast iron, including compact graphite iron, feature, too. Some 60% of part numbers delivered are supplied fullymachined,MrDenholmreveals,addingthatthisisareflection of the market's desire for single-source supply. Indeed, the company acquired a Telford machinist in 2006, although machining isn't all carried out in-house. As a matter of policy, some will take place overseas – "to maintain customer involvement and provide customer access", the head of engineering offers.

Premiere league player The list of its top-end clients, who inhabit the F1, supercar

and premiere luxury automotive market segments, for example, plus its direct-to-line supply of series produced, assembled, fully tested and packaged aluminium engine blocks for a famous UK-headquartered luxury brand, offer strong proof of its premiere league credentials.

Outside of automotive powertrain, the company also makes structural elements for prototype automotive body-in-white duties, with 4x4 vehicles, for example, making use of complex

3D castings to give strength to the body, although they may be encased in sheet metal, so not visible. (For production, these would be pressure die-cast.) Says Mr Denholm: "There is a big growth in that market. Prestige vehicles have more castings beneath the skin than you might imagine." As for the move towards electric vehicles, while there may be fewer block and head castings, others will take their place, including those for in-wheel motors, complex driverless systems and challenging 4x4 technology. "There won't be fewer castings, but different castings. And the requirements might change: instead of having to deal with heat, they will have to be lightweight; instead of containing oil, they'll have to contain sound, for example."

The aerospace market is also a customer. Previously, this was jet engine ancillaries, but now includes light aircraft piston engines, which are similar in technology to automotive engines and need to be lightweight, well made and durable. In the defence sector, the company offers a lower cost one-piece option versus multi-part fabrications.

Grainger & Worrall's Bridgnorth factory is not a homogenous operation, but instead houses a number of "small and nimble" businesses that "remain focused and excel, attracting high valuework".Indeed,therearethreedistinct,definedbusinessunits on the Shropshire site – prototyping (which is Mr Denholm's area of responsibility), series production (batches of 500-5,000/annum) and motorsport (batches of 50-500/annum).

The proportion of business split across these three can vary, but, currently, the split is around one half in prototyping, withafifthtakenbymotorsportandthenseriesproductionaccounting for the rest, the latter seeing 90,000 castings produced annually. The S-Print HHS investment supports the prototyping operation, which has also seen investment in a further prototyping foundry at Bridgnorth, bringing the total number of lines to six – one for cast iron and stainless steel parts; one for motorsport parts, using the Cosworth pressure-pumped method; and four gravity-fed aluminium lines, one of which is given over to prototype parts, the other three to small series production.

There's a real buzz around 3D printing these days – the production of plastic or metal parts by fusing layers of material, driven from 3D CAD data.

Engine blocks for the Bentley Mulsanne is one of the prestige projects Grainger & Worrall is involved with

Prototyping defined Prototyping sees batches of 1 through to 1,000 castings

produced, with these made in any of the materials processed by the company. The majority of this prototype work is automotive-focused, with development driven by the push to reduce CO2 emissions, which means reduction in both size and weight, leading to a corresponding increase in unit loads, pressures, torque and power density, Mr Denholm explains. As a result, the prototyping area takes in much work that is effectively "R&D and risky".

To understand the pressures on automotive supply companies to support fast prototype development, the head of engineering offers that, 20 years ago, a project would take 36-48 months to take from drawing board to a design ready for production. "Today, you have 12 months to do everything, so we have deployed technology to help us achieve that." And the investment in the sand printer is a part of that.

"The technology isn't new. It has developed over the last 10 years, but it wasn't able to do what we wanted it to do. Then, in 2012, we considered that the technology had developed far enough and that it was now appropriate to our mixed needs, so we installed it, in Q4 2012." The company previously used a similar, but not identical, machine installed at CTI, which is located at the Advanced Manufacturing Park near Rotherham, on a subcontract basis.

The casting process The S-Print HHS is used for prototype core production

(patterns for the external part contours, which are easier to make, are still produced via the traditional route). The machine, driven by CAD data, puts down layers of 0.2 mm thickness from, depending on requirement, a variety of sand mixes, with a layer put down every 40 sec.

The machine at Grainger & Worrall can employ a phenol bonding system, which remains strong at elevated temperatures

(the CTI system is not a phenol system). The phenol system requires pre-heated sand, with cores subsequently cured to fully realise the high bond strength. While this is currently typically only required for steel parts (turbocharger and exhaust parts), with castings getting smaller and channel dimensions shrinking proportionately, Mr Denholm explains that the phenol capability willfindwideruseinthefuture,sothisinvestmentoffers"futureproofingintheareaofhighperformancecastings",whileitalsodelivers "the lowest gas castings on the planet".

Fundamentally, the system at Grainger & Worrall underpins very fast turn-around prototype casting manufacture, plus it offers a capability to produce complex cores that might otherwise demand multi-part cores. Multi-part cores obviously offerpotentialformisalignmenterrorsand/orflashorwitnessat joints.

So, from receipt of CAD data, the company could be casting within 24 hours. For a steel turbocharger core, that is, say, two hourspercore;10hourspercompletedboxoffivecores(thebox measures 800 by 500 by 400 mm); plus 2 hours to cure. The traditional route, which would require the CAD-based design of tooling, plus its manufacture, would likely see cast parts not available within a week. "Now, we don't need to turn parts round in 24 hours, but part of our business requires us to be able to do so within two or three days," offers Mr Denholm, adding: "Before we couldn't do that; now we can." As at Machinery's visit, the company had undertaken some 150+ projects using the S-Print HHS, with heads, blocks and turbochargers the main focus of that.

Not always fastest For repeat parts, however, tooling has the edge, since

producing cores from hard tooling offers a faster production cycle.Insteadof,say,fivesetsofcoresin10hours,itwouldbepossible to make 100 with tooling.

So 3D sand printing is not a major threat to established

Pouring cylinder block castings

Keith Denholm in front of the S-Print HHS, holding a core

produced by the machine


techniques, except in the area of rapid turn-around prototyping or very complex cores, although Mr Denholm does not rule out the possibility of the company having multiple sand printers in the future.

Of course, rapid prototype core production is no good without a comparably fast method of checking parts, it is suggested. So complementing the sand printer investment has been additional spend on metrology kit, housed in an adjacent area. Grainger & Worrall now boasts two Yxlon CT machines – these take X-Ray slices through castings – which are able to measure at a rate of 19 sec/mm or 42 sec/mm, depending on the desired resolution of measurement. There is a limit, in terms of dimensional size and weight, so a GOM vision system is also available, as are more traditional CMMs.

Ceramic cores Grainger & Worrell has worked with

Southwest Research Institute based in San Antonioto, Texas, US to develop the application of hybrid ceramic-sand core casting technology. The interest level in this will grow over coming years, suggests Mr Denholm, as the push to smaller, lighter castings gathers further pace. Ceramic-sand remains stable at higher temperatures and thinner sections than does normal sand, but its drawback is a lower rate of heat transfer.

The project looked to see what, for example, would be the smallest cast passageway achievable with ceramic-sand for a

cast iron part. It turned out that, unexpectedly, a passageway of just 1 mm width (requiring a core of 1 mm cross-section) can be produced via this technique - Mr Denholm says that this was thought doubtful at the outset. He adds that this technique, forwhichthecompanyisajointpatentholderon,willfinditsway into use at Grainger & Worrall, but that it is not yet fully industrialised. When it is, very few companies will be able to offer the service, however.

UK castings industry According to the Cast Metals Federation,

the UK makes around a billion metal castings every year. Some weigh over 300 tons, while others are less than one gram. The UK foundry industry has bounced back after the extraordinary dip in all manufacturing in the 2008-10 recession, with the expectation that 2013's output will be around pre recession 2008 levels of turnover by both tonnage and value.Theheadlinefiguresfor2012outputare that there are 400 Foundries in the UK producing 523,000 tons of castings, with a turnover of £2.2 billion and employing 17,000 people.

Averagingthefiguresforallcompaniesmeans that each company employs 42 and turns over £5.5 million, which puts Grainger & Worrall at the top end of the industry, with

500 employees and £35 million respectively.

First published in Machinery, January 2014

Complex cores such as this are more easily produced using the sand printer


product review

Since Selee introduced the first silicon carbide based ceramic foam filter in the late 1980s, the product line has grown substantially and the company has delivered

hundreds of millions of these filters into a variety of casting applications.

This filter has gone through some improvements over the years, and Selee’s latest silicon carbide offering has been the “Selee IB” formulation introduced in 2002, which is considered by many foundries to have the highest hot strength of any silicon carbide based filter on the market.

Now Selee are introducing an aluminosilicate-based foundry filter. One of the biggest reasons for this change stems from the fact that the production of silicon carbide powder is a costly, environmentally unfriendly process with a significant portion of the world’s supply coming from China. In mid-2008, Chinese governmental export policies and local supply/demand dynamics resulted in dramatic price increases and declining availability. Since that time, conditions have eased somewhat, but remain volatile and unpredictable. These events mobilised Selee to embark on a new product development program in order to protect its customers from price increases and filter shortages.

A significant amount of time and resources were devoted to the program, and in January 2010 Selee developed “Selee IC™”, an aluminosilicate-based filter that was completely free of silicon carbide, yet capable of meeting the thermal shock and refractoriness challenges of iron and aluminium foundry filtration applications.

Aluminosilicate does not have a thermal conductivity equivalent to silicon carbide, but its thermal expansion is equivalent, and its refractoriness is quite good. These attributes, combined with a newly engineered ceramic formulation, enabled the creation of a product that is equal in performance with a far more stable supply chain. All aluminosilicate powder for this product is sourced in the

United States, which eliminates the impact of ocean freight costs, exchange rate fluctuations and political risks to the company’s USA-based plant.

Through extensive characterisation and testing of this filter, there is evidence suggesting that liquid slags tend to wet and adhere better to the surface of Selee IC relative to silicon carbide.

Figure 1 displays micrographs of spent IB and IC filters run under similar conditions in molten iron. In the micrograph on the left, the slag poorly wets the silicon carbide structure and does not penetrate into the ceramic, whereas in the micrograph on the right, the slag wets the surface of the Selee IC filter quite well and actually penetrates slightly into the intergranular porosity. Figure 2 additionally demonstrates the effectiveness of the Selee IC filter in capturing liquid slag.

In this particular case, the slag wets the ceramic so well that it even spans across ceramic struts.

Selee and Ceramic and Alloy Specialists (CAS), the South African distributors of Selee’s products, have been partners in the iron and aluminium filtration market in South Africa for nearly two decades.

For further details contact Ceramic and Alloy Specialists on TEL: 011 894 3039 or visit www.ceramicalloy.co.za or www.selee.com

Selee IC™ aluminosilicate-based ceramic foam filters

Figure 1 displays micrographs of spent IB and IC filters run under similar conditions in molten iron. In the micrograph on the left, the slag poorly wets the silicon carbide structure and does not penetrate into the ceramic, whereas in the micrograph on the right, the slag wets the surface of the Selee IC filter quite well and

actually penetrates slightly into the intergranular porosity

Figure 2 additionally demonstrates the effectiveness of the Selee IC filter in capturing liquid slag. In this particular case, the slag

wets the ceramic so well that it even spans across ceramic struts


Radioactive sources can find their way into scrap and recycling yards through both naturally occurring radioactive sources, such as scale on pipes in the oil

and gas industry and through orphaned industrial sources. Turning away a load could jeopardise a supplier relationship that has been built through extensive efforts. Facilities in this situation have an interest not only in protecting their personnel, but also in protecting their own facility as well as their business relationships. The subsequent passing on and melting of an orphaned source can result in millions of rands in lost revenue and clean-up expenses.

The RadEye PRD is the next generation of advanced radiation meters. Thermo Scientific’s newest Personnel Radiation Detector (PRD) was developed in response to a growing need for smaller, more compact detectors, which have even more sensitivity to unwelcome radioactive sources. The RadEye PRD represents a high-performance measuring device designed to be used in conjunction with a vehicle monitoring system, for persons who are responsible for detecting and localising radiation sources, such as scale operators, scrap inspectors or quality control personnel.

The RadEye PRD is a low-cost and convenient tool for helping to detect and locate orphaned sources or problematic NORM related sources. For example, if a small or well-shielded radiation source is deeply embedded in the scrap load it may pass through a vehicle monitoring system undetected. However,

when the surrounding scrap is removed during the unloading process, the small RadEye unit, worn by key personnel, offers a most efficient second line of defence. With the RadEye worn on a belt holster, personnel are always in a position to locate an unwanted radioactive source.

The RadEye weighs a few hundred grams, and is about the size of a pager. The characteristic features are the use of

sophisticated low-power technology components and fully automatic self-checks, which result in minimum maintenance. It is one of the only instruments of this size, which is able to compensate for the variations of the natural background that is present in most locations, thus full sensitivity is combined with the virtual absence of any false alarms.

The RadEye PRD incorporates Thermo's NBR technology (natural background rejection). NBR enables the RadEye to have enhanced sensitivity with fewer false alarms. It also gives an indication of whether the source is high energy, low energy or likely to be naturally occurring radioactive material (NORM).

A dedicated optional Windows based GateCheck software and an accompanying reader device is available for downloading scan readings for printing on a radiation certificate, which can then be sent together with the scanned load to the destination.

For further details contact OEN Enterprises on TEL: 011 675 4447 or visit www.oenenterprises.co.za

RadEye PRD radiation meters for use in the recycling and scrap markets

ASK Chemicals has now successfully transferred the established Ecocuretm Solventless (SL) technology to iron casting applications. With this new cold-box technology

from ASK Chemicals, foundries can not only dramatically reduce emissions, but also improve performance.

Thanks to the significant reduction in solvents used in part two of the solventless system, emissions have been reduced throughout the entire process. But Ecocuretm SL for iron casting also offers a number of other impressive performance properties: For example, the production of gas, condensate and smoke is reduced in the casting process thanks to the new technology. In addition, particularly high initial strength and reduced sand sticking are also achieved. The reduced proportion of solvent used in this technology also means that the demand for amines is likewise reduced.

The new system for iron casting has already demon-

strated its strengths. Working hand-in-hand with its customers, ASK Chemicals has successfully adapted the new system to the customers’ specific conditions and requirements, and as a result very soon after the launch of the new system various cast iron components, including brake disks, transmission housings, crank cases and castings for hydraulic systems, are already being manufactured with the new Ecocuretm SL technology.

With all the benefits it offers, the Ecocuretm SL cold-box technology is the perfect solution for meeting all of the current and future requirements of aluminium and iron foundries, particularly in terms of the ever-increasing demand for high-

performance yet eco-friendly cold-box solutions.

If you are interested in finding out how Applied Casting Solutions can give your business the cutting edge, please contact them on TEL: 011 922 1701 or visit the website www.chemsystems.co.za

Ecocuretm Solventless cold-box technology now also available for iron casting applications


The X-Treme R828 is a unique high performance flap grinding disc from Norton, offering a higher and faster metal removal rate than standard products. Designed to

work on both carbon steel and stainless steel, the X-Treme R828 discs can provide a 20% increase in cut rate and 30% increase in product life, according to Norton.

The X-Treme R828 is made using a special polycotton backing designed to offer a consistent wear and a longer life. 100% Norzon grain guarantees a fast and aggressive cut in all conditions. This enables X-Treme to perform at optimal level longer than other zirconia flap discs.

The Norton X-Treme R828 125 mm flap discs are characterised by the latest generation of zirconium abrasive grain, sustainable and innovative binding system and are optimised for controlled abrasion characteristics. The X-Treme discs can be used when working with steel, and are also suitable for stainless steel, inconel, chromium, cobalt, titanium and other difficult to machine materials. The Norton X-Treme flap discs are equipped with a heavy polyester support, for the purpose of additional tool life.

BackingOptimised mix of polyester

and cotton impregnated with new Norton technology resins system offers a perfect support, longer life and comfort during use (less vibration).

Abrasive100% Norzon grain coating offers an extremely high and

consistent cut rate, thanks to the strong and continually sharp grains. Performance and durability are enhanced compared to standard product.

Bonding systemA high performance resin system - developed to be

compatible with the cloth backing - works together with the 100% Norzon grain thus improving grain retention under tough working conditions.

For further information contact Willie Gillan of Norton on TEL: 012 657 2800

Discotom-100/-10 are versatile table top cut-off machines designed to give you a cost-efficient way to expand your cutting capabilities and streamline your cutting processes.

Spacious, versatile and easy-to-use, Discotom-100/-10 deliver exceptional cutting flexibility and more cutting options so you can clamp and cut all types of workpieces efficiently, with less effort and minimum deformation.

Largest cutting table in their classMeasuring 620 x 270 mm, the Discotom cutting table is

almost twice the size of competing machines. A large selection of clamping tools for the 10 mm T-slots make it easy to clamp workpieces of almost any shape or size.

Unmatched user-friendlinessThey are also extremely user-friendly. The icon-based user

interface, the easy to operate turn/push knob and

joystick, the automatic cleaning program AxioWash

and the electric brake ensure easy operation

and reduce the risk for user errors.

Latest cutting technologies

The instrument features the latest in

cutting technology. Discotom-100/-10 offer automatic and manual cutting capabilities. OptiFeed ensures the correct feed speed without compromising cut quality or wheel economy. Combine the manual cutting mode with ExciCut to allow faster cutting of even very hard materials.

Use one of the four MultiCut functions of the optional automatic x-table to cut slices of the same or varying thicknesses, or cut your workpiece precisely in pre-defined positions.

For more information, contact your nearest IMP branch, Gauteng TEL: 011 916 5000, Kwazulu Natal TEL: 031 764 2821, Western Cape TEL: 021 852 6133, Eastern Cape TEL: 041 364 2544, Free State TEL: 018 293 3333 or email [email protected] or visit www.imp.co.za

Expand your cutting capabilities with Discotom-100/-10

Struers’ new automatic and manual cut-off machines are versatile and easy to use.

Norton X-Treme flap grinding discs


Liquefied Petroleum Gas (LPG), a gas mixture consisting primarily of propane (C3H8) and butane (C4H10) – both saturated, chain-type hydrocarbon compounds – normally

occurs as liquid natural gas when crude oil is being pumped from significant depths, or is obtained as a by-product in the crude oil refining process. Propane is non-poisonous, colourless and odourless, and has a mild narcotic effect at high doses. Butane is also colourless and odourless, hardly soluble in water, but slightly soluble in alcohol and ether. In larger doses, butane has a narcotic effect similar to propane.

LPG is liquid at a low pressure level and can be stored and transported in suitable containers. The ignition temperature is around 450 ºC. LPG has a very high temperature expansion coefficient and therefore reacts to every temperature fluctuation with a corresponding change in volume. In certain countries this factor is not taken into account when unloading or dispensing LPG; in other words no appropriate, temperature-dependent correction factor is applied. This generally results in less than favourable terms for consumers.

Multivariable flow measurementThe above issue was recognised early on by

Endress+Hauser who as a consequence developed the LPGmass – a new flow meter designed especially for unloading and dispensing LPG according to the Coriolis measuring principle. This meant that it was finally possible to fulfil the call from various consumer organisations for temperature compensation.

As a multivariable Coriolis flow meter, the LPGmass measures several process variables simultaneously: Mass flow, fluid density and fluid temperature. This means it is possible to display the measured full scale value in volumetric units as well using conversions internal to the device together with the temperature compensation or by taking the API table into account.

The LPGmass is the first flow meter ever to integrate the internationally recognised API table 53 (API = American Petroleum Institute) to take the temperature expansion coefficient into account. API is the largest lobbying association for the oil and gas industry in the USA, including the petrochemical industry. An important part of API’s work is creating technical guidelines and standards. The impact of the API extends far beyond the USA.

The LPGmass was developed primarily for two highly typical and frequently occurring applications:

• Refuellingvehiclesviafueldispensers• DistributingLPGbytrucktosmallconsumerssuch

as small and medium-sized companies.

Other applications for the LPGmass are also entirely feasible such as private residences and blocks of flats.

The large range of nominal diameters from DN 8 to DN 40 allows the customer to select the most suitable measurement device for their application and his flow rates:

• Refuellingvehicles→DN8,DN15,DN25

• Unloading trucks→DN25, DN 40

Unique featuresThe LPGmass sets new standards because safety and

reliability during operation are always given first priority when handling liquefied gas:

• Highoperationalsafetyduetoitsperfect production quality

• Space-saving,exceptionallycompactandrobust design; the ideal replacement for piston dispensers

• Integratedtemperaturesensorasstandardand API conversion table for volume correction for standard volume measurement

• Highlevelofresistancetovibration,e.g.foroperation on trucks

• Nomovingpartsorseals• Excellentmeasuringaccuracythankstotraceable,

accredited calibration facilities• World-wideacceptedEx-approvals• Numerouscustodytransferapprovalsfor

commercial transactions

Simple and safe commissioningThe “FieldCare” configuration and service software from

Endress+Hauser is a simple, dependable way to commission measuring instruments and to modify device parameters. The “Fieldview” add-on module also allows you to visualise measuring data, to display the data in graphical form and evaluate the data for diagnostic purposes, right down to individual measuring points. This means that operators of LPG systems can gain insights into the dispensing process and can optimise this process or track down irregularities if required.

Define and order the right instrument onlineChoosing and ordering the most suitable product for

your application according to industry requirements is now possible in one online workflow with Endress+Hauser. The 24 hour online access to all relevant instrument data simplifies and streamlines the processes from engineering to operations.

The integrated selection and sizing tools in the Online Shop speed up your engineering and purchasing processes. Upon entering your process parameters you are offered a selection of suitable devices. The link to the product database ensures that you have all the up-to-date information, prices and production times to help you make the most appropriate decision.

Speed up supply chainAs soon as you release the order or request a

quotation, the product configuration will be transferred to the local Endress+Hauser contact online. Ordering online facilitates prompt delivery. During maintenance you can easily identify spare parts and order them instantly 24 hours a day. For further details contact Frans van den Berg of Endress+Hauser on TEL: 011 262 8000 or visit www.za.endress.com

LPGmas - The new Coriolis flow meter for LPG with volume correction function

vol 15 no 2 - castings sa › wp-content › uploads › 2014 › castings...6 castings sa vol 15 no...

Documents