Archive: November 29, 2024

Malben Engineering’s passion for excellence wins SEIFSA Environmental Stewardship Award

November 29, 2024

Reflecting its ethos of being ‘passionate about excellence’, Malben Engineering, a pioneering industry trailblazer in the ongoing drive towards sustainable manufacturing in the automotive sector and MIBCO (Motor Industry Bargaining Council) member, has recently been announced as the winner of the Environmental Stewardship category in the SEIFSA Awards For Excellence.

A national federation representing 16 independent employer associations in the metal and engineering industries – with a combined membership of over 1 300 companies employing over 170 000 people – SEIFSA created the Awards For Excellence to honour the brightest and best in the metals and engineering sector. The Awards not only recognise the talent within organisations, but also companies which champion excellence in the face of industry challenges.

Malben Engineering, which celebrates its 50th anniversary this year, is a Level 4 BBBEE supplier of stampings and welding components to local vehicle original equipment manufacturers (OEMs) and other sectors such as mining and construction. The company is also South Africa’s first automotive component manufacturer to trial ‘green’, low-carbon steel, and  recently scored an impressive 98% in an international Responsible Supply Chain Initiative (RSCI) supply chain audit initiated by Ford – the highest score ever achieved by a local supplier and another ‘first’ in South Africa.

Malben Engineering’s Operational Director Luca Smargiasso, notes that the increasing demand for green steel – and the ultimate decarbonisation of the local steel supply chain – will be game-changers for South Africa’s steel and automotive sectors.

“The SEIFSA Environmental award is dedicated to our founder Amerigo Smargiasso, for his inspirational leadership over the past 5 decades, and to our partners in the green steel venture. These are leading German steel and technology group Salzgitter AG and their local representative United Steel Services, which supplied the green steel; and local value-adding steel processor and merchant Allied Steelrode, which facilitated the sourcing and importation thereof.

“Malben Engineering is proud to be at the forefront of the sustainability evolution in South Africa, and see this award as another demonstration of our passion for supplying world-class product. Through agile decision-making and authentic, people-centric values, we are furthermore passionate about innovation and new technologies,” he says.

As such, environmental and sustainability imperatives remain at the core of the company’s operations.

“We would also like to thank our management and staff for their enthusiastic hard work and dedication in establishing, maintaining and continually improving our quality and environmental management systems. These focus on productivity and efficiency, minimising waste and pollution, optimising natural resources and ensuring that we have the flexibility to adapt to the changing needs of our sector and our customers,” Smargiasso concludes.

Galvanizing Africa: the HDGASA’s bridging role in promoting hot dip galvanizing and standards in Africa

November 28, 2024

Africa is poised for massive expansion in the power, energy and communications spheres – and hot dip galvanizing is firmly entrenched as a preferred corrosion control technology in these sectors, according to Robin Clarke, Executive Director of the Hot Dip Galvanizers Association of South Africa (HDGASA).  In light of this, and due to their kettle size and entrenched quality systems, many South African galvanizers are well suited to galvanize large structural articles, enabling them to partner successfully with progressive engineering and construction companies working throughout Africa. Consequently, Clarke points out, sectors such as mining, irrigation and warehousing are well serviced.

“A further area under development – in conjunction with companies specialising in duplex coatings – is hot dip galvanized articles that are over-coated with carefully selected organic coatings,” he adds.

Clarke advises that duplex coatings have extended into the sphere of architectural requirements, or requirements for extra coating thicknesses, in extremely harsh environmental conditions. A good example is that of a façade for a bank in Mozambique, which required exceptional corrosion resistance, as well as specifying aesthetic appeal.

Clarke remarks that, to date, few hot dip galvanizing plants north of South Africa have enjoyed sufficient volumes to allow for sustained utilisation of their facilities or justified investment in equipment and training. Developmental opportunities related to infrastructure spend may change this, particularly if governments promote local content development.

“This requires the HDGASA to consider both the consolidation of our Southern African presence and extending our footprint or influence into the rest of Africa. Although this is a challenge, progress has already been made,” he says. “Through our relationship with multinational consultants, some of whom run offices out of South Africa, the Association has advised on technical issues such as the selection of corrosion control technologies and the setting of specifications and standards during project initiation phases,” he explains.

“Conditions on the continent vary greatly. As a local example the difference in corrosivity between a town in Namaqualand and coastal conditions a mere 200km West, like Oranjemund, is enormous. Similarly, climate and geographic diversity exists in Equatorial and Northern Africa. “There are a number of standards authorities which are concerned that some internationally-funded projects may be vulnerable to poor component supply and workmanship – and want not only to better understand the specifications – but also to apply the correct testing methods, to verify product compliance. We were happy to provide support,” he says.

Troubleshooting in Africa

Unrelated to advisory services rendered by the HDGASA, the Association has also been called on to troubleshoot on coating failures, post plant commissioning. Clarke explains that there are two scenarios where failures typically occur: the first is when contractors forego the correct specifications and purchase sub-standard materials on price and the second occurs when – despite a correct specification – there is no expertise or means of verifying whether compliance exists.

Given the competitiveness of the market into Africa, both issues may become a challenge, he believes: “There are many examples of compliance checks having been performed by the HDGASA – from coating thicknesses of earthing rods in the Sudan to irrigation system pipes for Egypt, heavy structures and sub-assemblies used in mining applications in the DRC to premature corrosion of roof sheeting in new housing complexes in Nigeria,” he enumerates.

Clarke also recalls how the HDGASA was asked to intercept and inspect vehicles carrying materials for an electrical transmission tower in Gaborone, Botswana.

HDGASA’s ‘bridging’ role

Further to compliance-related consulting performed by the HDGASA, a project which epitomised the ideal scenario – in which humanitarian aid, technical assistance and a positive commercial outcome all came together – was the Association’s interaction with an American non-governmental organisation (NGO) that was trying to address extremely hazardous river crossings in remote villages in Africa. “Wooden structures were temporary as their service lives were limited and no effective maintenance programmes were available to ensure safety. We discussed the viability of steel bridges and options related to corrosion control systems required for extended service life, subject to low maintenance scenarios. A further goal was to create upskilling opportunities for those building the bridges.”

The NGO, aptly named ‘Bridges to prosperity’ was able to meet its objectives through the supply of the required rib and plate components.

“The above example demonstrates that the HDGASA is well positioned to play a vital ‘bridging’ role when it comes to the promotion of hot dip galvanizing and the application of the required standards and test methods across Africa,” Clarke concludes.

Boiler update project by AES at food processing plant worth its salt, transforming production process

November 26, 2024

The replacement of 78 year-old boilers at a Western Cape food processing plant by leading boiler operations and maintenance service provider Associated Energy Services (AES), has not only proven to be a worthwhile investment for the client, but has transformed their entire production process.

This turnkey project – one of the largest in the sector and region – saw AES update the boiler house format, structure and technology, effectively positioning the company to meet growing demand for affordable protein into the future.

A new era of boiler operation

AES Projects Director, Gavin Evezard, believes the boilers were probably some of the oldest still operating in South Africa, prompting the new boiler manufacturer to place some of the parts in its industrial museum.

“Technology has completely changed to the point where it is almost impossible to relate to the world for which that equipment had been developed,” he admits.

In today’s era of innovation and sustainability, the four new, state-of-the-art chaingrate stoker-fired firetube package boilers which were installed represent significant improvements over their predecessors with the latest spiral tube technology, bigger surface areas and a secondary air system which improves operational efficiency.

The boilers, which were commissioned earlier this year, have total steaming capacity of 63t/h (from and at 100oC). In addition, the new technology includes emission abatement plant to ensure less than 120mg/Nm3 particulate emissions, an AES Remote Monitoring System (RMS), a de-aerator and hot well – together with a submerged ash conveyor system, shaftless conveyor fuel handling system and storage bunker.

In addition to providing technical management and oversight of the client’s existing steam generation plant throughout the project, AES also completed the plant layout, selection, installation, commissioning and testing.

AES Commercial Director, Dennis Williams believes that AES was awarded this extensive and project due to its innovative design and management approach, and substantial experience in implementing more than 40 complex outsourced energy contracts over more than 25 years.

“Our core business is energy plant operations and maintenance, so we know how to manage a project to ensure its success in the short-, medium- and long-term. We built this plant to run it, and that speaks to our overall project approach,” Evezard adds.

Steaming into the future

In addition to the age of the original boilers, there were three key drivers behind this large investment. The first was a switch from flue gas drying to steam drying to produce a better quality protein product. In the past, the company used the exhaust gases from the old boilers in the protein drying process.

The second was improving efficiency to increase production, and the third was to lower emissions in keeping with legislation, and to safeguard positive relationships with neighbouring communities; as well as the company’s own target of decreasing carbon emissions by 50% by 2030 to reach ‘carbon zero’ status by 2050.

To achieve these objectives, AES combined the new boilers with an advanced cyclone system: “The more a business is future proofed from an environmental and emissions compliance perspective, the less issues it will have going forward, including with surrounding communities. This system delivers competitively on that critical requirement from a capex and operational perspective,” Williams explains.

In terms of fuel source selection, the company elected to use locally sourced, cost-effective coal. AES, which is fuel-agnostic, was able to optimise the energy efficiency thereof effectively.

The projected commenced in December 2022, with the new boilers arriving at the end of 2023. Once the foundation slab was cast for the placement of the equipment, the boiler house structure was built around it.

“The complexity of constructing both phases of the project in parallel was like choreographing a particularly intricate dance and presented some fairly unique challenges. The installation and commissioning of the boilers and ancillary equipment, as well as the boiler house itself represented many ‘moving parts’, all of which had to be managed in accordance with tight deadlines,” Williams remarks. AES played a supporting and facilitation role to ensure that all parties simultaneously delivered a successful result.

Robust results

To date, plant particulate emissions have been reduced by 42% – while the high-tech boilers and updated production process, coupled with plant upgrades and modernisation have improved overall efficiency by at least 15%.

In addition to these impressive operations and maintenance-related metrics, Evezard says one of the most rewarding highlights of the project was upskilling of the 14 boiler operators on site in the use of the new technology: “The ancillary systems and the old boiler house were manually intensive, and the fuel and ash systems were also manually driven. Now, much less manual intervention is required,” he points out.

Reflecting on the success of this challenging project, Evezard concludes: “Although it is very difficult to create a fully autonomous boiler system – especially one based on solid fuel firing – AES always seeks to optimise the way in which we operate, so that the operational staff can concentrate on the important things – the quality of the emissions, the set-up of the boiler and the required operational efficiencies.”

Reaping what they sow: Bolt and Engineering Distributors relaunches fruitful agri, mining and industrial expo in Klerksdorp

November 22, 2024

Bolt and Engineering Distributors (B.E.D.) is proud to announce the relaunch – with great success – of its popular Industrial and Technology expo, which was held in early November at Flamwood Walk in Klerksdorp. The two-day event was free to visitors, and brought together customers, suppliers and other industry partners to showcase and experience the latest advancements in industrial products and technologies.

After a hiatus of some 4 years due to the Covid pandemic and its aftermath, this celebrated event was once enthusiastically welcomed again by the mining, industrial and agricultural sectors, making it even more poignant and impactful.

The Klerksdorp event underscores B.E.D.’s legacy of leadership in the industrial sector. Reflecting on B.E.D.’s history of hosting this iconic industry event, CEO Mike Giltrow comments: “We have always believed in the importance of face-to-face engagement. In an era dominated by digital communication, events like this are crucial for building trust and fostering meaningful connections. The positive feedback we have received confirms that our customers value these interactions.”

Blazing a trail

Giltrow further highlights B.E.D.’s role as an enduring industry trailblazer, referencing the company’s recent Trailblazer sponsorship at Steel Awards 2024: “Our mission as an industry trailblazer is to do just that – blaze a trail, and stay ahead. We do this not just by showcasing products and solutions, but by proactively leading industry forward. Our industrial and technology expo is a testament to – and manifestation of – that commitment.”

MD Jan Viljoen agrees, citing a metaphor which agricultural customers will identify with: “It is all about sowing seeds for a harvest throughout the year – seeds of trust. Therefore, this is not just about immediate sales, but about building relationships that yield results in the long term.”

Furthermore, as Giltrow explains, the expo went far beyond the typical trade show experience: “The modern contemporary showroom venue allowed us to easily accommodate live product demonstrations, enabling customers to experience the technology for themselves. They could ask, ‘Can this really work for us?’and we could say, ‘Absolutely, let us show you how – and why!’ It is about demonstrating and proving the product or solution’s value, application and relevance to our customers in their specific sectors – building trust, and ensuring they see the real benefits thereof.”

Customers were not the only attendees that benefitted from the event: “Our area sales managers and operations managers were deeply involved, gaining hands-on knowledge of our products so they can effectively serve their regions,” notes Viljoen.

“In this way, the expo was not just a showcase for our suppliers and customers, but also an educational opportunity for our own team. We want them to be equipped with the latest insights so they can provide our customers across South Africa with the best solutions,” he advises.

Impressive supplier line-up

This year’s expo featured an impressive line-up of 65 supplier exhibitors, showcasing a diverse range of products and solutions. “The expo brought together everything from welding equipment to bearings, personal protective equipment (PPE), hand tools and power tools, catering to diverse industries like mining, agriculture, fabrication, manufacturing, transport and even the food sector – demonstrating that we are here to provide solutions for every industrial and engineering-related requirement,” says André Esterhuizen, Operations Manager at B.E.D. Welkom and a longstanding member of B.E.D.’s expo committee.

B.E.D. colleague and equally longstanding expo committee member Carlien Bruce-Smith, Distribution Centre Manager at B.E.D. agrees: “Our expo is not just an opportunity to showcase the diversity of our product range to our customers and area sales managers – but also to strengthen relationships and loyalty, while providing on-site solutions and insights directly from our welding, cutting and other industrial sector experts.”

Community support

Furthermore, B.E.D.’s commitment to community support also shone through at the expo, in its longstanding partnership with Cancervive, a dynamic non-profit dedicated to supporting cancer awareness and education.

This year, Cancervive raised R30 000 from the sale of unique pink toolboxes, gardening and electrical equipment – all generously priced so that the profits made on the stand could go directly towards Cancervive.

Additional contributions brought the total funds raised for Cancervive to approximately R50 000.The participation of rugby legends Bismarck and Jannie du Plessis further amplified the cause, with the auction of an autographed Springbok rugby jersey.

Supplier best stand awards

The much-anticipated Supplier Best Stand awards were a highlight of the expo, recognising suppliers who created exceptional displays, of which this year there were two.

Einhell Germany AG Power Tools South Africa was honoured for their dynamic and interactive stand, which featured live demonstrations, expert advice and an impressive showcase of their innovative tool range. CNC Dynamix received accolades for their professional presentation of cutting-edge machinery, offering attendees a hands-on experience with their precision-driven technology.

“Both winners demonstrated creativity and excellence, leaving a lasting impression on attendees and setting the benchmark for future industrial and technology expos,” Viljoen comments.

B.E.D.’s commitment to industry

The successful revival of B.E.D.’s Industrial and Technology expo in Klerksdorp this year has entrenched its position as a key player in agri, mining, industrial and many other sectors, fostering collaboration and providing valuable insights into cutting-edge technologies.

“B.E.D.’s commitment to innovation, customer satisfaction, and industry excellence will be at the heart of this enduringly popular industry outreach for many years to come. We are incredibly thankful and appreciative to all who played a role in making this world-class event such a success!” Giltrow concludes.

Swinging into a new chapter with LTA Autecon!

November 4, 2024

LTA Autecon, formerly known as Grinaker-LTA Mechanical & Electrical, hosted a golf day and dinner at the Glendowner Golf Club on November 27 to celebrate its first year in business as a rebranded and refocused SMEIPP industry stalwart.

As such, the company recently redefined its distinct identity and strategic positioning as a market leader in the SMEIPP construction sectors. With over 40 years of experience, LTA Autecon specialises in delivering an array of construction projects tailored to the oil and gas and mining sectors.

At the post-golf prizegiving and dinner, Managing Director Bheki Mdlalose welcomed over 65 clients, thanking them for their support during the first year of operations.

Mdlalose also thanked LTA Autecon’s management and staff, whose unwavering support assisted with the transition of a company that is once again trading under the original and very well-known name used during the 1980s, but implementing a revitalised vision and organisational culture.

Those enjoying a day out on the greens represented a number of different sectors that are serviced by LTA Autecon’s three distinct business units: Oil & Gas, Metals & Minerals and Electrical & Instrumentation; as well as the wholly-owned, independent subsidiary Grunwald Manufacturing, which  manufactures electrical and instrumentation equipment for a host of vertical sectors which are typically not serviced by an SMEIPP business.

The prizegiving before dinner featured first, second and third four ball team prizes, as well as a fun prize for the golfer with the lowest score, and for the one closest to the pin. Together with a bonus prize raffle, this rounded off a highly enjoyable event perfectly.

“LTA Autecon is looking forward to a very positive 2025, which will see us casting our net wider and impacting on several key vertical sectors,” Mdlalose comments.

“The company has been known for many years in the mechanical and electrical sectors, and this year’s relaunching and refocusing move has been a positive one. The outcome is a well-established SMEIPP business with a proud heritage, which is perfectly positioned to be the partner of choice managing projects for the oil and gas, mining and industrial sectors within South Africa and throughout Africa he concludes.