Archive: September 29, 2025

B.E.D. Klerksdorp and BPI Manufacturing: over two decades of growing agri equipment success

September 29, 2025

A collaboration that began over twenty years ago between Bolt and Engineering Distributors (B.E.D.) Klerksdorp and BPI Manufacturing, continues to drive agricultural equipment reliability and innovation across South Africa’s agricultural sector. United by the shared values of service, trust and technical excellence, the two companies exemplify what long-term supplier-customer partnerships can achieve.

Based in Bothaville in the Free State, BPI Manufacturing is an original equipment manufacturer (OEM) which produces a range of high-performance implements including grain trailers, fertiliser spreaders and tillage tools. Founded in 1968, the company has grown into a key player in the agri sector, supported by enduring relationships such as the one with B.E.D.

Lukas Brits of BPI Manufacturing, says the business was built on a foundation of strong supplier relationships: “Our history is based on the relationship between supplier and customer,” says Brits. “When we moved our operations to Bothaville, the connection with B.E.D. Klerksdorp became integral to how we manufacture and support our products.”

Relationship rooted in reliability

From custom gearboxes and sprockets to tailored power take-off (PTO) shafts and bearings, B.E.D. provides engineered drivetrain solutions aligned with BPI’s unique equipment specifications. More than just a parts supplier, B.E.D. is a deeply embedded agri equipment partner, working alongside BPI’s design team to co-create components optimised for performance and uptime in harsh on-farm conditions.

Ian Lloyd, Operations Manager of B.E.D. Klerksdorp notes: “We understand the demands of agricultural timelines and supply our valued customers such as BPI with those needs in mind. Whether it is a rapid gearbox replacement during harvest – or pre-season planning of bearing kits – we ensure that BPI can deliver to its customers without interruption.”

B.E.D. supplies BPI with a comprehensive range of premium SKF agricultural bearings, including dust-resistant, maintenance-free options which extend equipment life and reduce failure rates. Brits explains: “BPI Manufacturing does not compromise on quality. SKF products have proven themselves in-field, and our clients recognise that. When farmers see a BPI implement, they know it is made from the best components.”

 B.E.D.’s support is reinforced by its national network of 13 branches, allowing for swift product supply, technical advice and consistent service levels across the country. “We are a large organisation operating on tight seasonal schedules,” says Brits. “We cannot wait for weekly deliveries or chase multiple suppliers. With B.E.D., there is someone at our premises almost every day. This support helps us keep our promises to farmers!”

B.E.D.’s value goes beyond parts supply. Its welding division, in partnership with leading technology providers like Fronius, equips BPI and its dealer network with access to advanced welding tools and mobile power systems, such as portable AccuPocket battery welders. “B.E.D. brings the latest innovations right to the farm,” explains Brits. “They do not just deliver the product, they deliver the knowledge!”

National co-ordination, local support

“While visiting farms in Middelburg, I saw a BPI grain trailer being used,” says Kobus Moolman, Area Sales Manager (ASM) at B.E.D. Klerksdorp. “I can confidently say that every component, from bearings to gearboxes, was provided by B.E.D. BPI’s colleagues and customers also know our products across the country – making it easier for us to support dealers and co-operatives nationwide.”

The ultimate goal of the B.E.D.–BPI partnership is to maximise uptime and reliability for farmers. This requires more than technical know-how – it requires mutual trust, clear communication and responsiveness to changing demands: “If a BPI implement has an issue, the farmer calls us, and we call B.E.D. We know the problem will be solved – fast! That is why we trust them. We are not just planning for the next season. We are building the future of agriculture together,” says Brits.

For B.E.D., the relationship with BPI is a true showcase of its broader strategy to deliver value through responsiveness, customisation and long-term trust. “Our goal is to make it easier for OEMs such as BPI to manufacture with confidence – and for farmers using the implements they make, to work without delays. Our valued partnership is a model for the way in which we strive to support the entire agri value chain,” Moolman concludes.

A ‘cracking success’! – DEKRA Industrial sets new standards for asset integrity in local petrochemical sector

September 26, 2025

DEKRA Industrial South Africa has strengthened its position as a leader in hydrogen-induced cracking (HIC) inspections through a strategic combination of advanced non-destructive testing (NDT) techniques, investment in state-of-the-art inspection equipment and global technical collaboration. This enhanced capability provides clients in the petrochemical, refinery and related industries with the accuracy, confidence and reliability required for early detection and management of cracking and damage within steel assets.

“Hydrogen-induced cracking remains one of the most critical threats to the integrity of pressure vessels, pipelines and steel infrastructure in the petrochemical sector,” says Bennie Groenewald, Business Line Manager, NDT / Advanced NDT at DEKRA Industrial. “Our advanced inspection portfolio – particularly in HIC detection – is not only technically robust, but backed by DEKRA Industrial’s global network and local expertise. With continuous investment in equipment and people, we are setting new standards for asset integrity in South Africa’s petrochemical sector.”

Precision techniques for a complex threat

Unlike surface damage, HIC occurs internally due to atomic hydrogen diffusing into steel structures, leading to blistering and stepwise cracking. The challenge lies in accurately detecting early-stage damage before it escalates to catastrophic failure.

To meet this challenge, DEKRA Industrial employs a phased approach which incorporates:

  • Total focusing method (TFM) for high-resolution ultrasonic imaging and sub-surface defect detection as small as 200 microns
  • Time-of-flight diffraction (TOFD) ultra-low angle (ULA) techniques for enhanced probability of detection and length sizing
  • Metallographic verification and destructive testing where needed, to ensure complete characterisation of damage

These methods allow for qualitative and quantitative evaluation of HIC, significantly improving maintenance planning, repair decisions and operational safety.

Global expertise, local capability

What gives DEKRA Industrial a unique competitive edge is the integration of global research and development (R & D), European standards and hands-on field experience in the South African context. Backed by the DEKRA Group’s international innovation and research teams, the company has direct access to the latest techniques, procedures and technical feedback from similar NDT inspections performed across the world.

In support of this, DEKRA Industrial South Africa recently invested in new advanced inspection equipment, tailored specifically for HIC and related forms of damage. This includes next-generation phased array ultrasonic testing (PAUT) units and data-processing software, now operational across key sites in the local petrochemical sector.

Furthermore, three senior DEKRA NDT specialists (each certified to Level 2 and 3) have undergone specific international training to ensure their effective use of these technologies. This investment in people and technology ensures that inspection results are interpreted with a high degree of accuracy and consistency, giving clients actionable insight.

Beyond HIC: HTHA and RAI

While HIC is the main focus of DEKRA Industrial’s inspection offerings, the company also offers expertise in detecting high-temperature hydrogen attack (HTHA), using techniques such as advanced velocity ratio measurement (AVR), automated ultrasonic backscatter techniques (AUBT), and high-sensitivity TOFD.

In addition, DEKRA Industrial’s Remote Access Inspection (RAI) capabilities – soon to be introduced locally – will support safer and more efficient inspections in confined or hazardous environments. By deploying crawler-based, camera- or drone-assisted inspection tools, the company can perform HIC and HTHA assessments without exposing inspection team members to unnecessary risk or requiring prolonged shutdowns.

Commitment to industrial safety

As part of its broader mission, DEKRA Industrial remains committed to promoting safety, reliability and technical excellence in the industries it serves. “For a petrochemical refinery, a hydrogen plant or a remote pressure vessel site, our approach is always rooted in accuracy, safety and international best practice,” adds Groenewald. “We do not just find cracks – we help our clients to prevent ensure asset integrity, and prevent potentially catastrophic failure.”

From fossil fuel facilities to hydrogen infrastructure and green energy projects, the company’s inspection technologies are tailored to support the evolving needs of the South African and African industrial landscape.

The choice of thermal carrier is critical to ensure optimal manufacturing and processing says AES

September 19, 2025

Historically steam, fuelled by coal, has been the most prevalent thermal carrier in South African industry. However, according to Dennis Williams, Commercial Director of boiler operations and maintenance service provider AES, times are changing, with the manufacturing and processing sector needing to review the energy reticulation systems and thermal carriers currently in use.

When it comes to the correct choice of thermal carrier, Williams believes many questions must be asked: “How is steam being used? Should steam supply be outsourced? Is steam the right fit for every process in the manufacturing or processing facility? How much of that facility is aligned with steam – and how much with another thermal carrier? What are the implications of switching those? If changes are made, could the cost of production be reduced and quality improved?”

He advises that the best place to start is by fully understanding the company’s primary product, and the potential roles of different thermal carriers in the production process.

Steaming ahead

Steam remains the most user-friendly thermal carrier. Inert, non-toxic and safe, it minimises dangers such as product contamination or fire in the event of a leak – which can happen with thermal oil, which is highly flammable and operates at high temperatures. Therefore, from a process safety management perspective, steam is a good choice.

Furthermore, steam can be generated across a range of pressures and heating can be tightly controlled: “For the purposes of controlling temperature to cook food, one does not want to scald it. When relying on steam at a certain pressure, the thermodynamics preclude that,” Williams explains.

When using thermal oil or other heat transfer fluids, temperature control is more challenging, because the production process hinges on a temperature differential with no phase change: ”If thermal oil is used at 350°C and only 180°C is required for the product, the flow must be controlled to avoid scorching the product. However, a significant flow is also required to transfer the same amount of energy – compared to using steam – because that phase change is not there and heat transfer relies on sensible heat transfer,” he advises. 

Pressurised hot water

Williams says that lower temperature requirements of 120 to 150°C do not require steam. Instead, by using a pressurised water heater, the water temperature will rise to the desired level without boiling and flashing to steam.

This process is used quite extensively in companies such as breweries. Another example is when cleaning plant or equipment. Pressurised hot water can be used to heat up a caustic solution, which is then reticulated through the plant.

Gas and hot air

The textile and paper industries use these extensively. “In the paper industry, there is a hood over the main paper cylinder which is heated using gas. The flame is not fired onto the paper. Instead, it is directed to the air directly in front of the burner flame. A flue gas-air mixture radiates onto the paper surface – to dry out the last bit of moisture,” Williams explains.

Alternatively, manufacturing or processing companies can use a combination of thermal carriers. For example, an AES client making coffee and coffee creamer sprays a liquid slurry from the top of a tower. As the droplets cascade downwards, a counter-current flow of heated air removes moisture – so that dry product can accumulate at the bottom of the tower: “The major portion of heat input comes from a cold air-to-steam heat exchanger. The steam heats up the air. A direct fire on gas then fine-tunes the temperature of that air,” he outlines.

Thermal oil

Thermal oil is widely used in the textile sector, where it is reticulated through stenters and other textile machinery to provide the temperatures required for heat treatments to fabrics.

“Thermal oil therefore has specific applications, where higher temperatures can be achieved than when using a typical industrial process steam application. You do not want to be running a 45-bar boiler to achieve 265°C. You would rather run thermal oil, which operates at a higher temperature range,” Williams points out.

Making the right choice

Williams says that for many in the manufacturing or processing sector, it is useful to invest time in going back to the drawing board – as making the right choice of thermal carrier is critical: “The way things have always been done may no longer be the right way now – and decision-makers could unlock far more lasting and meaningful savings by carefully analysing key issues such as sustainability and efficiency,” he points out, adding that many companies are now integrating different thermal processes into one fully optimised system.

Condensate and low-grade heat can also be recovered for re-use in optimised systems. However, the capital outlay will differ across thermal carriers – with decisions influenced by fuel and technology selection.

In summary, when considering thermal carrier changes or upgrades, Williams warns against price-based procurement and recommends a longer-term, value-based approach: “When you understand why you are doing something, the value reveals itself. It is not about paying less. It is about deriving maximum value from the production process and achieving optimal operational performance, margin and end-product,” he concludes.

DEKRA Industrial showcases South African expertise in global vehicle testing and mapping projects

September 17, 2025

DEKRA Industrial South Africa has successfully completed an advanced road mapping project for DEKRA Japan, collecting highly accurate, terrain-specific data across five key South African routes. The initiative forms part of a global effort to enhance infotainment and navigation systems for the automotive industry, ensuring they are calibrated to real-world conditions and optimised for diverse environments.

“This project proved South Africa’s unique value to the global automotive sector. In one country, we can offer virtually every road type and weather condition in the world, from mountainous passes to urban gridlock, and from tropical humidity to dry semi-desert. This diversity allows us to test vehicle technologies in ways that deliver meaningful, real-world insights for our clients,” says JP Muller, Supply Chain and Inspections Manager at DEKRA Industrial.

The mapping data gathered will enable international automotive manufacturers to fine-tune advanced driver-assistance systems (ADAS) and in-vehicle infotainment (IVI) technologies for African conditions. “By providing manufacturers with terrain-accurate data, we help them fine-tune lane-keeping assist, adaptive cruise control, and navigation routing – so drivers get safer, more accurate and more user-friendly systems,” says Muller.

Overcoming technical and logistical challenges 

The project demanded precision and adaptability. As Muller explains: “We faced everything from patchy network coverage in rural areas to unpredictable weather. To keep the data flowing, we ran duplicate GPSs (global positioning systems) on two different mobile networks and used high-quality GoPro cameras to make sure every image was crystal clear.”

Through pre-route reconnaissance, adaptive scheduling, and multi-network SIM configurations, the team minimised downtime and delivered accurate, report-ready data on time.

This achievement demonstrates DEKRA Industrial’s ability to deliver internationally compliant, high-quality data in diverse – and frequently challenging – African conditions. Muller believes the country offers unmatched testing potential. “There is a niche market here for global manufacturers. That is why international clients keep coming back.”

Electric vehicle (EV) testing breakthroughs 

In addition to mapping, DEKRA Industrial tested pre-launch BYD electric vehicles in South Africa. The tests covered energy usage, charging efficiency, regenerative braking, satellite navigation accuracy, and performance under load. “It was the first time I had ever driven an electric vehicle, and I can tell you: it is the future,” said Muller. “I would buy one tomorrow, but the charging time here is still much longer than in places like China, where a full charge can take just 15 minutes.”

The data also revealed the impact of South Africa’s varied terrain on battery performance: “We found battery life was slightly shorter than expected under certain conditions; however manufacturers told us our roads are excellent for testing – even better than in some parts of Europe,” Muller notes.

To ensure accuracy, the team used calibrated metering for energy use and verified geolocation with multi-constellation global navigation satellite system (GNSS) receivers.

Advancing safety and market readiness 

Artificial intelligence is already supporting DEKRA Industrial’s data processing. “AI helps us to spot anomalies in massive datasets, like variations in EV range across different terrains,” Muller explains. “In the future, we will use it for predictive modelling, so we can simulate performance in conditions we have not yet physically tested.”

DEKRA Industrial’s mapping insights directly improve ADAS and IVI capabilities – ensuring vehicles are safer, more reliable and more suitable for their target markets: “By delivering precise, high-quality data from both mapping and EV testing, we help manufacturers bring vehicles to market which are better adapted, safer and more reliable. This is a win/win for global clients and for South African drivers alike.

With further vehicle testing projects already planned, DEKRA Industrial is set to expand its role in shaping the future of automotive technology in Africa and beyond,” Muller concludes.

Colossal Concrete Products to play a ‘concrete’ role in Africa’s rail revival

September 12, 2025

For Southern Africa’s largest railway sleeper manufacturer, Colossal Concrete Products (CCP), this year’s Southern African Railways Association (SARA) conference and expo in Johannesburg, was an invaluable opportunity to showcase its capabilities, identify opportunities and network with key stakeholders who are poised to make Africa’s long-awaited rail revival a reality.

Chief Executive Officer Gwen Mahuma-Madida is excited to see the beginnings of a rail revolution after many years of under-investment and lack of maintenance: “In line with the SARA expo’s theme of Transporting Africa Forward: accelerating rail growth to boost mobility and economic activity cross Africa, we saw a more positive mindset. We welcome African governments’ commitments to upgrading freight rail – and look forward to seeing CCP play a significant role in developing, repairing and maintaining a network of rail corridors that will become the backbone of Africa’s economy.”

Keeping track of African development

Mahuma-Madida points out that CCP – which has the capacity to manufacture at least 1 million sleepers per annum at its Brakpan and De Aar facilities – has long been viewed as an innovator in rail.

The development of a unique and sustainable system of modular, portable ‘project factories’ which cater for specific pan-African initiatives and can be dismantled post-completion, gives the company a competitive edge further from home. At the same time, these minimise project risk.

“Project factories not only enable us to support development, but facilitate the upskilling of local communities and the use of local resources. As a black women-owned, Level 1 B-BBEE manufacturer, CCP is a quintessentially African company which fully understands clients’ needs and challenges in an African context – and fully appreciates why local beneficiation and job creation are essential,” she notes.

Mahuma-Madida underscores Transport Minister Barbara Creecy’s observations at the SARA Congress that this is a complex time for African economies in the wake of disruptive import tariff policies, which are undermining long-standing trade agreements.

She agrees that the African Continental Free Trade Area (AfCFTA) now takes centre stage and provides important opportunities via high-speed rail projects, urban commuter expansions and the modernisation of freight corridors.

“We view the entire African continent as our market! Already, significant rail projects are emerging on the back of surging demand for minerals and products, the expansion and opening of mines and growing competitiveness of regional supply chains. We are working on some very promising prospects and focusing on Angola, Namibia and the Democratic Republic of the Congo,” explains Sales Executive Mothemane Makhura.

CCP has also made a conscious decision not to mechanise, to avoid reducing its labour inputs – and therefore has a robust production process which can be rapidly repaired.

“We strive to find synergies between technology and utilising our labour force, because Colossal Concrete Products remains committed to creating jobs, and uplifting the individuals who make our African continent great!” advises Makhura.

A track record on local lines

CCP is well positioned to benefit from the national rail reform programme that is already underway in South Africa, and which was discussed at length at the SARA conference.

“To date, we have developed over 40 rail-related products as well as infrastructure products such as poles, masts and culverts integral to the upgrading of rail and other infrastructure. Our product portfolio and track record is extensive, encompassing rail products and projects for local and Sub-Saharan railway networks featuring either Cape or standard gauge tracks,” Makhura points out.

As such, he welcomes the identification of 11 private sector operators for 41 routes across six rail corridors, which are expected to carry an additional 20 million tonnes of freight per annum from the 2026/27 financial year, as well as Transnet Freight Rail’s intention of increasing freight moved by rail to 250 million tonnes per annum by 2029 – and the proposed expansion of the Gautrain – to which CCP has contributed from the outset.

“Colossal Concrete Products has the widest variety and the broadest range of railway sleepers available in Sub-Saharan Africa. We specialise in pre-stressed concrete products, which we produce to very high specifications and differ completely from normal precast products – offering greater strength and durability, which is essential in Africa’s harsh environment.

“Our extensive experience of operating locally and in Africa definitely sets us apart. A highlight was last year’s contract to supply precast concrete railway sleepers for Transnet Freight Rail. We also supply PRASA via third-party contractors, as well as private sector rail projects such as a Northern Cape manganese ore mine,” Mahuma-Madida concludes.

Managing dynamic steam plant operation on a multi-user site requires technical skill and strong relationships says AES

September 5, 2025

In an ideal world, a single steam user has consistent load demand and operates continuously.  However, reality is rarely this simple – and managing a dynamic steam plant operation featuring multiple users requires strong technical skills, good communication and close attention to optimise results, explains AES Commercial Director, Dennis Williams.

Variations, including time and duration of use, steam draw profiles (either constant or batch, intermittent, staged), different steam pressure requirements, direct or indirect steam use and condensate return differences impact on operations – especially when it comes to training steam plant operators, different boiler technologies and fuels, and managing consistent steam pressure supply – all while factoring in the potential use of accumulators and steam pressure control valves.

Optimising efficiency of steam generation (boiler load balancing, fuel trims, emission management due to load changes), together with carefully managing changes to steam and condensate return reticulation systems (including startup / shutdown of lines / production from one or multiple steam users), specific water treatment requirements due to variations in direct / indirect steam use and the impact of reduced condensate return from steam users are also important additional factors.

Measuring and monitoring

“AES’s Remote Monitoring System (RMS) gathers steam generation plant data and records critical operational monitoring parameters including steam pressure (per boiler and header pressure), steam flow (total), steam loads per boiler, flue gas CO2 per boiler, stack temperature per boiler, overall feedwater temperature and quality, and other operational impactors. This data is essential to monitor boiler efficiency and steam quality,” Williams points out.

“Other critical measurements at reticulation and usage points include steam pressure, steam pressure control systems (let-down stations etc.), the condensate recovery system, particularly in terms of quality of condensate such as pH, total dissolved solids (TDS) and hardness or potential contamination through product leakage into the steam or condensate space),” he says.

The focus is not only on minimizing steam use to achieve energy requirements, but also on maximizing the percentage and quality of condensate return to save water and recover heat.

Process understanding and operational map

Understanding the process comes first when setting out to achieve efficient, optimal steam generation and thermal energy supply across a multi-use site, Williams notes: “This is critical in order to determine the energy flows required in terms of timing, tonnages, pressures, variability profiles and condensate return generated. These factors form an overall operational ‘map’ of the variation in demand and load on the steam plant.

”AES then determines the best operational strategy including when to start which assets, specific boilers’ load profiles at specific times, and the management of risk in the event of equipment challenges or breakdowns. Site-specific operating procedures (SSOPs) are optimised based on the configuration of the plant and user requirements. “

Throughout, says Williams, communication is key – particularly when it comes to setting realistic client expectations: “With AES’s hyper-focus on steam generation, there are fewer opportunities to point fingers. The boiler house has historically been blamed for many process disruptions. The data required to understand the root causes of issues was not always accessible. Fortunately, AES’s service level agreements (SLA) provide clear, measurable deliverables.”

Multi-use with multiple boilers

Williams acknowledges that it is far more complex to operate a multi-use site with multiple (duty) boilers, than with a single boiler: “Myriad factors under the control of the steam plant operator (AES) and the steam user (the client) must be coordinated. A single user site – while having the same operational requirements and levers – is inherently simpler. The demand input is less intensive – with lower impact around any potential operational issues on the generation plant.”

Additionally, pivotal Process Safety Management (PSM) within a multi-user environment requires consistent practices across multiple boilers: “We must ensure safe operation for multiple boiler plant (pressure vessels), multiple combustion devices operating, more hot surfaces, more maintenance (at heights and/or in enclosed spaces) and variations thereof if using different boiler designs, fuels or combustion systems. Therefore, a strong management system regarding permissions, task planning, risk review and procedure set-up is essential.”

On multi-user sites, there is also greater variability when it comes to pipework, valves, systems and operating procedures: “Start-up and shut-down of steam and condensate lines to particular units which are being brought into an out-of-service must be safely managed.

This includes heating of lines, condensate removal to prevent steam line water hammer as well as system lock-out to prevent steam burns and pressure release risks when restarting systems. Processes with different steam pressure requirements must be operated and maintained. Over-pressurisation of steam use systems downstream can have significant safety impacts,” Williams explains.

“Multi-user sites are challenging, demonstrating that crystal-clear communications and tried-and-tested technical skills and experience are imperative to ensure the successful integration of steam generation, reticulation and use,” he concludes.

Malben Engineering: driving continuous improvement, safety and corrosion protection with state-of-the-art e-coating capability

September 2, 2025

“It is a privilege to work in the automotive industry, with its constant drive to improve! Safety is an important cornerstone, and corrosion protection is part of this. Our success is built around pre-empting customers’ requirements – and ensuring we are not a passenger in the process.  A real partnership is defined by taking the lead and adding real value and innovation in one’s service offering – rather than just following,” says Luca Smargiasso, Operations Director of Tier 1 automotive component supplier, Malben Engineering.

When it comes to e-coating and powder coating – critical corrosion protection processes – Malben’s standards are already significantly higher than its OEM customers’ requirements.

“Our state-of-the-art e-coating laboratory constantly analyses real-time data – and everything is managed via our design of experiments (DOE) methodology,” Smargiasso points out.

Investing in corrosion control

The coating of automotive components has evolved significantly since Malben launched in 1974.  The company started an in-house plating plant in 1997, and by 2001, had upgraded this facility, moving to an alkaline and iron-zinc electro-plating process. In 2005, Malben set up its e-coating and powder coating line.

“Over the last few years, we have enhanced our processes to improve our e-coating facility in line with our customers’ enhanced corrosion protection requirements. More and more vehicles are being exported to highly corrosive environments. For example, a vehicle going into the Northern Hemisphere is going to be operating in a very demanding, corrosive environment – given the weather and the salt spraying done on those roads in winter,” explains Smargiasso.

Mirriam Ratlhogo, Electromagnetic Field (EMF) Plant Manager at Malben, explains that e-coating, electro-plating and powder coating resist chipping, scratching and corrosion.

A step-change in corrosion testing

Smargiasso says Malben has invested in extensive in-house testing processes to access real-time data rather than waiting on third-party information: “This gives us a lot more flexibility. It enables us to analyse process improvement in short time frames, and implement these changes quickly – which is important in an evolving environment,” he adds.

Although more complex testing – such as cyclic corrosion tests – are outsourced, Malben’s fully equipped e-coating laboratory can do wet analysis, assess coating thickness, e-coat solids and determine electro-magnetic field process compliance with C2, C3 1P85 WSS standards. The salt spray chamber facilitates accelerated corrosion testing through continuous fogging. Manual tests include scratch and rub tests to ensure paint is properly cured.

“Batch size sampling is essential due to the high volumes of components coated. During every 9 hour shift, tests are conducted 5 times. By working to its own higher specifications and standards, Malben has ‘room to move’ and quickly implement any adjustments required,” Ratlhogo explains.

Above and beyond

Malben recently engaged with another supplier to advise on process improvements required to achieve OEM standards, says Quality Director, Werner Kapp: “They wanted to understand what we were doing differently, as we had passed the corrosion test with flying colours.

Further to this, during one of our scheduled cyclic corrosion tests last October, we requested a third-party laboratory to continue the testing for a further 5 weeks – despite having reached the stipulated 9 week cyclic corrosion test requirements. This demonstrates how Malben goes above and beyond to ensure corrosion protection excellence,” Kapp advises.

Technical precision                                                                   

According to Ratlhogo, the conveyor system running from pre-treatment through to the curing ovens is also integral to the coating excellence achieved: “The ‘closed loop’ conveyor system guarantees repeatability in key areas: from ensuring that no process is omitted, to achieving contact time repeatability – which is fundamental to quality – to optimising repeatable coverage with design of experiment-approved loading jigs to maintaining workflow and ergonomics,” she explains.

Head of Maintenance Quinten Ballot adds that attention to detail and careful monitoring sets the company apart and gives it a competitive edge: “On the e-coating side, everything is minutely monitored. What cannot be measured, cannot be managed. Even the burner in the curing oven has been upgraded. Now AI-enabled, it constantly learns from its environment – adjusting to ambient/seasonal temperature variances to optimise heating patterns and gas usage, without compromising on quality. Thanks to ongoing investment not only in the e-coating facility and laboratory – but throughout the company – the lifting of the bar never stops!” Ballot concludes.