Category: Business

AES and the great decarbonisation debate – Providing powerful assistance with carbon footprint reduction

Although many manufacturing and industrial companies have stated objectives to reduce use of fossil fuels, there are not yet any silver bullets in the green fuel space, says Dennis Williams, Commercial Director at steam and boiler operations and maintenance service provider, Associated Energy Services (AES).

Supply and logistics constraints, high costs and technological limitations are just some of the challenges encountered by AES, as they assist an increasing number of clients to investigate the use of more environmentally sustainable, lower carbon fuel alternatives – thereby obviating the requirement to pay carbon taxes both locally and abroad.

“When a global business decides to reduce its carbon footprint – or even go carbon neutral – this decision seems to be applied across all marketplaces, irrespective of the local economic pressures and technical challenges.”

One AES client is already running out of time to meet the ambitious decarbonisation target of its global parent company: “We have reviewed all options – from electricity to solid fuels, liquid fuels, different gases, biomasses and agricultural residues – and shown the capex, opex and supply dynamics on multiple occasions. We have also considered the amount of space needed – and what each fuel choice will incur from an emissions and carbon tax perspective. In addition, we have looked at how much the steam will cost, the ash which could be generated and how to deal with that.”

Williams’s key message is that carbon taxes are here to stay – and that companies and consumers will not be able to absorb the costs of using fossil fuels indefinitely. Companies must be educated about different options that suit their specific needs.

Gas: just hot air?

For Williams, gas is best regarded as an interim step on the decarbonisation journey: “Not only is supply an issue in terms of gas – but it remains a fossil fuel with a carbon footprint. Companies will still pay substantial carbon tax and find themselves only part of the way to a zero carbon target. There is naturally also a cost associated with making this interim switch – so it is a less than ideal option in most cases.”

Apart from the predicted local shortages of locally available natural gas, converting and transporting this fuel as liquefied natural gas (LNG) is not environmentally friendly and is expensive – with recent price indications at US $18 to 20 per gigajoule, which is probably four times the cost of coal.

Biomass: why waste? 

Williams says bagasse, derived from sugar cane residues, was probably the earliest biomass fuel used in South Africa: “The business models for this have changed substantially over the years. Years ago, bagasse was regarded as a problem. This view has been turned on its head – to the point where local sugar mills maximise its use as energy feedstock in their boilers for steam and power generation.”

In the timber industry, the focus is on maximizing the useful yield from timber. Each log is scanned to determine the sizes, widths and thicknesses which can be cut; as well as the potential wastage. White wood chips are often sold for board manufacture, typically leaving mainly contaminated wood chips, saw fines and bark. These can be used for energy.

Other options are macadamia shells, sunflower husks and residue from maize harvesting. Seasonality and crop yields impact supply – while rural locations increase transport costs and vehicle emissions.

The potentially alkaline chemical composition of agricultural waste can damage boilers and heat transfer surfaces. The ash characteristics are also problematic, Williams notes.

When researching the use of sunflower husk for a client, AES found it challenging to find a workable and sustainable solution: “For years, there was a glut of sunflower husks in the market. Then, suddenly, sunflower seed pricing turned and it became more cost-effective for local manufacturers to import sunflower oil than to process sunflower seeds themselves. This put the viability of the project into question,” Williams recalls.

Wind and solar: blowing hot and cold?

The greatest challenge with this potential solution is grid constraints, with renewable energy companies unable to export electricity to the national grid without investment in additional power line capacity and challenges in wheeling the electricity to an end-user for use in an electrode boiler.

On site, Williams also points out that there is a big disparity between space available for the amount of solar panels realistically required to offset the megawatts of energy input from solid, liquid or gas fuels: “24/7 operations are looking at three to four times the surface area. If these are using five megawatts, they will probably need 15 to 20 megawatts. When the sun is shining, they will have to generate the extra energy and put it into battery storage. That comes at a substantial cost, but the space is simply not available in most cases” he argues.

The best of different worlds

AES is working with some clients to implement a phased approach. First is adapting their manufacturing processes to use less steam. A 10% drop in steam usage equates to a 10% reduction in fuel – and an immediate 10% carbon footprint improvement.

Next is outsourcing their steam boiler operations and maintenance to a seasoned industry expert such as AES to further increase energy plant fuel efficiency – another carbon saving.

When companies can upgrade, Williams proposes running boilers on different fuels to better understand the technology and the fuel supply marketplace: “One of our food sector clients is using bio gas, heavy furnace oil and biomass. This creates a lot of redundancy and opportunities for them to shift demand between those assets, providing substantial risk mitigation and flexibility on the fuel side,” he explains.

“We recommend a phased carbon reduction approach; as well as trialling various fuel source options to see which fits best in terms of operational and financial viability.

The need for a reduced carbon footprint – and the taxes associated with enforcing this – are an unequivocal rallying call to manufacturing and industrial companies to get their houses in order, before they are left behind. AES is there to assist every step of the way,” Williams concludes.

Malben Engineering achieves top score as Responsible Supply Chain Initiative-certified automotive component supplier

Malben Engineering, an established Level 4 BBBEE supplier of stampings and welding components to local vehicle original equipment manufacturers (OEMs),  has been certified in terms of the global Responsible Supply Chain Initiative (RSCI) standard for the automotive industry.

The Responsible Supply Chain Initiative RSCI e.V. was founded by the German Association of the Automotive Industry (VDA) with foundational members including Audi, Volkswagen, Mercedes Benz AG and BMW, as well as suppliers such as Brose, Robert Bosch GmbH and Schaeffler.

The RSCI e.V. ensures high sustainability standards at national and international level through independent audits. An RSCI certification and tag, or Responsible Supply Chain Initiative label, demonstrates compliance with stringent RSCI criteria which promote ethical environmental, and socially responsible practices.

Confirming that Malben Engineering had achieved a top score with a resounding 98% in the RSCI audit, Operational Director Luca Smargiasso says this reflects company’s dedication to excellence and integrated sustainability.

“We are proud of our people-centric approach. We view our workforce as a large family, therefore providing the best and safest working environment is absolutely essential to us. We have learnt that if people feel that their workplace is safe, production levels rise and brand loyalty increases,” he points out.

Malben Engineering was identified as a candidate for the RSCI audit by Ford, to which it is a tier 1 supplier of chassis components due to its high standards and quality product. The certification is valid for three years.

This year, Malben Engineering also became the first South African automotive component manufacturer to trial ‘green’, low-carbon steel.

As a leader in sustainability and supply chain assurance, DQS facilitates independent evaluations – such as Malben Engineering’s – against various international standards, including the Responsible Supply Chain Initiative (RSCI) standard for the automotive industry. Lucinda Kuys, Executive: Social, Sustainability & Ethical Compliance at DQS, says achieving a 98% score is an outstanding accomplishment, reflecting the company’s robust commitment to sustainability and responsible supply chain practices.

“From an RSCI perspective, Malben Engineering’s achievement reinforces the credibility and utility of the RSCI standard in driving industry transformation. It sets a benchmark for other companies, demonstrating the value of rigorous audits in enhancing supply chain transparency and responsibility. This milestone not only strengthens Malben’s reputation, but also contributes to broader industry goals,” she notes.

A ticket to the game

“When we do something, we do it well. We always ensure that we have a best-in-class, proactive approach to everything we do,” agrees Malben Engineering’s Commercial Director Marius Schafer.

Schafer adds that recognition of Malben’s high quality and operational standards not only positions the company to embrace future growth opportunities as stipulated by the South African Automotive Masterplan 2035; but raises the status of the company as a tier 1 supplier to all OEMs.

“For Malben Engineering, a sustainable supply chain not only entails looking at our upstream supply chain but also at downstream suppliers, and ensuring that both our people and those providing equipment to us are operating their businesses in a manner which is compliant with a sustainable supply chain. This equips our company to drive growth and seize the right opportunities to support global automotive OEMs – as well as businesses in other sectors. We term this a ‘ticket to the game’,” he explains.

Playing the game

“As part of this audit, a company does not only state what it does – but has to prove it – and its actions are verified via actual interviews with people on the shop floor. The results of the audit are based on what is happening in practice. We are not a company that relies on a file or a website full of policies or procedures. We do not just list our certifications, we are able to demonstrate that we are truly living them on a day to day basis,” Smargiasso adds.

Malben is also leading by example. Companies within its upstream and downstream supply chain have already requested assistance in getting their operations up to standard and implementing similar responsible supply chain practices.

The RSCI audit also paves the way for continued improvement, as it has helped us to understand what new industry best practices could be implemented, to ensure that Malben Engineering remains at firmly at the forefront of the industry,” Smargiasso concludes.

Steam: an enduring and effective heat transfer mechanism with myriad applications

The use of steam for industrial purposes dates back to the Industrial Revolution and, even in the wake of the fourth industrial revolution and with the proliferation of artificial intelligence (AI), steam boilers remain the unsung heroes of contemporary production and the ‘chameleons’ of manufacturing, as a recent blog describes them.

Dennis Williams, Commercial Director at steam and boiler operations and maintenance service provider, Associated Energy Services (AES) explains:

“The science behind steam use and heat transfer is fundamental to many processes, and will remain a requirement for many industries into the future.  The mode of steam generation might change and the fuels might change, but steam will be needed.

Accordingly, the evolution of industrial process steam boilers has included upgraded control systems and instrumentation. The fundamentals of the ‘boiler’ part of the system where energy is transferred from combustion flue gases into the water to generate steam has been well established for many years.  The focus has shifted to optimising combustion, improving efficiency, aiding operability (reaction time, load following capability, turndown) and improving emissions (reducing CO² and NOx).

When it comes to Eskom power-station sized utility boilers, change has centred on boiler materials and design – with the aim of increasing generation steam pressure to supercritical phase to drive power generation efficiency, and to then consider carbon capture and storage (CO2 capture options; as well as novel combustion systems to drive overall boiler thermal efficiency.

‘Steamy’ mix of old and new

The burning question around steam boilers is undoubtedly, has South African industry kept up?

Williams observes that the local boiler fleet is best described as “legacy” plant – evidenced by the very buoyant second hand / refurbished steam boiler market. This is because older boilers are extremely robust and, with proper operation and care, can last between 20 and 40 years.

“There are however ways for the combustion element (energy input mechanism) to be evolved via retrofits on control systems, fuel switches or technology replacements,” he suggests. 

New fuels have also ushered in various changes, with more gas-fired, biomass and novel fuel systems being implemented, to facilitate the use of (previously) inefficiently used resources to drive circular operating systems.

However, the main differentiator between South African boilers and those used in North America and Europe is the use of coal, which has been replaced by alternative fuel sources, particularly gas.

“On larger scale plants, there has been a lot of activity in fluidised bed systems, including bubbling and recirculating fluidised bed boilers. Their lower combustion temperature has a positive effect on NOx generation and the technology is suited to solid fuels. Fluidised bed boilers have also been used in a few limited applications in South Africa, but the substantial capital investment cost has detracted from this,” he continues.

Williams believes that steam is so enduringly popular primarily because it is an extremely useful and excellent heat transfer mechanism: “It contains both latent and sensible heat energy and can deliver substantial quantities of energy in smaller flows than alternative heat transfer mechanisms relying solely on sensible energy (temperature).  Steam can therefore ensure that temperature within a system is very accurately and effectively controlled.

Myriad steam applications

The use of steam is  widespread across the food (cooking, heating, cleaning, sterilising), rubber (curing, setting, heating), pulp and paper (raw materials preparation, drying, setting), textiles (dye house water heating, textile setting with heat exchangers), healthcare (sterilisation, air conditioning, laundry services, cooking), mining process (heating, activated carbon regeneration), medical manufacturing (sterilisation, air conditioning and temperature control), power generation (steam turbine driving), desalination (waste heat use for evaporative water process), wood board manufacture (fibre processing, platen heating for board curing) and chemical manufacturing (various processes for heat supply, as well as direct use through injection into raw materials) sectors.

Williams notes that, in South Africa, efforts to improve local industries such as the food and textile sectors could certainly see an increased demand for steam.

The right boiler for the job

He explains that there two main types of boilers: those with a fire tube  design, which is essentially a cylindrical vessel containing water, with tubes passing through it that carries hot flue gas through the inside of the tubes. Heat transfers through the tubes to the body of water on the outside of the tubes, eventually creating steam.  Water tube boilers contain less water volume per unit steam output, featuring upper and lower steam drums connected by boiler tubes. Water boils within the tubes, with steam rising to the top of the boiler into the steam drum.

There is also the option of a combined water tube and fire tube design.

Williams adds that optimising efficiencies and understanding a client’s current and future operational requirements are critical when selecting a boiler: “The decision needs to be robust and defensible in terms of longer-term business strategy. These assets are expensive to buy, operate and maintain – and have potentially long service lives if well maintained, so a selection error can impact on many fronts for a long time.”

The perfect partner

AES is the perfect partner in making such a decision, with many years of experience across numerous industries, operations and energy plants, equipping the company to provide the necessary on-the-ground capex, opex and other insights. After engaging with a client to understand their overall objectives, AES can provide an overview of potentially workable steam boiler alternatives – and assist in clarifying the technicalities of each.

“We can then assist with the execution of a project on a turnkey basis – or combine the turnkey project with an operations and maintenance SLA which covers a longer- term contract period (of at least three years).  AES can provide a solution while being fully accountable to clients around their operational outcomes,” Williams concludes.

Bolt and Engineering’s collaboration with leading PPE suppliers highlights commitment to safety and excellence

Bolt and Engineering Distributors (B.E.D.) is proud to highlight its enduring partnership with Dromex, a leader in the provision of high-quality personal protective equipment (PPE). This collaboration underscores a shared commitment to worker safety and excellence, driven by a deep ethos of care and responsibility from both parties. Over the years, this relationship has strengthened, showcasing the dedication of both companies to provide innovative and reliable PPE solutions.

Human connection

At the heart of this longstanding and successful partnership lies a strong human element and connection. Bolt and Engineering’s PPE Product Manager, Annelien Crock, emphasises the importance of personal accountability within the B.E.D. team: “Our relationship with Dromex is built on mutual trust and a shared commitment to safety. We align ourselves with suppliers who share our values and ethos, ensuring that we offer our customers the best possible protection. The products we provide are those which we would use ourselves, reflecting our dedication to quality and reliability.”

Dromex’s vision of a world where every worker is safe all the time resonates deeply with Bolt and Engineering. This shared vision has been a cornerstone of their partnership, fostering a strong bond and mutual support. “We do not just see this as a business relationship,” Crock adds. “It is a very valued partnership, where both sides provide their expertise and support each other. This synergy ensures that our customers receive the technical support and innovative solutions they need to maintain a safe working environment.”

Commitment to Excellence

As a leading PPE supplier, Dromex is renowned for its stringent testing and certification processes, ensuring that its products meet the highest standards of safety and reliability. This commitment to quality is mirrored by Bolt and Engineering’s dedication to providing their customers with the best possible products and services. “We only work with the best in the industry,” says Reinette Human, Marketing Coordinator at Bolt and Engineering. “Our clients know that the PPE they receive is accredited, trustworthy and tested. This gives them confidence in the products, and in B.E.D. as their PPE supplier.”

One of the standout features of this partnership is the comprehensive support and technical expertise provided by Dromex. Crock shares an example of this collaborative spirit: “We had a customer facing issues with recurring hand injuries, despite using gloves. Dromex promptly sent a technical expert to assess the situation, and together, we identified the right product for the specific application. This (literally) hands-on approach solidifies our partnership and ensures that our customers receive the best possible solutions.”

Expanding the circle of safety

The partnership between Bolt and Engineering and Dromex is not an isolated or once-off success story. B.E.D. has cultivated strong relationships with other key PPE service providers and industry leaders, such as Drager and Bata.

For instance, Bolt and Engineering recently collaborated with Drager to test various PPE masks in practical settings to determine their efficiency in the field. B.E.D. has also taken a unique approach by thoroughly assessing customer requirements, and standardising glove offerings to ensure quality and cost-effectiveness. “We aim to provide a complete turnkey solution for our clients, from the smallest nut to the PPE needed to safely use power tools,” Annelien explains.

Bolt and Engineering also provide personalised solutions, such as custom-conti suits, pre-packed and labelled PPE for annual issuing, and in-house embroidery services. These tailored services save customers time and money, streamlining processes and ensuring that their safety requirements are efficiently met.

The PPE division at B.E.D. has seen significant growth, particularly under the leadership of Annelien Crock. From 2023 to 2024, the division has rapidly expanded, a testament to the dedication and expertise of the team. “Our culture of accountability and responsibility is key to this success,” says Crock. “We live by our ethos of 100/0: 100% responsibility, with zero excuses. This approach has not only enhanced our service delivery, but also built confidence and trust with our customers.”

Looking to the Future

“As Bolt and Engineering looks to the future, our partnership with Dromex and other leading PPE sector suppliers will remain a highly-regarded strategic asset. The collaboration and cooperation at the heart of these partnerships ensure that they are more than just business agreements.

Rather, each of these represents a shared journey towards excellence and safety. By leveraging these strong relationships and continuously innovating, Bolt and Engineering is well-positioned to meet the evolving needs of our customers, and ultimately, to ensure safer working environments throughout industry,” Crock concludes.

Turn up the volume to boost sector recovery, says the Hot Dip Galvanizers Association Southern Africa (HDGASA)

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.

Clarifying boiler water treatment – Essential to ensure effective heat transfer and energy management

Poor boiler water treatment is the primary cause of poor boiler performance, according to Chris Paterson, Managing Director of specialist operations and maintenance service provider to the steam and boiler sector, Associated Energy Services (AES).

Not all water is created equal and there is a lot more to water treatment than ensuring that it appears clean, he says. Yet, this is where many companies are tempted to cut costs.

However, because correctly treated boiler water is integral to preventative maintenance and essential to ensuring boiler safety – as well as operational and energy efficiency – this is one of the first and most critical issues that AES addresses when taking over the operations and maintenance of a client’s boilers and energy plant.

A drop in water standards

Poor infrastructure has reduced municipal water quality – while the increased cost of this water source has persuaded many companies to switch to alternative streams such as borehole water and stored rainwater – creating a whole new set of challenges, says AES Operations Director Ray Lund.

“Each of these streams has different properties. Hardness levels (how much calcium and magnesium is in the water) and total dissolved solids (TDS) need to be considered. When using borehole water,  the iron and silica content need to be checked. Furthermore, boiler water should be thoroughly tested over time to see what is in it – and to check the variability of the various contaminants – so that one can design and install appropriate treatment equipment and technology,” Paterson advises.

According to Lund, the quality of water going into a boiler has two direct impacts: the first on the life of the boiler and the second on its heat transfer capacity and efficiency – which affects the overall energy plant management.

Corrosive water damages internal boiler surfaces, Lund explains: “It can cause pitting of the surface material. This often results in boilers either having to be downgraded to operate at lower pressures because the material has been compromised – or even scrapped.”

Clarifying boiler water treatment

Using the analogy of a domestic kettle, Lund explains that compounds such as calcium and magnesium form a hard scale which adheres to surfaces. This limits the transfer of heat from the fire side of the boiler to the water side, making the boiler inefficient when it comes to the production of steam.

However, this does not happen immediately. Paterson warns: “Poor water treatment damages boilers over long periods. Water does not go off specification in one day. Therefore, water treatment needs to be done correctly and consistently, every single day. Unfortunately, this is what many manufacturing and processing facilities miss.”

Lund notes that the relationship between on-site boiler operators and water treatment companies forms a strong foundation for a watertight boiler water treatment strategy: “We partner with water treatment companies to train boiler operators in the importance – and practice – of testing feedwater daily. If any elements are out of specification, they raise that with the regional AES team, and we escalate this to our water treatment partners.”

At the beginning of the process, solids are removed via different forms of filtration. Plants with very high TDS might require the installation of a reverse osmosis (RO) plant which can be a very effective energy-saver, as it requires fewer blow-downs of the boiler to clean it out.

“Typically with municipal water supply, the TDS is low, so we proceed directly to a softener. However, there are some areas in the country where the water is very hard. We look at various technologies to identify the most cost-effective way in which to manage that over the long term,” says Lund.

PH control is always critical, and must remain within the right parameters to facilitate the formation of a protective layer which protects the internal surfaces of the boiler.

Lund adds that oxygenates should also not be overlooked: “It is important to remove as much oxygen as possible before water goes into a boiler to prevent oxygen pitting – especially when boilers have economisers, as there will be oxygen left in the water, causing pitting corrosion and increasing the risk of equipment failures.”

Another consequence of poor water treatment is foaming: this results in liquids – rather than hot gas – being carried from the boiler into the steam piping network and flowing through the system, which can cause a condition known as ‘water hammer’. Pockets of water travel at the same velocity as the heated gas – potentially causing severe damage when reaching a pipe bend.

“This foaming also disrupts the measurement of water levels to the point where – despite indications that these are correct – there may be very little to no water in a boiler, causing it to overheat or even to explode,” he explains.

The last resort: tipping the ‘scales’

According to Lund, when scale has built up to the point where the equipment is at risk and efficiencies are compromised, clients have two options – using an on-line descalant – or a difficult and expensive off-line acid wash, which essentially “pickles the boiler”.

In this instance – in addition to lost production time – as it can take up to four days to acid wash a boiler: the cost of the chemicals, as well as neutralising and disposing of the resulting acid effluent can have a very negative financial impact. Boilers requiring repairs after this acid wash process will further add to the overall cost.

“Years of poor boiler water treatment can really add up, with negative operational and financial consequences. With this in mind – and aligned with our performance guarantee to clients, we do as much as we can to ensure that all AES clients are aware of potential water quality concerns and the related risks, allowing for timeous preventative action to be taken if required,” Paterson concludes.

Coated with success: B.E.D. announces major surface engineering company customer win

Bolt And Engineering Distributors (B.E.D.), a leading supplier of engineering products and services, proudly announces a significant customer win with a surface engineering customer, one of South Africa’s leading providers of thermal spraying and coating technology. This collaboration, which underscores B.E.D.’s dedication to providing top-quality welding solutions and exceptional customer service, began a year ago when one of the customer’s team members was introduced to Kevin Jenkins, the newly appointed B.E.D. Area Sales Manager (ASM) for the Vaal region. The customer – already acquainted with the high standards of Fronius’s welding machines – had a unit which required service and calibration.

Leveraging its expertise as a longstanding and experienced Fronius distributor, B.E.D. efficiently managed the repair process, returning the machine to optimal performance. This success was pivotal in building trust and demonstrating B.E.D.’s capability to meet the customer’s high expectations.

“We are very pleased to announce our collaboration with this valued customer! This is a testament to B.E.D.’s unwavering commitment to quality and customer satisfaction – and to the excellence of our supplier Fronius’s welding equipment and solutions,” says Mike Giltrow, CEO of B.E.D.

Addressing customer requirements

Following the repair and return of their welding machine, the customer encountered an operational issue regarding the selection of the correct settings for a specific welding application. Demonstrating dedication to customer satisfaction, a specialist from B.E.D.’s welding division accompanied the ASM to the customer’s site. The hands-on support and training provided speedily resolved the issue, again showcasing B.E.D.’s commitment to ensuring optimal operational performance for its customers.

Recognising the need to remain competitive in the market, the customer then expressed interest in the Fronius TPS400i Cold Metal Transfer (CMT) machine, driven by their requirement to offer advanced welding processes to their clients. B.E.D.’s welding specialist provided comprehensive insights into the CMT machine, initiating the quotation and purchasing process.

Expertise and confidence

“The customer’s expertise in surface engineering, and the variety of welding processes required for this – including, for example, their familiarity with the cold metal transfer welding process – combined with their confidence in B.E.D. and in the Fronius brand – played a crucial role in their decision-making process,” Jenkins explains.

He adds that throughout the discussions, B.E.D.’s welding division’s extensive industry knowledge was very evident: “Our welding team addressed all the technical queries raised by the customer, providing detailed explanations on materials, machine capabilities and optimal welding settings. This technical support was instrumental in securing the order of the new CMT machine.”

B.E.D.’s welding division’s in-depth technical experience, and understanding of Fronius’s products and solutions assured the customer of the quality and reliability of their purchase. The promise of ongoing support and backup service, along with training for the machine operator post-commissioning, further reinforced the customer’s confidence in their decision. “In addition, our welding division team ensured that all potential issues were promptly addressed, providing robust operational support to the customer,” Jenkins advises.

Successful implementation

Upon delivery and commissioning of the CMT machine, B.E.D. also conducted thorough training sessions, ensuring that the customer’s welding team was well-versed in the use of the new equipment.

“This hands-on approach guaranteed that the customer could maximise the machine’s capabilities from the outset. Since automating their CMT process, the customer has reported outstanding results, reaffirming their satisfaction with Fronius’s welding technology – and the sterling support received from B.E.D.,” Jenkins enthuses.

“Our collaboration with this market-leading surface engineering customer exemplifies the synergy between our technical expertise and their commitment to excellence. By providing comprehensive support and high-quality solutions, we have strengthened their operations and affirmed our dedication to customer satisfaction.

B.E.D. is proud to have facilitated this customer’s enhancement of their welding processes, enabling them to maintain a competitive edge in their market. Our collaboration exemplifies B.E.D.’s ongoing commitment to delivering high-quality engineering solutions and fostering strong, supportive relationships with our customers,” Mike Giltrow concludes.

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

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

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

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.”