Category: Business

Colossal Concrete Products: ‘innovation station’ for rail and infrastructure sectors

March 20, 2025

National Transport Minister Barbara Creecy has again outlined the need to revitalise rail, revealing government’s target to move 250 million tonnes of freight on the Transnet network by 2030 – a substantial increase from 150 million tonnes in 2023/24.

Poised to provide rail clients with their 6 decades-plus wealth of experience is Colossal Concrete, Southern Africa’s largest manufacturer of precast concrete railway products. The company also has a robust portfolio of other infrastructure products.

Colossal transition

Technical and strategic consultant to Colossal, Kobus Burger – who received the Concrete Achiever of the Year award in 2009 from The Concrete Society of South Africa for his work on the pivotal Gautrain project, and what is now known as the universal sleeper – says Colossal has worked closely with Transnet and other clients to develop various products.

This began with replacing costly, scarce and (at times) poor quality wooden sleepers with modern concrete alternatives.

The first success was replacing wooden sleepers on turnout switches with the universal sleeper. This, together with the Infrabolt, was first installed successfully in 2005. Since then, Colossal has replaced approximately 480 378 meters of timber sleepers – which equates to an estimated 3 431 turnout switches.

Burger explains: “Traditionally, turnout switches were laid out dimensionally correctly on timber sleepers and then drilled and fastened onto the timber with coach screws. Each coach screw would be in a specific and unique position. With the more modern turnout switches, concrete sleepers are used with the fastenings in exact positions – millimetre-correct – so assembly can be done much like a Meccano set.”

Burger describes the Universal sleeper as a pre-stressed concrete plank: “We pull out the timber, insert a pre-stressed concrete sleeper and then drill through the concrete (without drilling through the pre-stress wire) and attach the sleeper to the steel work using the Infrabolt.  We were awarded the prestigious Fulton Award in 2007 for creating the Universal sleeper and the Infrabolt.”

The next product developed to replace timber sleepers was the low profile sleeper after a need to find a sleeper that could replace timber sleepers at platforms – as well as in tunnels – was identified. “It is interesting to note that most tunnels in South Africa were designed to accommodate steam locomotives. In addition to their limited vertical height, the later electrification of railway lines created an additional height challenge. Normal concrete sleepers are thicker than timber and, to accommodate this, we created the world’s first low profile concrete sleeper,” Burger explains.

Another technical challenge identified by Colossal was the transition between the resilient track on the ballast beneath the conventional track, and the solid track on the concrete inside tunnels:  “We developed a transition beam that is pre-stressed and post-tensioned to ensure that the transition from the resilient to the solid track is a gradual one. This was a major achievement, as some of the tunnel portals were on a curve and we had to measure the radius and produce the transition beam accordingly. Transition beams have been successfully installed at tunnel portals on the ore and coal lines.”   

Other noteworthy products developed by Colossal Concrete include:

  • Transition sleepers used in the interface of the 1 in 20 inclination of the open line sleepers and flat turnout sleepers. Various transitions from flat to 1 in 40, 1 in 60 and 1 in 80 are available
  • Signal sleepers with conduits to protect cables during tamping
  • The check rail sleeper for small radius curves
  • Derailment containment sleepers for bridges and viaducts
  • OHTE masts with augured foundations, which were used during the electrification of the Kimberley to De Aar line

Innovation further down the track

Colossal can also add the Gautrain commuter rail project to its list of noteworthy successes. At 1435 mm, this was the first standard gauge track in South Africa. When it came to supplying sleepers, Colossal competed with European competitors.

“We supplied the LVT (low-vibration track) for the Gautrain’s tunnels. This is the same system used in the longest rail tunnel in the world – which is the Gotthard Base tunnel in Switzerland – with a route length of 57km and a track length of 114km. In addition to this, we developed three types of sleepers and six types of turnout sleeper sets. All these product track solutions for the Gautrain have performed exceptionally well over the past 15 years.”

Innovation station

Colossal’s innovation mind-set has extended further into rail sector-related products such as rail electrification poles, masts, level-crossing systems, cattle grids, railway culverts, heavy-duty retaining wall beams and drain channels.

Durasafe protective shelters – a lockable concrete enclosure to protect rail signalling boxes – prevent trains from being illegally forced to a standstill and then looted. Burger says this opens up opportunities for further products that will protect other infrastructure installations from vandalism in the future.

As the producer of South Africa’s largest diameter concrete pipes – Colossal also provides product for much-needed storm water and sewage reticulation projects. Additionally, its large-diameter concrete pipes (2250mm-plus) are used at new power stations for the disposal of waste – and Colossal’s concrete poles have been used extensively for the roll-out of fibre optic cables.

“Different sectors use different rail and infrastructure products, according to different requirements. We are proud to provide each client with the specific products and solutions which are best for them.

Finally, we are also considering extending our product portfolio to new market segments,” Burger concludes.

Malben Engineering: investing in people, quality and excellence for over fifty years

March 6, 2025

“Customer- and people-centric” is how Operational Director Luca Smargiasso describes industry stalwart, automotive component manufacturer Malben Engineering, which is celebrating its 50th anniversary.

The company, which operates two state-of-the-art manufacturing facilities in Nigel, Gauteng, is very well-known and respected for its strong tool design and manufacturing capabilities; as well as the supply of high-level welded assemblies (of varying size and complexity), using the latest technologies and world-class surface finishing, including plating and e-coating, exceeding exacting customer corrosion standards.

Malben is also the first South African automotive component manufacturer to import and trial green, low-carbon steel.

Malben has supplied Ford MC SA at 1st tier level since 1978, and other 1st tier automotive suppliers. It has received Ford’s Top 20 Supplier of the Year Award five times – and recently scored 98% in an international Responsible Supply Chain Initiative (RSCI) supply chain audit – the highest score ever achieved by a local supplier.

Malben was also announced the winner of the Environmental Stewardship category in the Steel and Engineering Industries Federation of Southern Africa (SEIFSA) Awards For Excellence at the end of 2024.

Proudly local, Malben is a member of MIBCO (Motor Industry Bargaining Council), and automotive component manufacturers’ association NAACAM, with solid faith in both to represent and champion their interests.

Engineering a firm family foundation

Smargiasso says the family – and the greater ‘Malben family’ of staff – are the custodians of the Malben brand that his father, Amerigo Smargiasso, established back in 1974.

Amerigo Smargiasso remembers how he and five other founding partners – who immigrated to South Africa from Italy during the 1950s and 1960s – cashed in their pensions and, in his case, borrowed R2000 from his in-laws to raise the capital required to set up an operation manufacturing tooling and pressed metal parts for Malben’s first automotive customer, Fiat.

Additional capacity and tooling were urgently needed in the 1970s by South Africa’s fledgling automotive sector – and these highly skilled artisans worked seven days a week, often only returning home in the early hours of the morning.

“We shared the same passion, dedication to excellence and did business the same way. We were all equally invested and motivated to grow and gain experience,” he remembers.

The first ownership change followed in 1980, when three of the original six founders went on to pursue other business ventures. In 1985 and 1995 respectively, two more founders left the company, making Amerigo Smargiasso the sole owner.

The name, which represents the first letters of the hometown from which each of the Italian founders came, was retained as part of the company’s proud, five-decade legacy.

Major milestones

By 1978, automotive stalwarts BMW and Ford were added to Malben’s original customer base of Fiat and Alfa Romeo. In 1998, the company opened its plating facility and in 2002, its e-coating facility. A second plant opened in December 2021 – despite the Covid-19 pandemic making travel to South Africa by Chinese commissioning technicians extremely challenging.

Today, Malben offers a fully vertically integrated service, which includes tool manufacturing, component production / assembly and surface finishing.

“Malben Engineering was founded on a passion for supplying a world-class product through agile decision-making and authentic, people-centric values – all of which are still hallmarks of the company. Although our family provides a close-knit, solid foundation, we have also invested in succession planning throughout the company – and are already developing passionate young managers: introducing new, innovative ways of doing business and ensuring that our quality and production performance are maintained,” explains Luca Smargiasso.

Moving with the times

Malben has seen the automotive sector transform from only manual systems, through to its very first welding robot in 1988, and all the way from there to today’s highly automated systems –   entering the digital era with the same passion for excellence as for everything else on its five decade journey.

Commercial Director Marius Schafer notes that the company’s original, deeply entrenched values remain its bedrock: “What makes Malben truly unique is the hands-on approach to ensuring that quality remains consistent. This is vitally important – because many of the components which Malben supplies are integral to the safety of the people driving the vehicles in which they are used.”

Luca Smargiasso agrees, adding: “One of our key differentiators is that we have also spent a long time entrenching a culture of ownership in our people, across the company. This is no longer confined to our family, but applies to everyone in the company. That is where real sustainability comes in – it is inter-generational and broad-based.”

He also pays homage to his father’s approachable personality and daily dedication: “The key to the ongoing sense of togetherness is also my father’s continued presence on the factory floor. He is an example of passion and commitment. He and our mother – an extremely inspirational influence in all our lives, and who has worked very hard alongside him – were born during the Second World War. The learnings from those very challenging years underpinned the tenacity with which our parents and their co-founders went on to manage Malben’s first, formative years.”

The company – which the Smargiassos regard like a beloved family member – has a flat management structure, with an enduring ‘open door’ policy, and is characterised by three key elements: compassion, consistency and accountability.

Many of Malben’s employees have been with the company for many years. Quality Director, Werner Kapp, has been at Malben for 22 years; while Stanley Makwanazi, who started as an operator in 1978 and has worked beside Amerigo Smargiasso since then, is now Production Manager at Plant 1. Cheryl Tranfaliglia, who started as the receptionist, is now the Human Resources Manager.

Gearing up for the future

Malben is firmly driven by a continued focus on customer satisfaction, maintaining the highest quality, safety and technical standards, and investing in two core pillars:  its valued staff and consistent investment in new equipment and technology.

“We will continue to nurture and develop future leaders to work locally and further afield, as we grow the business overseas in new markets. Already, we supply automotive components which go into vehicles exported to Europe, North and South America. We are able to meet the stringent safety and quality standards for these regions, with their demanding, corrosive weather. We are confident about manufacturing and supplying directly in those countries,” Luca Smargiasso concludes.

Bold new levels of safety and quality with the S.A.T. flux system: a game-changing brazing innovation

March 3, 2025

First Cut subsidiary, gas safety expert Gas Safety International (GSI), is revolutionising traditional industrial brazing with cutting-edge technology which enhances safety, quality and efficiency. This innovative solution is game-changing for industries reliant on high-performance brazing, including the automotive, white goods, storage (racking and shelving), fabrication and engineering sectors.

Brazing is a crucial process in various manufacturing sectors, allowing for the secure joining or bonding of dissimilar (and similar) metal components: for example, copper to brass, or copper to copper. However, traditional brazing methods come with inherent risks, including gas leaks, inefficient fluxing, and safety risks due to high-pressure systems. Recognising these challenges, gas safety stalwart GSI has added its revolutionary S.A.T. regulator, valve and torch to the innovative liquid fluxing system known as the D69. The S.A.T. flux system significantly reduces gas contamination risks and enhances gas welding and brazing efficiency, optimising operational productivity.

Already, GSI has achieved extensive traction with the S.A.T. flux system in the nationwide branches of a well-known white goods manufacturer, as well as with national wheelchair and motorcycle frame manufacturers.

Commitment to safe and efficient brazing

Peter Rohlssen, Managing Director of GSI, highlights the importance of safety in brazing operations: “Our goal is simple: to make brazing safer and more efficient – without compromising performance. Traditional brazing systems are often negatively impacted by pressure-related hazards, contamination, and downtime issues. The S.A.T. flux system tackles these challenges head-on, by ensuring a safer working environment while improving productivity.”

The D69 fluxing unit enriches flammable gas (for example, acetylene) with liquid flux by passing the gas through a reservoir, where it absorbs the liquid before reaching the torch for brazing. This process enhances brazing efficiency, improves joint quality, and operates under negative pressure to increase safety by preventing backflow, reducing explosion risks.

The negative pressure approach not only minimises workplace hazards, but also ensures compliance with international safety standards, making it a preferred choice for manufacturers which prioritise worker safety and operational excellence. The system is further validated by American quality assurance institute UL (Underwriters Laboratories) approval, and its sister institute, ULC (Underwriters Laboratories Canada) – a globally recognised mark of product safety and quality assurance.

The GSI S.A.T. flux system also adheres to stringent industry compliance regulations, including ISO 2503, which governs gas pressure regulators for gas welding, cutting, and allied processes; ISO 5175-2 which governs the valve; ISO 5172, which sets standards for blowpipes used in brazing and gas welding applications; and SANS 3821, ensuring the integrity and safety of the flexible hoses used in gas applications.

Reducing downtime and Increasing efficiency

The S.A.T. flux system addresses one of the most pressing concerns in modern industrial manufacturing – downtime. In traditional brazing operations, equipment often needs to be de-pressurised for maintenance or reloading, leading to a halt in production and lost operational time. The S.A.T. flux system eliminates this obstacle, by offering a continuous operation model, ensuring that manufacturers can achieve peak efficiency without interruptions.

The S.A.T. flux system furthermore features a gas economizer with pilot flame, which ensures that the flow of gas and liquid flux to the torch stops when it is not in use, thereby saving product and time – and crucially, ensuring operator safety. “Economizer contamination is also prevented, substantially reducing the amount of maintenance required, from once every 2 months to once a year,” Rohlssen comments.

“In manufacturing, time is money. Every minute of downtime translates to lost revenue. GSI’s innovative S.A.T. flux system is about delivering a brazing solution not only enhances safety – but also optimises quality and operational efficiency. This is a game-changer for manufacturers requiring reliability and precision in their production lines,” says Ian McCrystal, CEO of First Cut.

Training, service and support

GSI is an authorised service centre for the D69 fluxing unit. With the exception of the gas fluxing unit itself (which is US-manufactured and imported), the heart of the S.A.T. flux system – namely the S.A.T. valve – is ‘proudly local’, manufactured by GSI in Johannesburg. In close co-operation with Messer Cutting Systems small, medium and large gas welding and brazing torches are used.

GSI can also offer a full repair service, exchange units and spare parts as required.

Beyond the technology itself, GSI is committed to providing comprehensive training and support for customers adopting the new system. Understanding that new technology adoption requires knowledge and hands-on experience, GSI offers tailored training programmes, ensuring that businesses can seamlessly integrate the solution into their operations.

“Implementing new technology is not just about the equipment; it is about ensuring that teams understand how to use it effectively,” Rohlssen adds. “That is why we offer in-depth training and support, helping companies to transition smoothly to a safer and more efficient brazing process.”

A bold brazing future

As manufacturers worldwide seek to improve safety, quality, reduce costs and enhance productivity, the demand for innovative solutions continues to grow. By setting new industry benchmarks with their forward-thinking approach to gas welding and brazing safety and efficiency, First Cut and its subsidiary GSI are set to redefine industry standards, offering manufacturers in a broad range of sectors a superior solution which prioritises both worker safety and operational excellence.

“We are always looking for ways to push the boundaries of what is possible in industrial cutting and joining technologies. Bringing this next-generation brazing solution to market truly addresses the needs of modern manufacturers,” McCrystal concludes.

The thermal combustion ‘balancing act’: AES analyses the implications of a fuel source switch

February 25, 2025

From carbon taxes to export tariffs, cost containment to security of supply and sustainability, companies are under increasing pressure to switch to greener fuel sources. However, warns leading steam and boiler operations and maintenance service provider, Associated Energy Services (AES), this pivotal change has some potentially serious knock-on effects.

For AES Commercial Director Dennis Williams and Projects Director Gavin Evezard, legal drivers and corporate head office decisions may initiate the process – but a fuel source switch needs to be case-specific. The ‘plus’ side to this is that carefully considered upgrades, such as the kind which AES manages for its clients, will not only see more effective combustion and better fuel efficiency. They will also enhance productivity and even relationships with communities in areas surrounding clients’ operational sites – ultimately future-proofing their energy plant. However, options must always be logistically and financially viable.

Williams and Evezard note that global commitments made by South Africa in terms of climate change tend to centre on so-called ‘big business’ – rather than on companies further down the supply chain, which are (typically) under immense pressure to contain costs and manage risk. These businesses are constantly juggling the demands of various stakeholders – government, investors, employees and even decision-makers at a multinational level – but will ultimately have to confront the thermal combustion and fuel source conundrum head-on.

Not all biomass is created equal

Because of the low energy density of biomass, it ironically often emits more CO2 per ton of steam than some conventional fossil fuels. “The use of biomass – timber for example – generates a higher tonnage of CO2 per unit useful energy than coal does, and this is a function of fuel qualities (composition, moisture content) and overall thermal efficiency. However, it has been accepted that the carbon in biomass derives from photosynthesis, has been removed from the atmosphere – and is not CO2 stored in the earth as coal or oil – it is deemed to be carbon-neutral,” Williams explains.

Evezard also notes that the potential opportunity for a switch to biomass is region-specific so there is not a ‘one size fits all’ approach when switching to greener fuels:  “Technology selection based on the biomass available is critical.”

Furthermore, space requirements for storing the more bulky biofuels present an added complication – as does long-term supply and pricing, together with potential logistics costs associated with long- distance transportation thereof.

“For industrial thermal applications, the operational cost of a biomass plant may be similar or slightly higher than for a fossil fuel plant. Having said that, the capex required to install that equipment is significantly higher than for an equivalent fossil fuel plant. The maintenance costs are also greater, because of the need for physically larger furnaces and boilers and more materials handling equipment is required to move four to five times more fuel volume when compared to an equivalent fossil fuel plant,” he continues.

The bigger picture

Alternatives to biomass also come with their challenges. While the capital cost of converting to liquid natural gas (LNG) is lower, accessibility is questionable and the energy costs are high. More cutting-edge options – such as green ammonia, green hydrogen and transferring solar and wind energy into a tangible fuel pool – are some way down the track. Those looking to change need to consider what is available now.

Overall, Williams says that AES is fuel-agnostic and always aims to operate a plant as efficiently as possible: “Inefficient thermal combustion and energy plant operation has a negative impact on resource use and emissions. Our involvement results in a ‘more output for less input’ approach. A key starting point for clients to consider is that they get a 100% saving for every unit of energy that their process plants do not need to consume. Energy auditing is a good starting point.”

Evezard adds that companies can also look at some ‘low-hanging fruit’ or very accessible energy savings, by addressing the issue of equipment that is not insulated, the scheduling of how heat is used – and operational equipment which is not in production and on standby for days or hours.

However, it is sustainable sourcing of biomass which remains the greatest challenge. Locally, large paper companies have installed massive energy plants, impacting on the availability of biomass in significant parts of the country. Consequently, clients who secure their biomass supply early are most likely to benefit, leaving latecomers to find other options.

In addition to monitoring technology and supply developments, AES can leverage its almost 30 years of experience in implementing thermal combustion solutions to provide the best one for each client’s business, says Williams.

“We are in a unique position, where our substantial collective experience on projects and operations can provide a client with a technical solution and capex offering. We furthermore guarantee the project outcomes when it comes to performance, efficiency, output and emissions. At the same time, we can provide clients with a steam and boiler operations and maintenance service level agreement with ongoing performance guarantees.”

From non-destructive testing to training: Dekra Industrial’s holistic service offering makes a tangible difference in many sectors

February 21, 2025

As Dekra Industrial and its adult-based education and occupational skills training division, the Institute of Learning (IOL) embark on a new year, the company reaffirms its commitment to offering a truly holistic service across many different sectors.

“By seamlessly integrating non-destructive testing (NDT) inspections together with adult-based education and occupational skills training, Dekra Industrial provides a comprehensive, value-driven solution which supports clients, making a tangible difference across multiple industry sectors,” says Managing Director Johan Gerber.

The company is also physically co-located in key centres including Sasolburg, Lephalale, Secunda, Middelburg and Cape Town.

Holistic offering for multiple sectors

Dekra Industrial and the IOL have strategically aligned their services, ensuring that where inspections and NDT services are provided, adult-based education and occupational skills training opportunities are also available.

“With this fully integrated approach, we are effectively positioned as more than just another industrial service provider – but as a strategic partner to our clients,” says Gerber. “Our co-located offices in key industrial regions also mirror and reinforce this strategy, ensuring that we offer an accessible and complete service portfolio to our clients.”

Together, DEKRA Industrial and the IOL offer a wide range of services, including non-destructive testing (NDT) inspections, vendor inspections, vehicle mapping, welding inspections, safety consulting, and adult-based education and occupational-based skills training.

This holistic service portfolio caters to a wide range of key sectors such as mining, power generation, petrochemicals, construction and manufacturing, ensuring that clients meet stringent safety, compliance and quality standards. By providing a comprehensive and integrated approach, Dekra Industrial supports businesses in maintaining operational excellence while enhancing workforce skills and regulatory adherence.

Enhancing safety, compliance and industry expertise

The combined expertise of Dekra Industrial and the IOL ensures that companies can meet stringent regulatory requirements – while equipping their workforce with the necessary skills to maintain high safety and quality standards.

Christopher Mörsner, Head of Training and Consulting at Dekra IOL, explains: “By providing comprehensive training alongside NDT and inspections, we not only address our clients’ immediate compliance needs – but also contribute to the long-term sustainability of their businesses. This holistic service offering and ‘dual-benefit’ approach supports industry safety, regulatory compliance and staff development in a way that traditional, ‘stand-alone’ services cannot.”

Growth and service excellence

Dekra Industrial’s approach to holistic service delivery also extends to vendor inspections, ensuring that quality control measures are seamlessly integrated across supply chains. In addition, the company now offers vehicle mapping services, in collaboration with Dekra in Japan.

This involves mapping and collecting data on South African road conditions to test and improve advanced in-vehicle infotainment (IVI) systems. By gathering real-time data across various terrains, the initiative aims to enhance navigation and vehicle system performance, aligning with global automotive safety and efficiency standards. This further strengthens the company’s role as a comprehensive partner to diverse industries.

“Our goal is to build on our competitive advantage by refining our offerings and reinforcing our brand as a holistic solutions provider,” Gerber points out.

“We are also placing strong emphasis on educating our teams internally to ensure that every staff member understands the full scope of our services, thereby enhancing the client experience by educating them about our other services which they can benefit from,” he adds.

Mörsner agrees: “Everything we do needs to be solution-based for our clients’ benefit. Our clients are looking for streamlined, efficient services – reflecting global innovation combined with local knowledge and experience. By offering these elements – all in a comprehensive, one-stop solution, we not only meet their needs, but also create added value. Success is a collective effort, and ensuring that, as a company, we succeed together with our clients!”

Strategic growth in SEMEA

DEKRA Industrial has also officially transitioned from the Asia-Pacific (APAC) region to the newly-created Southern Europe, Middle East, and Africa (SEMEA) region, as part of its parent company Dekra Global’s streamlined operational structure. This strategic shift positions Dekra Industrial in South Africa for significant growth, with opportunities to extend its holistic offering to key markets such as Saudi Arabia, a region known for its vast oil, petrochemical and industrial projects requiring NDT, inspection, testing and training.

Gerber expresses his enthusiasm about this regional realignment: “Being part of the SEMEA region opens up remarkable opportunities for our company! The Middle East – particularly oil-rich countries such as Saudi Arabia – presents a growing demand for high-quality NDT, inspection and training services. Being part of Dekra’s SEMEA region therefore strengthens our ability to deliver world-class solutions to a broader client base.”

Committed to continuous improvement

Looking ahead, Dekra Industrial is set to expand its holistic service offering, with a focus on innovation, regulatory compliance and tailored training solutions.

“Our clients are at the core of our strategy. Through our holistic service model, we are creating greater opportunities for safer work environments, improved industry standards and long-term, sustainable partnerships.

This is not just about meeting requirements: it is about adding tangible making a tangible difference to our clients’ businesses. Or, as we like to describe it, ‘expanding our roots for a brighter future’,” Mörsner concludes.

‘Bearing’ innovation and growth in mind: B.E.D. and SKF collaborate to meet customers’ power transmission needs

January 31, 2025

With over 16 years of successful collaboration to their credit, Bolt and Engineering Distributors (B.E.D.) and global bearings supplier SKF have created a significant impact across South Africa’s agricultural, mining and industrial sectors. Their collaboration focuses on providing robust, reliable and efficient bearings solutions which address the specific requirements and challenges of these industries.

At the core of this partnership lies a unique synergy, akin to a scale. On one end is SKF with its cutting-edge bearings technology and products – and on the other end are customers with distinct needs. In the middle, balancing and bridging the gap, is distinctive distributor B.E.D., with its unparalleled vertical sector knowledge and commitment to its customers’ success.

Transmitting power to customers

SKF’s extensive bearings product portfolio is complemented by B.E.D.’s deep industry insight and technical expertise. B.E.D. Product Manager and Agri Product Specialist Gerhard Botes explains: “We effectively act as a ‘bridge’, connecting SKF’s technological advancements and the specific needs of our customers. Our local knowledge and expertise enables us to understand their pain points and deliver solutions that truly make a difference.”

Over the years, B.E.D. has focused on sectors where the demand for high-quality and dependable power transmission solutions is paramount. Micaela Willers, SKF’s Power Transmission Manager for Sub-Saharan Africa notes:

“Electricity is a huge input cost in any sector. South Africa’s recent energy issues illustrated this very starkly. Our power transmission solutions essentially take the load off applications, thereby decreasing energy costs, while increasing productivity. An excellent example of this is in agriculture.

It takes specialised knowledge to serve the agricultural sector effectively. Gerhard and his team at B.E.D. bring this knowledge to the table, with an intricate understanding of everything from combine harvesters to crop sprayers – and more.”

B.E.D. has become synonymous with the providing the right solutions, especially in agricultural power transmission. “Our customers know that they can count on us for reliable products, which enhance efficiency and reduce operational costs – essential during the planting and harvesting seasons,” Botes advises.

Empowering customers through training and support

Both companies emphasise the importance of customer training as a strategic tool to maximise the benefits of SKF’s power transmission solutions. “The training we provide – together with B.E.D. – covers practical skills which are immediately applicable in sectors such as agriculture, mining and manufacturing. It is about more than just using the product; but is about understanding its full potential,” Willier explains.

“B.E.D. does not just push products: they build relationships. Rather, true to their company ethos and tagline ‘It’s our business to know your business’, they invest in understanding their customers’ businesses, which means providing meaningful ongoing support after the sale is made. This relationship-driven approach ensures SKF’s solutions fit seamlessly into customers’ operations.”

A future built on innovation and trust

Looking ahead, B.E.D. and SKF are poised to expand their collaboration into new vertical sectors – including food and beverage. B.E.D. is also planning to explore opportunities in original equipment manufacturing (OEM). Botes shares his enthusiasm for the future: “We see tremendous growth potential in areas where reliability and efficiency are non-negotiable, such as power transmission. With SKF’s commitment to research and development – combined with our extensive local footprint and expertise – we are confident that we can continue to deliver exceptional value!”

“By working with SKF, B.E.D. has access to a wealth of global expertise, as well as research and development-related resources. This enables us to bring cutting-edge bearings solutions to the South African and sub-Saharan African market, tailored specifically for these unique challenges and conditions,” Willers says.

This collaboration means access to best-in-class power transmission products that are both robust and user-friendly. B.E.D. ensures they have the stock and support to meet customers’ requirements – be they immediate or longer-term – backed by their own and SKF’s responsive after-sales support.

“Our goal is to be the go-to supplier for all our customers’ power transmission solutions across many different vertical sectors. We aim not just to provide products, but peace of mind, supported by the trust and excellent relationships which we have with SKF and with our customers,” Botes concludes.

From compliance to performance: LTA Autecon Oil & Gas coastal region celebrates World Quality Week

January 30, 2025

In November 2024, teams across LTA Autecon’s Oil & Gas coastal region celebrated World Quality Week with the theme ‘Quality: From Compliance to Performance’. This theme emphasises the shift from merely meeting compliance standards, to driving performance through a strong and entrenched culture of quality.

Assistant Site Manager Fadiel Meyer, who participated along with many of his colleagues, supports this initiative, as celebrating World Quality Week helps to embed a mindset which motivates LTA Autecon’s people to innovate, collaborate and improve. This echoes and reinforces the company’s own well-known operational ethos and motto ‘Home without harm, everyone everyday’.

“It is vital to ensure that our teams are constantly sensitised to – and aware of – the need for quality in all that they do. It is also important to utilise these initiatives to celebrate the work our teams do, and to show them our appreciation. Our people take these initiatives to heart!” he enthuses.

Celebrating quality through creativity and collaboration

At LTA Autecon, the practice of celebrating World Quality Week began in 2020.

In 2024, it became a uniquely coastal initiative at four of the LTA Oil and Gas sites, in which teams were encouraged to proactively contribute ideas, take ownership and drive quality performance across all projects. The initiative was driven by two of the company’s Quality Co-ordinators: Dean Pierce in KwaZulu-Natal and Randal Jacks in Cape Town.

During weekly alignment sessions leading up to World Quality Week, teams were asked to recommend quality-related initiatives. Management and staff buy-in – and interest – ultimately resulted in many exceptional projects.

Standout examples included:

  • Quality pledge noticeboard: a collaborative pledge noticeboard, where both employees and management made personal commitments to quality improvements. This helped to reinforce a shared dedication to maintaining the highest standards across all operations.
  • Custom hard hat stickers: designed by the Island View site team to commemorate World Quality month, these were a fun and impactful way to show the team’s commitment to quality on-site.
  • Digital awareness displays: teams rolled out digital awareness displays across various workstations. These displays served as constant reminders of goals and achievements.
  • Live quality query registers: a real-time digital tool was created for team members to share complex quality issues and collaborate on solutions. This tool allows teams to address concerns quickly and efficiently on a shared platform, connecting employees across various locations.
  • Recognition of outstanding performance: individuals who went above and beyond in maintaining high-quality standards were recognised and celebrated with special awards. These awards highlighted their exceptional contributions to quality and their impact on project successes.

Safety in quality, quality in safety

LTA Autecon’s safety slogan, ‘Home without harm, everyone everyday’ – which as mentioned has become an integral part of the company’s culture and brand over the years – featured prominently during the company’s World Quality Week celebrations.

Meyer says the two go hand in hand: “A quality project has a core safety aspect to it – and a safe project is always of high quality. After all, we never forget that in the oil and gas sector, we work in a volatile environment, with little room for error,” he points out.

Ensuring – and celebrating – client buy-in

Meyer says that ensuring the safety of clients and their staff is closely aligned with ensuring the safety, longevity and sustainability of oil and gas production plants: “This is the foundation of everything we do on a daily basis – and have done as LTA Autecon for more than 40 years. Our clients know that we do not compromise on safety.”

To make the World Quality Week initiative even more impactful, key stakeholders from client partners were invited to join the celebrations. Their presence underscored the importance of collaboration and shared responsibility in achieving quality excellence: “Our clients set the benchmarks and targets, and we work with their guidance. When we invite them, we are celebrating achieving their targets – or exceeding them. We are also showcasing future initiatives. During times like this, we discover commonalities with clients, and can align our goals: not only when it comes to day-to-day production, but for the long term.”

An example of how LTA Autecon Oil & Gas coastal region has met clients’ operational targets is its impressive welding rejection rate – which is maintained well below internal and client key performance indicators (KPIs) across the country.

Looking ahead, Meyer says that the coastal region management team and staff are excited to continue building on their achievements, further entrenching quality in everything that they do:

“Celebrating Quality Week remains a priority for us, demonstrating that LTA Autecon is constantly evolving to meet the needs of a changing environment, supported by our unwavering focus on quality and safety. The industry is changing: for example, we are seeing a shift towards automation and digitisation. As an organisation, we need to ensure that we stay current and relevant,” he concludes.

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

January 20, 2025

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

January 13, 2025

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

January 8, 2025

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.

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