Multotec has expanded its facilities and capacity of its mill lining factory in Spartan, South Africa, to meet the rising demand, enabling the company to manufacture larger mill liners for clients around the globe.

The expansion consists of the installation of three new presses at the factory that will boost manufacturing capacity by 15-20% to meet the demand for larger mill liners, as well the increasingly demand for Multotec’s new integrated mill liners that are replacing steel liners in the market.

Thando Makhoba, Managing Director – Rubber at Multotec, explains that the installation of one new press has already been completed, while the other two will be installed during  August this year. The new presses enable Multotec to manufacture larger mill liners, that are between 10m and 15m in diameter, whereas previously the company focused on 3m to 7m diameter mill liners.

“Most commonly used for platinum and copper applications, the new presses are more modern and offer greater manufacturing capacity, enabling us to produce integrated mill liners – consisting of lifter bars and shell or grate plates – as one piece. Previously, these components were manufactured separately and then installed at a customer’s site, which involved a considerable amount of time,” says Makhoba.

Reduced installation time

“Because we can now produce mill liners as a single unit that is then installed at a mine, it cuts down installation time by at least 24 hours, thus reducing plant downtime and saving clients’ time and money.”

Makhoba says that the growth in demand for mill liners, which prompted the installation of the new presses, was twofold. On the one hand, Multotec benefitted from winning the business of several competitors who have either left South Africa or have scaled down their local manufacturing capacity. On the other, the company has also seen a huge increase in demand for its integrated rubber liners, which are replacing steel mill liners in the market.

Another important feature of the new presses is that they are much safer, as this modern equipment allows operators to have less physical engagement with the machine during production. “The new presses come with a digital Manufacturing Execution System (MES) enabling the operator to log in on an app and monitor what the machine is producing via live data, that shows what is being produced, whether a specific press is running or not and how much capacity a particular machine has available,” says Makhoba.

Paperless shop floor

“Because of the digital MES, there is no need to print job cards anymore, as all the specifications are displayed on the user interface. This plays well into our push towards a paperless shop floor.”

“Furthermore, as part of our commitment to continuous improvement, we have employed a specialist who is an industrial engineer and is very well versed in lean manufacturing principles. Currently, we are also looking for new production and quality engineers, who will be on the factory floor to train our operators on the new technology,” he says.

“With the installation of the new presses, our mill lining factory has become more efficient and we are able to manufacture increasingly bigger mill liners. Ultimately, we don’t provide mill liners, but rather provide solutions,” Makhoba concludes.

Every two years, over 100 suppliers in the industrial sector gather under one roof to showcase their products, equipment and services to the local market in KwaZulu- Natal. This year’s KZN Industrial Technology Exhibition (KITE) took place from 18-20 July, where providers were exposed to the region’s largest gathering of industrial companies all seeking out their solutions.

First Cut exhibited at KITE 2023 and was in demand as South Africa’s leading manufacturer and distributor of cutting, welding and grinding consumables, capital equipment and precision measuring tools.

Standing out from the crowd

Its position as a supplier of equipment for the metal, timber, textile, meat, DIY, paper and plastic industries gave First Cut added versatility and appeal, and it was perhaps no surprise that they were a standout supplier at the event.

“There was a queue coming into our stand,” says National Sales Director, Stuart Beck, who adds that their presence at KITE 2023 – together with their new Pinetown-based premises – has really put First Cut “back on the map” in terms of their Durban market.

“On the opening day of KITE 2023, some of the organisers wanted to meet with us, and struggled to even get to us! They said that we had the busiest stand at the show,” Beck observes. As an unfortunate legacy of Covid, stands were smaller than in previous years, and the audience of buyers with high purchasing power were perhaps slightly more hesitant, he notes.

With that said, he was stunned and equally excited by the response First Cut received at KITE 2023, with return on investment already showing within a week of the show. “For example, we have already supplied several brand-new customer, which we had not met prior to the show and introduced our range to many more” he comments.

“The real work starts now though – we have a list of approximately 70 leads. The success of the show rests on how we follow up on these over the next few months. We aim to close deals and create new business from the pending enquiries we received.”

Product performance

With the exhibition aimed at providing industrial solutions to local businesses, First Cut knew they needed to showcase their best products and equipment. In this regard, they looked to their key consumables suppliers, namely Starrett and Eclipse, while also having two Everising machines on display from their extensive capital equipment range.

What began as a display ended up as a performance, according to Beck, and it certainly drew in the crowds. “We were cutting steel, with diameters of 150mm and 180mm, and cutting it so paper-thin that the material was bending,” said Beck. “People could not believe that a machine like that could cut steel that thin.”

“We had huge support from Starrett, who flew in one of their international trainers. We were cutting, drilling and sawing steel and drilling holes in wood…we made a huge noise, but this certainly worked to our advantage, as it attracted visitors to our stand.”

According to Beck, most of the product enquiries came from local business owners, production managers and key decision makers from Durban and its surrounding areas. Some of the new business leads also came from other parts of the province, such as Newcastle, Richards Bay and even further afield. “We also have two interested parties from Johannesburg, one of which I have already met with about a supply of blades and abrasives,” Beck added.

The status of industrial technology

KITE also provided opportunities for First Cut to interact with their fellow suppliers, swapping notes on key industry trends, innovations and legislative changes shaping the future of the industrial sector. These trends include product digitalisation as industrial technology evolves. “Industrial product innovation is of course very IT-based,” comments Beck: “For example, palettes on robots using sensors.

There were some large international companies at the exhibition, who are known for implementing open interface automation systems using PC-based control technology. It certainly is impressive how they are now integrating artificial intelligence (AI) into their product ranges,” he concludes.

Opening the door to one of Africa’s most exciting mining regions, Integrated Pump Technology appointed Congo Pump Solutions as its sole distributor in the Democratic Republic of Congo (DRC) earlier in the year.

This important strategic step is boosting the footprint of the quality Grindex range of submersible pumps, according to Jordan Marsh, Managing Director at Integrated Pump Technology. Marsh notes that Congo Pump Solutions – as a local firm run by experienced Congolese personnel – has already made considerable headway in the country’s mining sector.

“Mines in the DRC operate in one of the world’s wettest mining environments, so the performance and reliability of their submersible pumps is a priority for mining companies,” he says. “In line with the success that the Grindex range has achieved in Africa to date, we have seen a good start to the brand’s penetration into the DRC.”

Trésor Kamazani, Chief Executive Officer and Chairman of Congo Pump Solutions, highlights that one of the leading mines in the country has Grindex making up about 70% of its on-site pump population. Among the main pump features catching customers’ interest, says Kamazani, are the integrated starters on the drainage pumps which include run-dry capabilities – as well as cooling jackets and agitators on the slurry pumps.

Workshop facility

“An important aspect of our success to date, though, is our ability to understand and anticipate what our customers will need,” he explains. “We accurately forecast demand levels, and plan for those in our operational strategy. This allows us to have the necessary stock available and to deliver fast turnaround times when customers are in need.”

To ensure solid aftermarket support, the company has set up a workshop facility on site at its largest mining customer. A multi-purpose workshop is also under development to service Grindex pumps to the same high standard as is currently achieved in South Africa.

Congo Pump Solutions has supplied a range of Grindex submersible pumps mainly to DRC’s underground mines, many of which are expanding in response to growing demand for minerals globally. Popular among the underground drillers at the mining face is the Grindex Master H and Master SH 10 kW dewatering pump, and Master Inox pumps for corrosive applications where the water is acidic.

These typically pump water from the face to a collection point, where it is common for the 37 kW Grindex Maxi to be employed – pumping to a larger ‘fish tank’ repository. To dewater these, as many as six of the 90 kW Grindex Mega pumps have been put to work at a time, pumping water to a main pump station which dewaters to surface.

Kamazani also points to the take-up of Grindex pumps in slurry applications, where the Bravo range is suited for submerging in even heavy-particle slurry. “This has made the Grindex Bravo range a good choice for using around the process plant, where they must often deal with corrosive slurry,” he says. “These pumps are known for being strong, and range from the 4,7 kW Bravo 200 to the 70 kW Bravo 900.”

The sludge pumps in the Grindex range have also seen good market reception, with customers using them extensively around underflow thickeners in their plants. He notes that the stainless steel configurations of the Grindex Salvador, Sandy and Senior models are particularly appreciated where sludge is corrosive.

With well over 100 units already delivered, SEW-EURODRIVE in South Africa is set to continue supplying Ivanhoe Mines’ prestigious Kamoa-Kakula Copper Complex in the Democratic Republic of Congo (DRC), a joint venture with Zijin Mining of China, with a wide range of its X.e-series power packs.

According to Willem Strydom, Business Development at SEW-EURODRIVE, the power packs – which are integrated units comprising gearbox, coupling and motor – will be part of Kamoa-Kakula’s Phase 3 expansion. Since the mine’s first phase of development over five years ago, SEW-EURODRIVE has worked closely with both Ivanhoe Mines and the engineering, procurement and construction (EPC) contractor.

“As in previous phases of the mine’s development, our robust high quality power packs will provide reliable solutions in on-site applications such as conveyors, agitators, and slurry pumps,” says Strydom. “The size range in the order makes use of our wide capability range to provide a total solution, ranging from 55 kW units to 500 kW units.”

The latest order includes several X.e Series power packs for conveyor applications, planetary gearboxes for feeder applications, and spare gearboxes. The equipment will be delivered in staggered shipments this year. While the mine typically undertakes the installation of the equipment, SEW-EURODRIVE sends technical teams to site to check final alignment and overall installation parameters.

Sew-Eurodrive

The company has expanded its after-sales service teams considerably in recent years, allowing it to support the growing base of equipment throughout Africa. Its projects and engineering teams have also grown – developing a depth of experience to assist customers right from design phase onwards.

Strydom notes that SEW-EURODRIVE has significantly developed its infrastructural foundation in South Africa, and plans to develop a physical representation in over 23 other African countries. As a priority country for the company’s strategy, there is expected to be a representative in place in the DRC in 2023, he explains. Field service teams from South Africa are frequently at Kamoa-Kakula to assist with servicing of the existing power packs operating on the site.

“Our local assembly capability in our new facility in Johannesburg – combined with our ability to source from the group’s other global operations – has allowed us to meet the tight delivery deadlines for this substantial order of equipment,” he says. “Our global footprint and production capacity mean that we can deliver faster than most players in our field, and this is often an important factor for our market.”

While the company previously imported the larger X.e Industrial gearboxes from Germany, it is now able to assemble these in the new South African facilities. As part of its service, SEW-EURODRIVE will also handle the logistics of getting this large volume of equipment to site. The company’s training centre – the Drive Academy – in Johannesburg has also made a valuable contribution by providing training on the equipment and its maintenance.

In this project, the tropical climate was another important factor in the customer’s design requirements. This required the inclusion of certain cooling and paint specifications in the contract. SEW-EURODRIVE Head of Engineering Andreas Meid explains that special breathers were part of the design in response to high humidity levels – and served to ensure no moisture in the gearboxes. In outdoor applications where sun exposure was high, covers were also included to reduce heat build- up. Cooling fans were also optimised in certain cases to ensure optimal performance.

He highlights that Kamoa-Kakula is one of many projects in Africa to request the installation of monitoring equipment on the power packs. This facilitates real-time monitoring, using specialised sensors to measure key indicators like vibration and temperature from anywhere in the world.

“This allows the operation to monitor the equipment remotely, receiving early warnings of any issues in performance,” says Meid. “Responding timeously to this information can prevent serious damage and avoid unplanned downtime.”

As a preferred supplier, SEW-EURODRIVE first delivered a multitude of X.e Series power packs between 2019 and 2021 for the mine’s initial development phase. Motors ranging in motor from 7, 5 kW to 500 kW as well as planetary gearboxes were supplied during this time for feeder applications, together with several spare gearboxes.

For Kamoa-Kakula’s Phase 2 expansion, which doubled the concentrator plant capacity, SEW-EURODRIVE supplied many standard X.e Series power packs for the conveyors as well as planetary gearboxes for the feeders.

Dry-type transformer specialist Trafo Power Solutions has broadened its offerings to include modular substations – leveraging the company’s depth of experience in designing and providing custom engineered electrical solutions.

“Since our entry into the market supplying dry-type transformers, we noticed an increasing demand for complementary systems related to their application,” says David Claassen, Managing Director of Trafo Power Solutions. “Our evolution began with customer recognition of the level of our in-house expertise, and requests for packaged solutions which included our dry-type transformers.”

Customers needed a reliable supply partner with the competence and experience to understand the specific demands of each project and application, says Claassen. Trafo Power Solutions has proven itself in this role, right from the concept and design stage of a project through to facilitating the manufacture, delivery and on-site commissioning.

He notes that modular substations, often referred to as E-house, are prefabricated or modular structures that house electrical equipment and systems. They are designed to provide a centralised and secure environment for critical electrical components and infrastructure. Often used in industrial settings, power plants, mining operations, oil and gas facilities and other applications where reliable and efficient electrical power is essential, an E-house would house a variety of electrical equipment such as switchgear, transformers, motor control centers, distribution panels, and other power distribution and control devices.

Advantages

“Most significantly, modular substations are built and tested in controlled workshop conditions, making the process more streamlined and cost effective, and ensuring optimum quality,” he continues. “Dry-type transformers are perfectly suited to the philosophy of modular substations, as they can be safely accommodated inside the compact structure enhancing the benefits that modularity brings,” he says. “The attraction of the modular structure is that it can be more easily transported and installed on site – and having a built-in transformer just makes sense.”

Traditional oil-cooled transformers must be installed in a purpose built structure for safety reasons, as there is a risk of leakage, fire or explosion. This often means extra civil engineering construction on site, adding time and resources to the project. The cabling arrangement between the external transformer bay and the substation must then also be accommodated.

“The inherent safety of the dry-type transformer allows it to be installed close to the switchgear inside the modular substation, so there are shorter cable runs and easier installation,” he explains. “The extra cost and management of on-site civils work are also avoided this way.”

Increasing its solutions offering has bolstered the standing of Trafo Power Solutions in the market, as it no longer supplies just a single component, he continues. The company now provides a packaged and integrated solution that minimises its customers’ points of contact during their projects – be they an end-user or an engineering, procurement and construction management (EPCM) company.

“Not only does this save them time, but it also considerably reduces the risks associated with integrating the different aspects of electrical projects,” says Claassen. “There is certainly a trend in the market where customers are looking for more integrated solutions, which allows better quality control and ease of installation.”

He notes that the transition to a broader offering has been quite natural as Trafo Power Solutions has never just provided standard off-the-shelf transformers. It has always customised this equipment for each specific application, requiring an in-depth understanding of the customer’s needs before tackling the design process.

“Within our company, we have strong engineering expertise and experience so it was a spontaneous transition into dealing with the other aspects of modular substations,” he says. “We were always well acquainted with these broader elements in any event, as they informed the design of our transformers.”

This has opened up opportunities for Trafo Power Solutions in a range of industries, many of which may not previously have considered the modular substation concept in their project planning. Increased interest is evident in sectors such as data centres, oil and gas, food and beverage and renewable power generation.

The company has in recent years designed and supplied containerised transformer solutions for mining customers including the remote Bisie mine in the north-eastern Democratic Republic of Congo. So successful were these units that the mine recently ordered three more substations, again equipped with dry-type transformers.

“We expect the trend towards modular substations to continue strongly,” says Claassen. “We have, for instance, delivered multiple modular substations to a large data centre in Johannesburg. Here, we have provided a full medium voltage modular solution including switchgear and transformers, complete with cooling and control systems.”

Trafo Power Solutions is also engaged in the manufacture of almost 40 mini-substations with dry- type transformers, following a large order from a copper mine in southern Africa. In all its transactions, the company is able to design and provide the required equipment with a quick lead time, ensuring customers of on time delivery and on budget, he concludes.