The industry voice of Africa - FEBRUARY 2020 - Packaging And Print Media
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th ANNIVERSARY VOLUME 15 NUMBER 2 FEBRUARY 2020 The industry voice of Africa SPECIAL FEATURE n Sustainability pacts, projects, products, tools COVER STORY n Flowe-Pac celebrates 20 years as key flexible packaging player FEBRUARY 2020 PRINT MATTERS n Polyflex: Africa’s link in Global Premedia Network | Plate mounting, cleaning advances | 4Packaging Africa’s triple renovation strategy CONVERTING MATTERS n 2020 labelling and blown film extrusion trends | The launch of packwise-africa | Greif grows jerry can production FMCG PACK n Easy-to-switch shrinkwrapper | Unlocking solvent coding versatility OFC_PPMFeb2020.indd 11 2020/02/19 1:47 PM
th ANNIVERSARY Flowe-Pac celebrates two decades From very humble beginnings in 2000 as a one man operation in a 50m² space to now employing more than 100 staff in a 5 000² company-owned premises that produces a wide variety of packaging materials, Flowe-Pac has evolved into a multi-driven operation. Owner and founder, Anthony McCeary’s valuable technical and mechanical knowledge in the textile industry, along with unhindering business focus and drive Pietermaritzburg-based Flowe-Pac to succeed, has contributed to the company’s success and impressive growth rate of over has become a key player in the 100% since 2015. South African flexible packaging During the last three years, almost R40-million has industry. As the company been invested in machinery across five departments. ‘Although we’ll continue replacing older technologies celebrates its 20th anniversary, when necessary, consolidation is on the horizon to Nici Solomon tracks its history perfect the wide range of packaging materials already and future plans. produced,’ Anthony says. One of KZN’s leading distributors of Solvents and chemical raw materials. We service and supply multiple industries, including Automotive, Paint and Coatings, ink manufacture Adhesive and Printing industries. Congratulations to FLOWE-PAC on their 20th Anniversary FEBRUARY 2020 2 www.packagingmag.co.za Fo T 031 464 0713 • C 084 677 2385 • E info@swiftchemicals.co.za Em 03-10_FLOW-PAC.indd 2 2020/02/19 3:31 PM
From film extrusion to slitting and rewinding Flowe-Pac uses the finest quality raw materials in its blown film extrusion process, producing superior- quality coextruded, shrink, form-fill-seal and stretch films that can be supplied plain or printed, or converted into bags. To accommodate the needs of its broad customer base, Flowe-Pac extrudes 100 to 3 000mm wide films. According to key accounts manager, Sam Complementing this extrusion excellence are four Green, this accommodates the wide array of products departments that focus on printing, bagmaking, manufactured. lamination, and slitting. The company’s latest extrusion technology So far as printing is concerned, continual investment investment, to be installed and commissioned during in cutting-edge technology, such as a fully-automatic February, is a three-layer coextrusion line with Bobst eight-colour flexographic gearless printing automatic web and gauge control. Replacing three press, featuring automatic register, quick and efficient older lines, it’s expected to boost blown film production job changes, ensures the highest industry quality by 200t/month. standards. An integrated development process allows Flowe-Pac’s management team to work alongside customers to create the most appropriate flexible packaging to suit their needs. Proud to be associated with Flowe-Pac and wish them all of the best for next 20 years. We specialise in Assets and Liability Insurance Cover Arrangements and we are passionate about excellent Service, Competitive Premiums and FEBRUARY 2020 Personal Advice on your Personal and Commercial Insurance needs. www.packagingmag.co.za 3 For further information contact: Dennis Watkins o.za Email: dennis@allaboutins.co.za • Mobile: +27 083 627 6164 • Telephone Number: +27 033 386 0400 www.allabout.co.za 03-10_FLOW-PAC.indd 3 2020/02/19 3:31 PM
th ANNIVERSARY Flowe-Pac is equipped with a large variety of downstream bagmaking equipment, capable of converting printed or plain film into side, bottom, spine seal, patch handle or gusseted bags. Its Uteco laminating capabilities include plain and printed speciality films, barrier films and solventless lamination. Sealing properties for individual product applications can also be customised to improve packaging performance and aesthetics. Equipped with high-speed automatic slitting and rewinding equipment, Flowe-Pac converts large reels of laminates, film, paper, as well as printed and coated materials into smaller reels. Dedicated to world-class production and speedy delivery, Flowe-Pac offers retailers, manufacturers and distributors across South Africa the convenience of a one-stop flexible packaging shop. Recycling plant These departments are supplemented by a recycling plant to recycle scrap plastic into a reusable raw material. Established 15 years ago, this is a prime example of Flowe-Pac’s commitment to sustainability and ecological responsibility. It’s also fed by secondary packaging and paper cores collected from customers’ facilities. ‘We pay customers a good price for these materials because we’re reusing them and benefitting from stabilising the price of recycled raw materials, previously governed by outside suppliers, giving us a more cost-effective end product,’ Anthony explains. ‘Additionally, we assist customers who need to improve their sustainability credentials by incorporating recycled content from their packaging waste and offering them a market-related price reduction.’ The recycling plant, with a 200t/month capacity, currently employs 25 people who manually sort waste. Materials that can’t be recycled on-site, such as BOPP and PET, are baled and delivered to recyclers in Durban. FEBRUARY 2020 4 www.packagingmag.co.za 03-10_FLOW-PAC.indd 4 2020/02/19 3:31 PM SRF_ad_
Quality control and R&D Flowe-Pac’s ISO 9001 quality management system was first implemented in 2004. In July 2019, the company was awarded its ISO 22000:2018 food safety compliance certificate. Additionally, Flowe-Pac will be a Level 4 B-BBEE company by its next audit. The QC team – headed by internal auditor, Winnie Dlamini – continuously trains operators to hone their skills. Winnie is assisted on monthly customer site visits by an accounts manager. ‘We enjoy establishing personal relationships and being involved with our customaers’ businesses,’ Anthony maintains. ‘Once we’ve established that bond and become an integral cog in their product development process, they always consult us for packaging advice.’ th As Anthony sums up: ‘It’s gratifying being involved ANNIVERSARY in new projects from the ground up because it opens doors and creative opportunities. We use our experience and knowledge gained from trade show visits and research to examine trends and technologies that can benefit our customers. We’re happy to trial and test new material constructions in the factory. However, the key to our success, is not forgetting to focus on what we’re currently doing to the very best of our ability.’ Training centre FLOWE-PAC employs 120 people and has a dedicated training centre for upskilling employees. For the past two years, factory mantaintance managers, Giovanni Benigno, an electrical engineer, and Michelle Rouillon, a mechanical engineer, have been providing in-house tchnical training to the operational teams. Supervisory, junior management and quality control courses are conducted by external trainers. Managers have reported a positive mindset change on the production floor since the implementation of these training programmes. Employees are also encouraged to apply for study scholarships to pursue their academic interests, and for financial assistance with their children’s schooling tuition. FEBRUARY 2020 www.packagingmag.co.za 7 03-10_FLOW-PAC.indd 7 2020/02/19 3:31 PM
th ANNIVERSARY FEBRUARY 2020 8 www.packagingmag.co.za www.packagingmag.co.za 03-10_FLOW-PAC.indd 8 2020/02/19 3:31 PM
Customer credentials Flowe-Pac has enjoyed a 12-year partnership with Orange Grove Dairy. ‘In 2008, Flowe-Pac started supplying our milk sachet material. The price was good and the owner, Anthony McCleary, who was hungry for a new customer, has supported us with technical knowledge ever since,’ reports operations director, Guy Deveroux. ‘We’ve grown into UHT formats and Flowe-Pac supplies all our shrink and pallet wrap.’ Once a month, a quality controller visits the dairy to conduct a quality check, full audit and to train the operators. Additionally, the team, regularly introduces innovations and support. ‘This is an example of how Flowe-Pac is positively dedicated to servicing our industry with passion,’ Guy adds. Flowe-Pac has also worked with the Willowton Group for the past seven years. ‘The team is very accommodating of our print needs, and has gone beyond the call of duty to assist us with innovative ideas,’ says group head of packaging, Salim Gani. ‘Attention to detail and quality have exceeded all expectations, and we hope to grow our partnership further in years to come.’ Proud suppliers to Flowe-Pac from there first kg of ink CONGRATULATIONS Here’s to the next 20 years. FEBRUARY 2020 www.packagingmag.co.za 9 03-10_FLOW-PAC.indd 9 2020/02/19 3:31 PM
th ANNIVERSARY Service superheroes According to owner, Anthony McCleary, Flowe-Pac’s foundations are built on teamwork, accountability, passion and flexibility in both development and production, which drives everyone to perform better, achieve more and deliver faster. Proud Partner ‘This approach complements our training programme and mission of providing customers with excellent quality and the best possible service, as well as our We wish Flowe-Pac vision of being the preferred flexible packaging supplier a very happy in the local market and surrounding areas,’ he asserts. On-time deliveries are ensured by Flowe-Pac’s 20th Anniversary! fleet of trucks, which include a four-ton,14-ton and four 8-ton models, whose drivers work according to a route plan. This, says Anthony, is a far more reliable proposition than relying on a third-party service Passionate about packaging... provider’s delivery schedule. ‘We wouldn’t be celebrating this 20th-anniversary without the support of our staff and customers. We view our highly-motivated and dedicated employees as our greatest asset, and we’re grateful to our customers for their continued loyal support,’ Anthony enthuses. Sales and Service ‘We believe placing customers first and Tel: 011 433 2686 • bmmarketing@beswick.co.za accountability are key factors in building and www.beswick.co.za maintaining long-term partnerships, standing by our motto – “By service we grow!”, to ensure business growth and meet the ever changing market needs.’ FEBRUARY 2020 For more information, visit the 10 website: www.flowepac.co.za www.packagingmag.co.za 03-10_FLOW-PAC.indd 10 2020/02/19 3:31 PM
Powering a new plan Editor’s LETTER TWO events recently piqued my interest: a spikes has resulted, in many cases, in equipment presentation by David Nicholls, who retired as having to be replaced or decommissioned. This has Eskom’s chief nuclear officer in 2018, explaining further hindered the local industry’s ability to meet why 2020 decision-making is crucial in resolving deadlines and supply orders in time – opening the the country’s power crisis; and president door for more finished product imports – which places Ramaphosa’s State of the Nation Address (SONA) thousands of local jobs at risk. setting out government’s key policy objectives and deliverables. Buy local master plan David Nicholls explained that coal-fired power A government initiative that could help to counteract stations have a 50-year lifespan on average and local job losses is designating 1 000 locally-produced because maintenance execution cycles and timely products, which must be procured from SMMEs, to funding for replacement parts were so problematic create a larger market for small businesses. The for Eskom, South Africans can expect four of these president announced that projects with an investment to reach this stage and go off the grid by 2028. He value of R9-billion have already been completed, and reiterated that they ‘cannot be saved’ and that the 27 projects worth R250-billion – to build factories for only way forward is to flatten them and rebuild from manufacturing food, power cables, smartphones, cars, scratch. The snags are that it leaves the country and tyres – are in implementation phase. with an even bigger power shortfall than we are Additionally, commitments made by retailers to buy currently experiencing and it takes around 10 years goods locally, the launch of a Special Economic Zone from the time a decision is made, funding is secured, hub in Tshwane for producing automotive components, contractors and suppliers are appointed to finish and a Clothing and Textiles Master Plan, all promise building and commissioning a new one. That means sector level growth for the plastics packaging and a potential two-year shortfall where manufacturing broader industry. facilities could face serious power outages that prevent Further steps such as new tariff codes to clamp operations, making the current load shedding problems down on under-invoiced products and illegal imports appear minuscule. So the underlying message is that are positive measures to gain better control over the the government needs to decisively set and commit to products coming into the country. They also form part a course of action this year in hopes of securing future of PlasticsISA’s industry master plan, being developed power supply and preventing investment and economic in conjunction with the Department of Trade & Industry, Armageddon. to stimulate growth by lowering tariffs and introducing During the SONA, the president announced incentives for local manufacturers; and limiting plans to negotiate supplementary power purchase the importation of plastic waste to help protect the agreements from existing wind and solar plants, and environment and grow demand for local waste. to allow municipalities in good financial standing, to The overriding question is: can packaging and procure power from independent power producers. printing industry value chain be cautiously optimistic David Nicholls, however, cautioned against viewing about the plans and strategies unveiled by the wind and solar generation as the cure-all because president? Yes, provided that he displays strong of the logistical/infrastructural challenges and cost political will and leads the rest of the government and implications involved (more than nuclear) in feeding its public and private sector partners to take decisive them into the national grid. action on these plans. To secure the future of the local manufacturing sector and the economy in general, it’s Heavy costs of load shedding high time they walk the talk! We are left with the reality that load shedding will continue for the foreseeable future so that Eskom can execute much-needed maintenance and repair programmes to prevent further collapses into darkness. The practical implications for manufacturers are hard-hitting. A good example is from the plastics packaging and recycling sector, where conversion methods for plastic fabrication are electricity-intensive and account for 15-18 % of manufacturers’ operating costs. These manufacturers and recyclers rely on a consistent supply of high voltage electricity to operate machines at maximum capacity because it usually takes a minimum of two to three hours for them to start-up and reach optimal temperatures. Losing power numerous times during the day and/or mid-operation has, therefore, disrupted businesses and resulted in large amounts of raw materials and resources being wasted because each time machines need to be scraped clean for the start-up process to begin anew. Load shedding has also exacerbated voltage fluctuations, and the damage caused by electricity FEBRUARY 2020 www.packagingmag.co.za 11 11-13_Eds_ContentsCredit_PPMFeb2020.indd 11 2020/02/21 12:05 PM
CONTENTS FEBRUARY 2020 UPFRONT Security Printing: Kennedy & Associates’ 48 11 Editor’s Letter: Energy action fixes specialised paper product range now or face 2028 bust 14 News & Events: Twizza’s cannery CONVERTING MATTERS ramps up production of Clark & Sons 50 Labelling & Narrow Web: Labelling mixers; Mpact reaches agreement trend predictions for 2020; packwise- on historic acquisitions; drupa’s five africa brings leading printing/converting knowledge-sharing forums technologies to Sub-Saharan Africa 16 Interview: Nampak CEO Erik Smuts 57 Plastics in Packaging: Blown film shares his views on effective management extrusion trends; Verigreen Plastics and Teqal’s technology partnership extends 17 Women in Print: Sonja Groenewald, rigid plastics portfolio; Greif grows jerry SA’s go-to educational book printer cans’ regional footprint 18 WPO News: Lifetime Achievement 63 Flexible Packaging: Uteco’s Diamond citations for Keith Pearson, Joe Foster HP press meets evolving market needs 23 Sustainability Update: SA Plastics 64 Surface Treatment Update: Locally- Pact launched; Eastern Cape pilots produced corona treaters backed by returnable PET bottles; CTP Packaging’s 30 years’ expertise Earth Choice brand; In-store coffee cup recycling; Digital tool measures circular economic performance; SRF drives FMCG PACK collaboration; Nestlé creates packaging 66 Packaging Design: Clive highlights the venture fund; Mpact Versapak’s rPET best in promotional packs grape punnets 69 Coding, Marking & Labelling: Squid Ink 31 Into Africa: Propak East Africa 2020 unlocks solvent coding versatility; Mass show preview market prestige labels; Post-industrial and post-consumer waste boost label’s eco credentials PRINT MATTERS 71 End-of-Line Packaging: Easy-to-handle 38 Flexo Forum: Polyflex becomes Africa’s shrinkwrapping system Global Premedia Network member; Latest plate mounting and cleaning developments FINISHING TOUCHES 45 Gravure Matters: 4Packaging Africa’s 72 Yours Irreverently three-pronged renovation project; Bobst 73 Diary of Events balances automation and affordability; 74 Index of advertisers and their web Global news in brief addresses FEBRUARY 2020 12 www.packagingmag.co.za 11-13_Eds_ContentsCredit_PPMFeb2020.indd 12 2020/02/21 12:06 PM
don’t let TOOLING The industry voice of Africa be a This month’s cover story PRESSing th ANNIVERSARY FROM humble beginnings in 2000 as a matter. VOLUME 15 NUMBER 2 one-man operation in a 50m² space to employing more than 100 staff in 5 000² company-owned premises, providing a wide variety of flexible packaging materials, Pietermaritzburg-based Flowe- Pac has evolved into a multi-driven FEBRUARY 2020 operation. Owner and founder, Anthony McCeary’s valuable technical and mechanical knowledge gained in the textile industry, The industry voice of Africa along with an unhindered focus and drive to SPECIAL FEATURE n Sustainability pacts, projects, products, tools COVER STORY n Flowe-Pac celebrates 20 years as key flexible packaging player succeed, has contributed to the company’s success and impressive growth rate of over FEBRUARY 2020 PRINT MATTERS n Polyflex: Africa’s link in Global Premedia Network | Plate mounting, cleaning advances | 4Packaging Africa’s triple renovation strategy 100% since 2015. CONVERTING MATTERS n 2020 labelling and blown film extrusion trends | The launch of packwise-africa | Greif grows jerry can production FMCG PACK n Easy-to-switch shrinkwrapper | Unlocking solvent coding versatility For the full story, turn to page 2. Publisher: Susi Moore susi@packagingmag.co.za T 010 5940342 C 082 5686729 PO Box 652358, Benmore 2010 Managing Editor: Nici Solomon nici@packagingmag.co.za T 010 5940342 C 071 5300775 Western Cape Editor: Gill Loubser gill@packagingmag.co.za T 021 7120030 Junior Editor: Malissa Smit malissa@packagingmag.co.za T 010 5940342 C 084 2402234 Business Manager Glywnnis Wells glywnnis@packagingmag.co.za Western Cape/KwaZulu-Natal: T 021 7628825 C 083 4655874 New Business Development Manager: Samantha Moore samantha@packagingmag.co.za Designers: Banie Stafford flair@baniedesign.com T 010 5940342 C 073 1951313 will solve C 074 1927827 Carla-Lee Lawrence carla@packagingmag.co.za it in a Advertising Admin/Circulation: Kgaogelo Khumalo kgaogelo@packagingmag.co.za T 010 5940342 Contributing Editors: Brenda Neall, Susan Unsworth European Correspondents: Nick Coombes, Des King PACKAGiNG & Print Media is published by Packaging Chain cc and printed and bound by Tandym Print, Cnr Mail & Park Road, Western TANDYM Province Business Park, Epping, PO Box 775, Eppindust, 7475 Cape Town T +27 021 975 6763 OFFICIAL JOURNAL: Flexographic Technical Association of SA E pascal@rotocon.co.za Institute of Packaging South Africa Johannesburg Official Media Partner: Gold Pack Awards T +27 011 397 2172 Media partner: Printing SA E patrick@rotocon.co.za Durban T +27 031 701 0383 E akhmuth@rotocon.co.za www.rotocon.co.za 11-13_Eds_ContentsCredit_PPMFeb2020.indd 13 2020/02/21 12:06 PM
New cannery ramps up production News & Events of Clark & Sons mixers SOFT drinks company Twizza has commissioned Job creation a state-of-the-art canning line in Queenstown, ‘As well as allowing us to meet increasing market Eastern Cape, to can its popular Clark & Sons demand for our beverages, the new line has created mixer range. ‘We’re really excited to announce that our very first 24 new full-time jobs,’ Ken continues. canning line is up and running and in full operation,’ The Clark & Sons brand recently launched two says Ken Clark, who established Twizza as a start-up new flavours, Baobab and Ginger Cola, to its existing operation in 2003. The plant now marks a significant 13-strong range. Both new variants were curated milestone as an indicator of the company’s growing specifically for local market tastes. presence in the carbonated soft drinks sector. The Queenstown plant is positioned as a modern A high-spec Ocme line from Italy has been installed. production line, producing the highest-quality Completely automated – from depalletisation to beverages. ‘This includes the aesthetic presentation of palletisation and through to finished product – it the product and its on-shelf appeal,’ says Ken. ‘We’re handles 3 600 cans/hour. exceptionally proud of being an authentic South African Running pre-printed cans, the plant is designed for company and of the superior products we make. flexibility to accommodate any packaging configuration Opening this plant, which offers the most sophisticated and all can sizes. In addition, the cannery also offers a canning equipment, bodes well for our continued contract packing service when capacity is available. growth into 2020 and beyond.’ Mpact reaches agreement on historic acquisitions MPACT has responded to a media statement issued by the Competition Commission regarding a settlement agreement. According to Mpact, the agreement relates to the acquisition of various minority interests by the company’s predecessor-in-title, prior to Mpact’s listing on the JSE in 2011, which were not notified to the Competition Authorities at the time of acquisition. The parties have reached a comprehensive settlement amounting to R7-million to resolve all matters relating to the minority shareholdings held in these entities. The settlement agreement is comprehensive in that it covers the failure to obtain the prior approval of the Competition Authorities, and any potential concerns the Commission may have regarding the relationship between Mpact and the sheet plants concerned. At all relevant times, Mpact and the sheet plants in which it had minority shareholdings were principally in a supplier-customer relationship. As such, Mpact maintains that, contrary to the Commission’s portrayal, the relationship between it and the sheet plants has not been collusive in nature. However, as the company notes, the settlement agreement finally resolves all potential concerns in this regard. laminates business cited ‘substantial changes in the market for enhanced packaging which have affected or business for laminated products’. AIPIA postpones Asia Smart Packaging Summit China: AIPIA, the Active & Intelligent Packaging Industry Association, has postponed its Summit, scheduled for April in Shanghai, owing to ongoing API initiates bankruptcy proceedings uncertainties raised by the spread of the 2019-nCov US & UK: API’s bankruptcy filing affects its laminates Coronavirus in China and many other regions. Says Eef and foils business in the US and UK. The US laminates de Ferrante, AIPIA’s MD: ‘Our first priority is the safety business is actively engaged in a sale process, during of members and delegates attending the Summit. While which period normal operations will continue. The foils the efforts to control the virus are increasing, the risks business will be liquidated. remain, and the lockdown on travel in and out of China In a letter to customers and vendors, API’s US is likely to continue for the foreseeable future.’ FEBRUARY 2020 14 www.packagingmag.co.za 14-16_News&Events_PPMFeb20.indd 14 2020/02/20 8:23 PM dru2002_
Eleven days of vision and inspiration DRUPA is much more than just a global trade show economy with more for the print industry; it ranks as a top international diversified sales fair that identifies important trends, offers insights channels, new into future developments and drives inspiration. collaboration models, and To provide visitors with the best possible experience, the changing expectations drupa invests in top-class knowledge transfer through of connected customers its five special forums, the drupa Cube being one of in a social media culture them. – all against a backdrop ‘educate|engage|entertain’ has been chosen once of the industry’s growing again as the slogan of the drupa Cube for 2020, sustainability and circular designed to provide a broad spectrum of relevant economy obligations. content that’s motivating, stimulating and interactive. ‘Our primary aim is to World-renowned speakers are set to create a buzz present as many ideas as with a visionary range of topics. Best-selling author possible that delegates Michael Gale and internationally-renowned designer can implement in their James Sommerville are among contributors to the top- own companies,’ says class programme with their keynote presentations. Sabine Geldermann, Featuring some 40 sessions, the drupa Cube serves drupa director at Messe Düsseldorf. ‘We want to offer as a source of inspiration and expertise on new digital a programme that meets their actual needs.’ business models, bringing participants up to speed Pre-registration is required for these sessions. The with global megatrends that have already left their complete programme of the drupa Cube, which takes mark and are on course to shape the future. place for the entire duration of the fair from June 16 The focus is on innovative web-to-print and to 26, is available online at the end of February at packaging technologies, the potential of a platform www.drupa.com/cube-en branding and design sustainability and circular economy brand integrity and safety discover trends find solutions connected consumer and e-commerce and visions customization and personalization drupa 2020 time-to-market and supply chain June 16–26, 2020 quality and Düsseldorf/Germany color control www.drupa.com/tpp-en 14-16_News&Events_PPMFeb20.indd 15 2020/02/20 8:23 PM dru2002_TPP_Anz_210x148+5_ZA.indd 1 16.12.19 16:33
INTERVIEW PPM’s Nici Solomon and Susi Moore learn more about Nampak CEO, Erik Smuts’ approach to leadership, training and overcoming industry challenges. Simplifying and future-proofing Nampak Fifteen days into his new role as Nampak CEO, PPM caught up Erik Smuts to discover his views on leadership, the impact of artificial intelligence on skills development, and how to make a positive impact in the packaging industry. Ed: What are the greatest challenges you and Ed: What challenges and opportunities does the Nampak face in the year ahead? fourth industrial revolution present from a skills Because the packaging environment is changing, we need development perspective? to adapt to it, and overcome three primary challenges. I don’t believe the artificial intelligence component will These encompass rebuilding stakeholders’ trust, affect people at the top and bottom of organisations navigating a severely-pressured economic landscape, – it will affect those in the middle tier performing and simplifying the business for optimisation and growth. repetitive tasks. The affected employees will need Legislative changes, such as a levy on single-use plastics, to be upskilled to enable them to add more value are also a distinct possibility. Fortunately, I thrive on through creativity as new technologies are introduced challenges! and the market changes. Machine learning will also assist staff in becoming more efficient by Ed: How would you describe your business complementing their duties and providing task philosophy? support. The country’s education system needs to Simplify to satisfy. To make sense of all aspects of your adapt to ensure improved mathematical and technical business and the environment that you operate in, you skills, to produce youngsters who can become data need to uncomplicate things to ensure greater success. scientists/actuaries, or have the skills to operate robots or create the algorithms driving efficiency Ed: And your leadership style? improvements. Trust is vital in any relationship and is built up over time. I prefer to give my staff room to prove themselves Ed: How is Nampak future-proofing skills and to take accountability for their roles rather than to development? micromanage tasks. I also like to keep formal meetings It is vital to employ the right kind of people and as short as possible. I encourage informal discussions help them grow through dedicated training and as they tend to produce the best problem-solving mentoring programmes. Operators are offered training results, and enjoy people who question one another in technical skills, while a graduate programme in a constructive way, as critical thinking and curiosity prepares those identified for management roles to generate new perspectives and ideas. make the transition and to implement Nampak’s succession plans. Ed: What are the biggest lessons learnt from Additionally, we are encouraging top-level managers working in other African markets that can be to complete at least one training course annually, applied locally? at their own pace and convenience. Consistently People in developing markets are beacons of acquiring new skills helps them to keep pace with resourcefulness. They have to come up with creative change. ways of overcoming unique sets of challenges; they achieve great things through a positive attitude and Ed: What advice would you give to someone a hunger to improve systems and processes so that starting in the industry? operations run more efficiently. Unions also have a Any newcomer in a business needs to make their critical role to play in the success of South Africa’s mark early on. Thinking beyond the job description manufacturing sector. By becoming invested in the and showing initiative brings their contributions to a company’s success (improvements in volumes and the notice of management. Moulding jobs around efficiencies), they help secure the long-term viability incumbents’ particular strengths helps deliver the of members’ jobs. best outcomes. FEBRUARY 2020 16 www.packagingmag.co.za 14-16_News&Events_PPMFeb20.indd 16 2020/02/20 8:23 PM
Reliably perfect printing Women in PRINT booms in Bapsfontein Three years ago, PPM noted that Sonja Groenewald, Bapsfontein’s business ball of fire, was building a printing empire through unwavering dedication and sheer slog. Nothing has changed, except that the empire is expanding as trojan Sonja devotes every minute to finetuning her principle of ‘reliable perfection’. Susan Unsworth checked in with her. IF a Colourtech customer spends R100, Sonja Groenewald provides R200 in value. It’s a simple maxim with maximum impact that has seen the company become South Africa’s go-to supplier for educational books. Everything about Colourtech makes perfect business sense – its position on the Groenewald farm on the road to Delmas, close to major cities and airports; its turnkey service (through the support of an inhouse textbook publishing operation and three other Educational printing specialist, Colourtech, is stronger than sister companies onsite), which includes textbook ever after almost 30 years in business, proof that owner Sonja delivery not only to colleges but to individual students, Groenewald has wiped the floor with her homework and aced and has led to a long-standing partnership with the her apprenticeship in this highly competitive industry. education department; its expertise in e-learning; in-house representatives in courier companies, and marathon, but you must work extremely hard in any warehousing facilities for customers. circumstances. You cannot afford to tarnish your good Sonja’s success is no accident – she does name with slapdash products. Your reputation, good or everything with design and determination. bad, will precede you.’ A major turning point was the 2016 purchase, made Sonja rarely stops to soak in the rewards of with characteristic business bravery, of Africa’s first her efforts. She is currently on a mission to assist Screen TruePress Jet520HD. ‘That unit enabled us institutions by revitalising textbooks and printing them to print exceptional-quality colour books affordably, in full colour at black and white prices. ‘Learning will which is not only good for us, but helps our customers’ be more exciting and students more empowered businesses flourish,’ Sonja explains. More recently, two to achieve goals and reach their full potential,’ she Canons offering high-definition image quality at litho maintains. prices have bolstered the company’s printing prowess. Tough times call for innovative thoughts. Companies Information technology is also top-notch and are printing less, so Colourtech is producing books with customers integrate easily with Colourtech’s processes, fewer pages, but greater aesthetic appeal and user- remaining fully informed of progress from order friendliness. E-learning is being brought in to create placement to delivery. ‘Our upgrades have enabled blended learning. us to almost double our team, as we can serve more It’s hardly surprising that Sonja lists Colourtech customers with top-class products,’ she states. as one of her two main hobbies, the other being Sonja’s relationship with employees is a cornerstone photography. ‘I love what I do,’ she stresses. ‘I would of the business. ‘Nothing is more important than gladly go to work in the middle of the night, every service, which builds strong, lasting connections night.’ with customers, but first come strong, enduring Living in a rural area and schedule permitting, Sonja relationships with employees. revs up her quad bike and starts a dust storm with her ‘Communication and teamwork are essential sons, Etienne, who is in the business, and farmers because everyone must pull together to tackle Gunter and Ben. Husband Deon also farms, but often unforeseen problems. Not everything in business is pops in to see how the business he helped found is about making money.’ doing. He doesn’t need to bother. The testament to a life explored fully, one may Sonja is adamant that she is exactly where she argue, is a hankering to have done certain things should be. ‘As a devout Christian, I believe I was differently. Not in Sonja’s case. ‘I wouldn’t change a placed on earth, specifically in Bapsfontein, to make thing,’ she insists. ‘Every hardship, trouble and triumph a difference in the lives of staff and customers. Mark has made me what I am. Twain said: “Whoever is happy will make others happy ‘Occasionally life’s a stroll, more often it’s a too.” I hope people feel these words describe me.’ FEBRUARY 2020 www.packagingmag.co.za 17 17_Women in Print_PPMFeb20.indd 17 2020/02/19 1:49 PM
Lifetime Achievement citations: Keith Pearson, Joe Foster As one of the international adjudicators, Gill Loubser spotlights some of Keith Pearson’s and Joe Foster’s outstanding achievements that led to their being honoured with WPO Lifetime Achievement Awards. THE WPO (World Packaging Organisation) has named two recipients in the ‘Lifetime Achievement’ category of the 2020 WorldStar Awards: they are South Africa’s Keith Pearson and Australia’s Joe Foster (the latter, a native of Ireland, resided for many years in South Africa!). ‘The Lifetime Achievement in Packaging Award acknowledges and rewards excellence in all aspects of packaging science, technology, design and application,’ explains Pierre Pienaar, WPO president (incidentally, another South African now domiciled in Australia!). ‘As the discipline of packaging is truly global,’ Pierre continues, ‘the WPO is in a unique position to identify leading practitioners from around the world who have In 2018, at the consistently pushed the boundaries in advancing culmination of the art, science and application of packaging. These an 18-year-long prestigious awards celebrate and preserve their involvement in the achievements in perpetuity.’ WPO, Keith Pearson retired from his position as general Keith Pearson: a South African icon secretary of the organisation. Keith Pearson’s activities within the South African packaging industry are legendary, both his dedication to the industry in general and to the Institute of fields of corrugated, carton and print, cores and tubes Packaging SA (IPSA) in particular. and multiwall paper sacks – advancing finally to the To start at the beginning, Keith’s packaging career position of divisional chief executive of Kohler Carton kicked off in 1970. He was first employed as an & Print. engineer at Kohler Corrugated and later transferred But aside from his success in the commercial world, to Namibia to fill the role of production manager at Keith also shone as a member of IPSA, serving as Walvis Bay Containers. Throughout the following three a regional chairman and later as national chairman decades, Keith continued to grow within the Kohler (2000-2004); he also chaired and was a member of group – with his multifaceted experience covering the IPSA’s education committee. FEBRUARY 2020 18 www.packagingmag.co.za 18-19_WPO_PPMFeb20.indd 18 2020/02/19 1:50 PM
During his time as national chairman, Keith WPO News represented IPSA on the WPO board, and this proved to be a powerful precursor to his subsequent long-term involvement in the organisation: he went on to become an integral member of the WPO leadership team for 18 years, including heading up the education committee before serving two terms as president (2006-2011) – the first WPO president from Africa – and finally as general secretary (2012-2018). Ever passionate in his leadership role, networking formed a vital component of Keith’s modus operandi; he played an important role on the international packaging stage, helping to put the organisation more emphatically on the world map, thanks to high-profile programmes such as the WorldStar Awards, and the WorldStar Student Awards. He also brought about greater brand recognition by establishing a marketing plan and a new website, and criss-crossing the globe to represent WPO at conferences and trade fairs. He also forged closer links between WPO and the International Packaging Press Organisation to ensure better understanding of WPO activities by ensuring a ‘good press’ in the world’s leading packaging journals. Keith was closely involved in packaging development Spotted among 166 000 visitors tramping the aisles at interpack 2011 were two ex South Africans now living ‘down throughout Africa, helping to create packaging under’ … Pierre Pienaar, a previous national chairman of IPSA, institutes in Ghana, Nigeria and Tanzania, and now an independent packaging consultant, president of the ultimately the establishment of the African Packaging Australian Institute of Packaging, and president of the WPO, Organisation. and Joe Foster, MD of Foster Packaging. The latter, having established successful businesses in South Africa, Kenya More recently, further evidence of his passion for and Ireland, relocated to Australia in 2010 where his business packaging education was unveiled when he travelled ventures have been outstanding success stories. to Iran on three occasions to help establish the Iranian Institute of Packaging. ‘My approach has been to take ownership, to take In 2007, his achievements were recognised with responsibility for the products I sell,’ says Joe. South Africa’s highest accolade, being named The early inclusion of the word ‘International’ Packaging Achiever by the Packaging Council of in the company’s name was also prophetic. From South Africa (now Packaging SA). And at Pack Expo the beginning, Joe’s extended horizons and broad (Chicago) in 2018, the Packaging & Processing Hall perspectives saw him seeking out partners in South of Fame welcomed South Africa’s Keith Pearson as Africa and around the world who could provide cost- a member. effective, high-quality alternative packaging formats. And over the years he made concerted efforts to keep Joe Foster – inspired by goals Foster International Packaging at the forefront of the In 1998, when Joe Foster embarked on an ambitious global market, for instance taking part in any number venture to establish his own packaging business, he of trade shows, both in South Africa and abroad. told me: ‘It will be very successful and the name Foster In 2002, Joe relocated to Dublin to better manage will be big in South Africa and internationally.’ this global expansion, and then in 2010 he moved How gratifying it is to confirm that his bullish again – this time to Australia, where he established prediction was correct! Foster Packaging Australia, among other things Some might quip ‘it’s the luck of the Irish’, but Joe breaking new ground by offering digital printing for Foster doesn’t buy that. His view is more prosaic. ‘If short-run flexible packaging. you want more luck, you have to take more chances, Then, in 2016, came the merger between Foster be more active, show up more often,’ he maintains. Packaging (both the South African and Australian Joe’s involvement in packaging started when he operations), and Australia’s Omniverse, resulting in was 16; and he was just 20 when he moved from his the Omniverse Foster Packaging Group. native Ireland to Zimbabwe, where he was involved in A wise man once said: ‘Goals. There’s no telling engineering and production at a packaging plant, which what you can do when you’re inspired by them; there’s led to production and sales positions at Kohler Flexible no telling what you can do when you believe in them; Packaging. Aged 34, he left Kohler and set about there’s no telling what will happen when you act upon fulfilling his dream of ‘flying solo’ by the time he was 35. them.’ That sentiment seems perfectly apt for Joe Indeed, it was his ‘can-do’, self-assured attitude Foster. – putting a deadline to a dream – that saw Foster So, on behalf of the entire South African industry, Packaging evolve from a humble office in Joe’s the PPM team says ‘cheers’ to these two men, whose Cape Town home to a well-respected global player, commitment and vision has caused the South African now Omniverse Foster, operating from Australian and Australian flags to fly high on the international headquarters. packaging stage. They will be recognised at the ‘Ownership’, ‘responsibility’ and ‘service’ are the WorldStar Awards ceremony taking place in Düsseldorf rocks on which his business success has been built. during interpack 2020. FEBRUARY 2020 www.packagingmag.co.za 19 18-19_WPO_PPMFeb20.indd 19 2020/02/19 1:50 PM
Crackingnews Cracking on with UV LED curing Rotocon’s investment in developing Users of UV LED flexo inks report significantly faster production speeds compared to mercury curing technology. its Ecoline brand of UV LED curing Additionally, thanks to their significantly longer lifespan, systems is meeting demand from South instant on/off capability and reduced maintenance, UV LED Africa’s narrow-web market, where systems offer enhanced press uptime. ‘UV LEDs operate up to 20 times longer (20 000+ hours) converters are upgrading their systems than medium-pressure mercury arc UV curing systems,’ from traditional mercury arc UV curing Pascal explains. ‘Their instant on/off capability means no systems to the latest LED technology. waiting is required to restart a press. Faster changeovers via flexible controls and curing adjustments, such as wavelengths, working distance, dimming level (UV energy ROTOCON has recently retrofitted the first of its newly- output), are also possible. All these factors contribute to introduced Ecoline range of UV LED curing systems to a improved uptime, resulting in higher production rates,’ he six-colour press at Durban-based label converter, GTV states. Label Master. As previously reported (PPM July 2017), Durban-based According to Rotocon director, Pascal Aengenvoort, GTV Label Master’s relationship with Rotocon stretches the first major benefit in switching to UV LED curing is back to 1992, when brothers, Ravi, Ricky and Vernon Pillay significantly lower operating costs thanks to energy savings, took over from their father, Thangvaloo, and continued fewer consumable parts, and lower maintenance costs. running the business based on his founding principles of ‘UV LEDs typically use up to 70% less energy compared good printing practices and uncompromising quality. to traditional UV curing,’ he states. ‘Not having to keep ‘Since 1992, we’ve been purchasing rewinding and consumable parts on hand, such as lamps, ballasts, finishing machines, flexible dies and tooling from Michael reflectors and fans, provides additional costs savings. Aengenvoort,’ reports co-owner, Ravi Pillay. ‘When it comes Finally, lower maintenance costs result from less time to any investment decision, we’ve always considered spent replacing lamps and cleaning/servicing the other technical back-up and service to be as important as the components,’ he adds. brand we buy. And the Rotocon team has lived up to our Rotocon director, Pascal Aengenvoort, and Durban branch manager, Akmuth Sayed, with the GTV Label Master team, and Chinese technicians who helped developed Rotocon’s Ecoline UV LED curing system. 20 www.packagingmag.co.za 20-21_ROTOCON CRACKING NEWS.indd 20 2020/02/19 1:50 PM
expectations in this regard,’ Ravi adds. ‘In fact, as there was only one Ecoline UV LED curing system already installed in the country, we took a leap of faith with our latest purchase, based on our track record with Rotocon’s Ecoline brand of machines and consumables, and faith in Rotocon’s technical abilities.’ The existing UV curing system, which had proved troublesome throughout its life, was very old and spare parts were no longer available. ‘With power outage challenges,’ Ravi goes on to relate, ‘we were advised to move away from mercury UV lamps, which tend to blow, and to invest in an LED curing system because the lamps cool immediately and don’t require a warm-up period.’ Although the brothers were slightly sceptical, because some converters had experienced teething troubles with newly-installed LED curing systems, they’re happy to report the absence of any issues. ‘We’ve been so pleasantly surprised by the system’s performance that we’ve now specified another eight units be fitted to a new press on order,’ remarks an enthusiastic Ravi Pillay. An injection of cleaning power ROTOCON’S distribution partnership with ECO cleaner model can accommodate various Netherlands-based Jet Europe provides the local plate sizes for simultaneous cleaning, utilising two narrow-web converting market with six fully- brushes and a variety of cleaners for any plate/ automatic Jet ECO cleaner models for cleaning, ink combination,’ reports Rotocon director, Patrick rinsing and drying flexo and letterpress plates – Aengenvoort. ranging from 450 to 1 400mm wide – in a single Over the past four years, Gauteng-based self- cycle. adhesive label and price marking specialist, KS This blue-chip supplier, with 30 years’ experience Scales & Labels, has partnered with Rotocon by in photopolymer plate processing, offers a high investing in three Ecoline slitter/rewinders (PPM degree of expertise and craftsmanship. ‘Each Jet April 2019) and a Jet Europe plate washing machine. In 2019, owner, Nathan Naidoo, became the first local label converter to invest in a Jet ECO cleaner to further improve print quality by ensuring all UV ink residue is removed from plates at each job changeover, representing a major upgrade from manual plate washing. ‘To remain competitive, we needed to invest in high-quality equipment to improve our printing results,’ Nathan states. ‘We’re confident we have the most cost-effective system. The Jet ECO cleaner 450 has helped to save cleaning time and has improved our print quality as there’s no longer any Using the Jet clogging of fine print. It has also improved storage ECO Cleaner 450, processes, making plates easier to find after night plates are carried shift work and minimising plate damage.’ automatically into The washout, rinsing and drying cycle usually the processor via takes around three to five minutes, depending on transfer rollers, plate thickness. with speed and temperature being Although KS Scales & Labels cleans 250mm wide controlled via a plates in the machine, it can accommodate touchscreen. a maximum plate width of 450mm. www.packagingmag.co.za 21 20-21_ROTOCON CRACKING NEWS.indd 21 2020/02/19 1:50 PM
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Sustainability Update Busisiwe Khumalo, Danone’s corporate communications officer signing the SA Plastics Pact’s founding member commitment at last month’s official launch in Cape Town. Plastics Pact: value chain’s ambitious 2025 targets The SA Plastics Pact – an 11-month collaborative making 100% of plastic packaging reusable, recyclable project between the World Wide Fund for Nature or compostable; ensuring 70% of plastic packaging is (WWF-SA), the South African Plastic Recycling effectively recycled; and including 30% average recycled Organisation (SAPRO) and Waste and Resources content across all plastic packaging formats. Action Programme (WRAP) UK – to keep plastics Founding Pact members are Addis, the Clicks in a circular economy model and out of the Group, Coca-Cola Africa, Danone, Distell, environment was recently launched in Cape Town. HomeChoice, Massmart, Myplas, Nampak Rigids, Pick As reported in PPM’s March and July 2019 issues, n Pay, Polyoak, Polyplank, Shoprite Group, Spar, Spur the Pact has been developed specifically for the South Corporation, TFG, Tiger Brands, Tuffy, Unilever, Waste African context but also shaped by experiences of Plan and Woolworths. others in The Ellen MacArthur Foundation’s Plastics Non-profit organisation members include the City Pact global network, in particular, the UK Plastics Pact, of Cape Town, Department of Environment, Forestry led by WRAP. & Fisheries, Fruit South Africa, Institute of Waste Aligned with the New Plastics Economy vision, Management of Southern Africa, PET Recycling South Africa joins France, the UK, The Netherlands Company, Polyolefin Responsibility Organisation, and Chile in exchanging knowledge and collaborating Polystyrene Association of SA, SAPRO, and Southern to accelerate the transition to a global circular African Vinyls Association. economy. Following the launch, GreenCape, with the support The SA Plastics Pact will be managed and delivered of WWF-SA and WRAP, will develop the Pact’s 2025 by GreenCape, a not-for-profit organisation that roadmap towards collective action in the local market, assists businesses; investors; and government (local, including annual public progress reports. WRAP has provincial and national) in establishing and growing secured funding to support this work for the first six a resilient green economy through supporting policy months. Additional funding will, however, be sought and regulatory advocacy; sharing market intelligence; for specific projects and activities. and facilitating market access, skills development, Members are confident that by delivering on the networking and events. 2025 targets, they’ll help boost job creation in the The Pact’s founding members have committed to plastics collection and recycling sector, and create new four ambitious 2025 targets that prevent plastics from opportunities in product design and reuse business becoming a waste/pollution problem. models. These goals encompass taking action on problematic For more information about the South African or unnecessary plastic packaging through redesign, Plastics Pact, visit www.saplasticspact.org.za innovation or alternative (re-use) delivery models; or email: info@saplasticspact.org.za Progressive planning The UK Plastics Pact – driven by The Waste and Resources Action Programme (WRAP), a key advisor in South Africa’s Pact development plan – has been running for over 20 months, and made positive strides towards its 2025 targets. • Pact members are across the half-way mark of making all their packaging recyclable. • The UK is more than half-way towards recycling 70% of plastics packaging, following huge investment in recycling infrastructure, which has enabled an extra 240 000 ton capacity. • Members are a third of the way towards an average of 30% recycled content in their plastic packaging. • A billion problematic and unnecessary single-use plastic items will be eliminated by the end of 2020. FEBRUARY 2020 www.packagingmag.co.za 23 22-29_SUSTAINABILITY UPDATE.indd 23 2020/02/20 3:17 PM
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Coca-Cola launches Sustainability Update returnable two-litre PET bottle AFTER successfully completing internal trials in in our packaging and ensuring more packaging is October 2019, Coca-Cola Beverages South Africa collected and recycled,’ Velaphi adds. ‘This launch (CCBSA) introduced a two-litre returnable PET is another way we can use innovation to unlock the bottle in the Eastern Cape market, which offers value in waste and support a circular economy in consumers value for money, while being kind to South Africa.’ the environment. During 2018, more than 98 000 tons of post- These returnable PET bottles are higher in density consumer PET was collected through the PET than the standard ones because they can be reused Recycling Company, which Coca-Cola supports up to 14 times, before being recycled and made through voluntary levies, and diverted from landfills into new bottles. The rollout – which is being piloted in South Africa, saving 612 000m2 of landfill space. in the Mandela Bay and Border-Kei districts – has been proceeding so successfully that the project will be expanding to other parts of the country in the upcoming months. These PET bottles are decorated with a new paper label, with the word ‘Returnable’ clearly printed in green. ‘Through innovation and our infrastructure investment in this packaging line, we’re providing consumers with greater value for money, while introducing a reusable PET bottle,’ comments Velaphi Ratshefola, MD of CCBSA. ‘Their launch is one way in which CCBSA is investing in innovative and more sustainable packaging,’ says Velaphi. ‘They also support our company’s global commitment to address the world’s waste problem.’ Once a bottle is returned, it enters a looped journey to be cleaned to Coca-Cola’s stringent requirements before refilling and starting its next lifecycle. When the bottle reaches the end of its 14 reusable lifecycles, it can be recycled and turned into another PET bottle. ‘We’re committed to increasing recycled material Nestlé adopts franc approach to formidable challenge FOOD-GRADE recycled plastics are hard to The company will seek operational efficiencies come by, but that has not deterred Nestlé from to keep this initiative earnings neutral. committing CHF2-billion to source up to 2-million En route to a waste-free future, Nestlé is also tons and setting aside CHF1.5-billion for the tackling packaging innovation, including new premium-price tag they carry. materials, refill systems and recycling solutions. The investment is part of the company’s 2018 In addition to its significant in-house research undertaking to make 100% of its packaging through the Nestlé Institute of Packaging Sciences, recyclable or reusable by 2020, developing innovative the company plans a CHF250-million sustainable sustainable packaging solutions and reducing its use packaging venture fund to invest in start-up of virgin plastics by 33% while doing so. companies that focus on these areas. Its efforts, in collaboration with like-minded groups, These initiatives complement Nestle’s ongoing will advance the circular economy and help to remove efforts to achieve its goal of zero net greenhouse plastic waste from oceans, lakes and rivers. gas emissions by 2050. FEBRUARY 2020 www.packagingmag.co.za 25 22-29_SUSTAINABILITY UPDATE.indd 25 2020/02/20 3:17 PM
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