site visit presentation – 7 october 2013 · machine to a 500 ton hypet 144 cavity machine...
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Durban
Harare
Brits
Johannesburg
Atlantis Paarl
Plastics
Staff numbersEmployees 155 (permanent)
Capacity
Wadeville 40 000 tons per annum
1.6 billion units per annum
Raw materialsWadeville PET
Certifications/Accreditations
Wadeville ISO 9001/2008
ISO 22000 / 2005
ProductsWadeville Carbonated soft drink bottle preforms
Wide Mouth food jars
Hot Fill bottles
Mpact Plastics Wadeville
Cape Town
Overview – Preforms, Bottles and Jars
3
106 product lines:Injection moulding: carbonated soft drink bottle preforms ; edible oil bottle preforms; general bottle preforms
Stretch blow moulding: Hot Fill preservative free and carbonated soft drink bottles; edible oil bottles
Injection stretch blow moulding: Wide Mouth food jars; specialised bottles; household detergents
Manufacturing process and product overview
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PAGE 4
First to SA market with Wide Mouth design
First to SA market with Hot Fill
First to SA market with 144 cavitation
First PET wine bottle in South Africa
First in light-weight neck design in South Africa for carbonated soft drinks
Design centre based in Cape Town
Product innovations
5
Equipment (8 machines):
Husky Injection Moulding Systems
machines, Luxembourg
Description:
Range from a G line 48 cavity
machine to a 500 ton Hypet 144
cavity machine
Injection moulding equipment
6
Dryer
Injection moulding machine Preform
Mould
Cooled core pin
Injection of polymer
Typical machine cycle = 900 000 preforms per machine per day
Resin drying = minimum 5 hr @ 180ºC
280ºC - 290ºC
Mould cooling@ 7ºC
Preform temperature
@ 45ºC
Source: SANS Fibres Polymer Technical
Injection moulding process
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Equipment (6 machines):
Sidel rotary machines and moulds, France
Sipa linear stretch blow moulding machine, Italy Hot Fill technology (PET 2 stage blow moulding) Enables preservative free product formulation
Description:
4 Rotary blow moulding machines
2 Linear stretch blow moulding machines
Stretch blow moulding equipment
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Preform is positioned in
mould
Exhaust after a thermal process
Deformation axial and radial at the same time by stretching and
preblowing around 7-10 bars
Blowing at 40 bars
Source: SANS Fibres Polymer Technical
Stretch blow moulding process
9
Equipment (13 machines):
Nissei wide mouth bottle machines, ASB Japan
Aoki single stage machine, Japan
Description:
8 single stage wide mouth machines for jar manufacturing
5 single stage machines for bottle manufacturing
Combines the processes of injection moulding and stretch blow moulding in one machine
Single stage blow moulding equipment
Overview - Closures
Staff numbersEmployees 60 (permanent)
Output
Wadeville 4,500 tons per annum
1.5 billion units per year
Raw materialsClosures PP
HDPE
Poly liners
Master batches
Various printing ink
Certifications/AccreditationsWadeville ISO 9001:2008
ISO 22 000 / 2005
State-of-the-art lab testing facility
ProductsClosures All types and colour caps
Plastic 2-piece closures most non-coke CSD products
as well as carbonated energy drinks 1-piece short neck closures for lightweight
products
Glass: 2-piece closures for returnable CSD market and medical applications
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Equipment (11 Machines):
Compression moulding machines and moulds manufactured by SACMI Italy
Injection machines from Milacron Ferromatic in China
Description:
Five continuous compression moulding machines (CCM) each with a folding and slitting station
Speed on single piece = 49 500 caps per hour
Speed on two-piece = 45 000 caps per hour
3 liner manufacturing and inserting machines (PMD)
3 injection moulding machines
Closure manufacturing equipment
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Equipment:
3 machines manufactured by
Tampo print in Germany
Dual row printing on each
machine enables a speed of
120 000 caps per hour
In-line vision systems allow
for 100% inspection of all
Printing process – Tampo print
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