In The Spotlight
Terna, the company that manages the Italian national electricity transmission grid, led by Pasqualino Monti, and STEG, the Tunisian electricity and gas grid operator, have awarded Hitachi Energy, a global leader in electrification, a contract worth approximately €770 million (approx. US$893mn) for the construction of the converter stations for the Elmed project, the first electricity interconnection between Italy and Tunisia
The awarding of the contract for the converter stations marks the completion of the procurement process for the first high-voltage direct current (HVDC) submarine link between Europe and North Africa.
The tender, published in 2023 jointly by Terna and STEG in the Official Journal of the European Union, concerned the design, supply and construction of the converter stations for the interconnection. The project is one of the infrastructure initiatives included in the Mattei Plan for Africa, aimed at strengthening economic, energy and geopolitical partnerships between Europe and African countries.
The two infrastructures will be built in Italy at Partanna, in the province of Trapani, and in Mlaabi, in the Menel Temime area of Tunisia. The link, powered by advanced HVDC technology, will have a capacity of 600 MW and extend for approximately 220 km, mainly through submarine cable, reaching a maximum depth of around 800 metres in the Strait of Sicily.
Hitachi Energy will provide the HVDC solution, combining its expertise in HVDC converter valves, its MACH digital control platform, power transformers and high-voltage switchgear. The company will also deliver system studies, design and engineering, supply, installation supervision and commissioning services. The project will leverage its experience gained through the successful delivery of some of the world’s largest and most significant interconnection projects.
Other consortium members, including D’Agostino Costruzioni Generali S.p.A. for the Partanna station and Orascom Construction SAE for the Mlaabi station, will mainly undertake civil works, electromechanical installations and auxiliary systems.
Representing a significant step towards greater interoperability between European and North African electricity systems, Elmed comes as governments and transmission system operators worldwide accelerate investment in transmission infrastructure. These developments are supporting the move towards fully electrified energy systems capable of integrating renewable energy sources at scale, strengthening cross-border interconnections and improving energy security.
Elmed is a major infrastructure project designed to strengthen energy security and integrate electricity systems between Europe and North Africa, aligning with energy transition and market integration objectives under the Integrated National Energy and Climate Plan (PNIEC).
The project, which is strategically important for Tunisia, has the full support of Tunisian authorities and forms part of the country’s national vision to strengthen energy security, promote regional electricity market integration and support the energy transition.
Elmed also supports the European Commission’s REPowerEU objectives of reducing dependence on fossil fuels and achieving decarbonisation targets, primarily through diversified energy supplies and increased renewable energy development.
With a total investment value of €1.42 billion (approximately US$1.65bn), the electricity link has received €307 million (approximately US$356 million) from the European Commission through the Connecting Europe Facility (CEF) grant programme managed by CINEA. For the first time, the European Union has financed a project involving a non-member country, highlighting the strategic importance of the interconnection.
The project is also supported on the Tunisian side by additional European and international financial institutions, including the World Bank, the European Investment Bank, the European Bank for Reconstruction and Development and KfW.
Master Power Technologies (MPT), a pan-African provider of turnkey data centre and critical power solutions, has opened a new regional headquarters in Midrand, South Africa
The site also contains a new ‘Customer Experience Centre’, a R50mn (US$XXmn) investment designed to showcase MPT’s engineering capabilities and provide a hands-on environment for customers, partners and trainees.
The centre features advanced test facilities, including a 2 MVA UPS test platform and a 400kW cooling systems test centre, which is the most comprehensive of its kind on the continent.
In a statement, the company said it marked a step in the company’s continued expansion and commitment to advancing Africa’s data centre infrastructure.
“The Experience Centre represents a new chapter for Master Power Technologies. It’s about creating a space where customers can engage with our technology, see it in action, and understand the depth of our capabilities,” said MPT founder and managing director, Menno Parsons, a former electrical engineer.
“This centre will be the most impressive UPS and cooling training facility in Africa, allowing our clients to touch, feel, and work with real systems in a way that has never been possible before.”
Founded in 1999, MPT has grown from its origins as a Uninterruptible Power Supply (UPS) provider into a diversified engineering firm that delivers end-to-end solutions for data centres across Africa and the Middle East.
Today, it designs, manufactures, and assembles a wide range of products under its flagship brands, SURE and AIVA, tailored to withstand Africa’s demanding operational environments.
The new Midrand facility spans 6,000 square metres and will serve as MPT’s African headquarters, housing approximately 200 employees.
Strategically located between Johannesburg and Pretoria, the site is positioned close to a number of major data centre hubs.
The launch of the Midrand offices and Experience Centre underscores MPT’s role as a trusted partner in Africa’s rapidly growing data centre sector, according to Parsons.
The Experience Centre also highlights MPT’s commitment to local engineering and manufacturing.
MPT assembles and engineers complete modular data centre and energy centre solutions within Africa, an approach that reduces logistical risks, supports local industry and ensures solutions are tailored to regional requirements.
Beyond technical demonstrations, the centre will also serve as a hub for training and collaboration, equipping engineers and clients with practical knowledge to optimise data centre performance.
It also integrates MPT’s proprietary Advanced Infrastructure Visual Analytics (AIVA) monitoring platform, which manages and records metrics across more than 200 data centres in Africa, offering advanced analytics and operational insights.
“Our business has always been about more than just selling equipment. We engineer solutions for Africa, by Africa,” said Parsons.
“This Experience Centre is a testament to that philosophy, which strengthens our ability to train, innovate and deliver world-class infrastructure while remaining rooted in local expertise.”
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Parklands data centre receives power and cooling update
FPT, a brand of Iveco Group N.V., and its distributors Bimotor and Avoni Industrial, joined Green Power Systems to power one of Algeria’s largest agro-industrial projects
The new facility is set to transform powdered milk production in the North African country.
The project, worth US$3.5bn and cofounded by the Algerian National Investment Fund and Qatari dairy producer Baladna Q.P.S.C., involves the construction of one of the world’s largest integrated dairy farm and powdered milk facility, spanning 117,000 hectares of agricultural land, and designed to support 270,000 dairy cows.
Located in Algeria’s Adrar province, the agro-industrial facility is scheduled to start production in late 2027.
Once fully operational, it expected to produce up to 100,000 tonnes of powdered milk per year, meeting about 50% of Algeria’s needs.
The gensets provided by Green Power Systems and powered by FPT engines will play a key role in feeding the dairy cows and a huge non-stop irrigation project — a challenging assignment with temperatures often exceeding 40° C for over 130 days a year.
In total, Green Power Systems delivered 50 GP330 S/I-A generator sets powered by FPT CURSOR 13 engines, providing up to 330 kVA, suitable for round-the-clock operation of irrigation systems in extreme conditions.
The FPT-powered Green Power Systems will support central pivot irrigation systems, a crop irrigation method in which the equipment rotates around a central pivot and crops are irrigated using sprinklers, thus creating circular irrigated area centred on the pivot.
Less labour-intensive and more water-efficient, this irrigation method is particularly effective in large plots of arid land and can rapidly transform them into agriculturally productive zones.
“Being part of a such a large-scale project, meant to improve Algeria’s food security and to create about 5,000 local jobs, is both a great honour and a great responsibility,” said Vittorio Bertalli, head of sales EMEA at FPT.
“But we are confident that our CURSOR 13 engines, together with hi-tech Green Power Systems products, will once again live up to the most demanding expectations.”
The CURSOR 13 is designed to deliver robust performance and optimised fuel efficiency for power generation applications, ranging from unregulated to Stage V / Tier 4 Final emissions standards.
Engineered with an electronically controlled unit injector, it ensures precise power delivery, rapid load response, and consistent fuel optimisation under all operational conditions.
The G-Drive configuration provides a ready-to-integrate solution, while highly regulated versions incorporate an ATS pack with patented Hi-eSCR2 technology, enabling advanced emissions reduction without compromising performance.
The engine offers 50/60 Hz frequency switching capability, facilitating inventory management for customers and is designed to maximise uptime and minimise maintenance requirements.
“Green Power Systems’ participation in this project further confirms its role as a reliable international partner in the supply of power generation solutions for large-scale agro-industrial and infrastructure applications,” said Flavio Faggiolini, export area manager for Green Power Systems.
“In projects of this magnitude, power continuity is essential to ensure the proper functioning of the entire infrastructure. The collaboration with FPT Industrial contributed to delivering a solution aligned with the reliability requirements of the operational context.”
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Nestle sites gain nearly 7MW of solar
GE Vernova drives Africa's industrialisation with integrated power
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In the final webinar of its African Review-hosted 2023 campaign, Convergent Group explored its modern, eco-friendly concrete solutions for African projects
Such solutions – delivered to cut maintenance costs by eliminating hazardous silicate products – were showcased by company experts in the form of Jean-Claude Biard, SEO of Convergent Group SA; Mputu Schmidt, former CEO of Convergent Group SA and founder of Bondeko MB (exclusive distributor of Convergent Group in Africa); Carlos Garcia, technical and sales for ADI Group (Spanish distributor for Convergent Group); and Amritpal Singh Sura, external consultant for flooring treatments, former distributor of Convergent products in the Middle East.
“A number of projects we were doing in the Middle East required protection,” remarked Sura. “Longevity of protection requires a system which basically impregnates and becomes a densified surface as opposed to something which is topical and lifts off due to moisture migration. I found that being exposed to Convergent, it was important to stay focused on those systems in the Middle East. Jean-Claude, Mputu and I met several times in Dubai and there was emphasis on providing systems which were affordable and still ending up having a robust, lasting longevity of product. So you are not spending money all the time in order to maintain the finishes which you have already paid for.”
Over the course of the session, the participants guided the audience through the potential of cutting-edge lithium silicate technology for enhancing the protection of concrete surfaces, maximising cost-effectiveness and meeting sustainability targets.
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In a comprehensive webinar hosted by African Review, a panel of professionals associated with Convergent Group explored new generation lithium silicate technology and why it is emerging as the optimum solution for concrete floor protection.
Robert Daniels, editor of African Review, was joined by Jean-Claude Biard, CEO of Convergent Group; Mputu Schmidt, former CEO of Convergent and founder of Bondeko MB, an exclusive distributor of Convergent; Hicham Sofyani, president of Texol; Carlos Garcia, technical and sales for ADI Group; and Marc Puig, commercial manager of Comace Import.
Each providing a unique angle, the panellists combined to provide a masterclass around concrete treatments and the increasing challenges around them, explaining to attendees how to choose the right formula for their requirements and touching on issues such as why lithium densifiers are better than sodium and potassium densifiers.
Throughout the session, those watching were treated to informative case studies showcasing how Convergent eco-friendly products are increasing abrasion resistance, raising ease of maintenance, and ensuring the highest quality gloss retention.
By the end of the webinar, a majority of attendees (many of which had not had much experience with Convergent) expressed their interest in using the company’s new generation lithium silicate technology with the rest indicating their desire to learn more about Convergent and its products. Watch the webinar, in full, to discover why viewers were convinced and learn more about advanced floor care solutions for your operations.
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Presenting on an African Review-hosted webinar, Martin Provencher, global industry principal for mining, metals and materials at AVEVA, explored the digital transformation of mining operations and its impact on sustainability.
“Sustainability is becoming a key aspect for mining operations,” remarked Provencher. “If we look at the latest EY research on the top ten business risks and opportunities for mining and metals globally in 2023, ESG remains at the top. Of course, most companies have environmental goals or are expected to reach a net zero emission by 2050, which is a pretty aggressive target. Many of them are targeting 30% reduction by 2030; seven years from now. So there is a lot of action that needs to take place quickly to get there. It is possible to get there, but we need to make sure we are doing this correctly.”
Fast becoming a huge part of ESG initiatives is fleet electrification where particular progress is being made in underground mines. While some countries are certainly more advanced than others here, Provencher noted that 40% of total emissions from the mining industry come from diesel trucks, making EVs a very attractive low-hanging fruit for companies to pursue.
There are, however, a number of challenges associated with bringing in electric vehicles which remains a barrier for introduction. One of the predominant reasons, is the limited range of EVs against diesel counterparts. To mitigate this, Provencher continued, data management is key and ensuring a strong grasp of real-time information coming in will show operators when machinery needs to be charged, allowing them to plan effectively for maximum efficiency on site.
Indeed, this is but a small advantage that digitalisation can bring to the mining industry as it grapples to meet ESG goals while achieving production targets. By getting a better grip of their data and using it to empower tools such as artificial intelligence, advanced analytics and machine learning, companies can achieve tangible benefits such as reduce downtime, enhance worker safety, cut operating costs and, of course, ensure compliance with environmental regulations and targets.
Through the course of the webinar, Provencher outlined this in more detail and explored AVEVA’s suite of cutting-edge software solutions, specifically designed to help mining companies make progress on their digitalisation journey and empower their operations.
Watch the full webinar, completed with detailed case studies and an insightful Q&A session.
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Convergent, in association with African Review, has held a detailed webinar exploring the usage and effectiveness of lithium silicates and densifiers over traditional methods of concrete surface management which often struggle to meet the increasing challenges posed by concrete surface management.
Convergent experts including Mputu Schmidt, CEO of Convergent; Carlos Garcia, product manager end-user solutions, construction chemicals, Spain and Portugal for the RD Group; Matteo Mozzarelli, CEO of concrete Solutions Italia; and Jean-Claude Biard, global senior executive for the Convergent Group, presented across the session.
Together, they delved into the latest cost-effective application methods for long lasting finishing of concrete that can help reduce maintenance costs and avoid unexpected repair action. In addition, they examined the advancements in technologies that can sustain increased abrasion resistant stains and ensure gloss retention to the highest quality.
As part of the webinar, the representatives explored case studies including a case in DRC where a medical centre had been constructed with a low-quality concrete floor. The customer was considering completely replacing the floor but instead, Convergent put forward a special treatment with its 244+ Pentra-Sil lithium hardener, densifier and sealer. With this solution, Convergent can increase the hardness of a surface by up to 40% and therefore saved the customer significant recuperation costs over a complete replacement. Convergent were happy to report that the solution was perfect for the facility and the customer was pleased to avoid the extra construction work that would have been required for a complete replacement.
Watch the full webinar, including more information about Convergent’s innovative solutions.
Daystar Power Group expands solar installations across Nestlé facilities in Côte d’Ivoire, Ghana and Senegal
Daystar Power Group has strengthened its energy partnership with Nestlé across West Africa, with solar installations now fully operational at four manufacturing facilities in Côte d’Ivoire, Ghana and Senegal
The projects bring Nestlé’s total installed solar capacity across these sites to 6,884 kWp, close to 7 MW, making it one of the region’s largest commercial and industrial solar partnerships.
The four facilities, including two sites in Abidjan, one in Tema and one in Dakar, are now operational. Each solar system has been customised to match the specific grid conditions and operational requirements of its respective location.
“Nearly 7 megawatts across four Nestlé facilities is a number we are proud of, but what it represents matters more than the figure itself. It means that one of the world's most demanding manufacturers has tested our model, trusted it, and come back. Our job now is to keep earning that, across every market where industry needs energy it can count on,” added Yischai Beinisch, CEO, Daystar Power Group.
From one site to four sites
The collaboration began with a single installation before expanding across three countries and four manufacturing facilities. In Côte d’Ivoire, Daystar Power has delivered 3,447 kWp of solar capacity across two Abidjan sites. Ghana’s Tema factory now operates with a 2,547 kWp system, while Senegal’s Dakar facility has an 890 kWp installation.
Each project has been designed to deliver measurable environmental and social benefits, including lower greenhouse gas emissions and improved energy resilience. The systems are tailored to local grid conditions and operational demands, providing reliable clean energy access while supporting local development and contributing to Nestlé’s publicly stated net-zero commitments.
“This investment reflects our commitment to building a business that not only grows but does so responsibly. By advancing solar energy projects in Ghana, Côte d'Ivoire, and Senegal, we are embedding sustainability into our growth, reinforcing our role as a force for good, creating long-term value for communities, and ensuring that our footprint actively contributes to a cleaner, more resilient future,” stated Samer Chedid, CEO, Nestlé Central and West Africa Region.
A footprint that keeps growing
Nestlé’s manufacturing network continues to expand across West Africa, including markets where Daystar Power has established strong operational capabilities. With projects now spanning three countries and nearly 7 MW of installed solar capacity, the partnership has created a foundation to support future clean energy expansion.
HMD Ghana Ltd. has reported strong interest following the debut of its ForLife heavy equipment protection programme at WAMPEX 2026 in Accra, Ghana
The programme — the first lifetime heavy equipment protection solution of its kind, available upon request alongside any new Tuboshu machine purchase through HMD and other dealers — drew interest from fleet managers, construction executives and mining professionals, HMD Ghana said in a statement.
First enrolments were completed at the exhibition stand, with a “robust pipeline” of qualified leads established, the statement noted.
The launch of ForLife formed part of HMD's broader market presence at WAMPEX 2026, reinforcing its established three-model access proposition — outright purchase, flexible equipment rental, and rent-to-own — applicable across HMD's full portfolio of heavy equipment brands, including Tuboshu.
As well as the HMD and Tuboshu exhibition stand, an outdoor display drew crowds for live Tuboshu machines, including the TG220 motor grader, the TF30D diesel forklift and the TTL12E solar tower light.
“Together, the three machines embodied Tuboshu's commitment to purpose-built equipment for demanding African operating conditions,” the HMD Ghana statement noted.
“The conversations at WAMPEX were not exploratory. They were operational,” it added.
“Visitors understood the proposition immediately and wanted to act on it. The response confirmed that the equipment sector has been waiting for something like this.”
Industry feedback centred on three themes, it added: the clarity and simplicity of the pay-per-hour ForLife model, the commercial relief of transferring breakdown risk away from the machine owner, and the flexibility of three distinct routes to machine access — purchase, rental, and rent-to-own — under one roof.
Used equipment operators and resellers noted the value of ForLife's transferability on resale, identifying it as a meaningful differentiator in the secondary market, HMD Ghana noted.
“ForLife is live and available, giving machine owners the certainty they have been asking for without delay or complication. The industry made its appetite for change clear in Accra, and HMD and Tuboshu are moving forward with a single objective: to turn every promise made on the stand into measurable value on the job site.”
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BCM Group wins US$400m Tulu Kapi contract, supporting Ethiopia’s major gold project with comprehensive mining services
BCM Group has been awarded the flagship mining services contract for the Tulu Kapi Gold Project in Ethiopia, reinforcing its position as one of Africa’s leading mining contractors
The long-term agreement, valued at more than US$400mn over the project’s initial nine-year mine life, was awarded by KEFI Gold and Copper through its Ethiopian subsidiary, Tulu Kapi Gold Mines Share Company (TKGM).
Under the agreement, BCM will deliver a comprehensive suite of mining services, including the supply, operation and maintenance of the mining fleet, recruitment, training and management of local employees, and execution of full-scale mining operations under TKGM’s supervision. The contract also includes the procurement and deployment of a new Caterpillar mining fleet to support project development and future production targets.
BCM group CEO Paul Coe said, “We are delighted to have been selected as the mining services contractor for the Tulu Kapi Gold Project. This award reflects BCM’s proven track record of successfully developing and operating mines across Africa and the Middle East, often in emerging jurisdictions where strong partnerships, local workforce development and operational excellence are critical to success.
“Tulu Kapi is a landmark project for Ethiopia’s mining industry, and we look forward to working closely with KEFI, TKGM, the Ethiopian Government and local communities to help deliver a safe, efficient and sustainable mining operation.”
With over 30 years of experience in delivering mining projects across Africa and the Middle East, BCM brings extensive expertise in mine development, fleet management and contract mining services. The Tulu Kapi project marks BCM’s entry into East Africa and highlights its ability to support major mining developments across the continent.
Tulu Kapi contains probable ore reserves of approximately 1.05 million ounces of gold and total mineral resources of 1.72 million ounces. Developed in partnership with the Ethiopian Government, the project is expected to contribute significantly to Ethiopia’s export earnings, job creation and economic growth.
The contract award further strengthens BCM’s reputation as a trusted partner for large-scale mining projects and reflects its ongoing commitment to its mission of Bringing Mines to Life across Africa and beyond.
Standard Chartered and the International Finance Corporation (IFC) have announced a new risk sharing facility aimed at strengthening supply chains across Africa
The partnership will introduce supply chain finance solutions in eight markets – Ivory Coast, Egypt, Ghana, Kenya, Nigeria, South Africa, Tanzania and Zambia – supporting companies in key sectors such as agriculture, healthcare and manufacturing.
The facility aims to help ensure suppliers get faster payments, freeing up working capital to improve production, pay wages and hire.
The risk-sharing facility will cover up to US$300mn in supply chain and trade finance assets originated by Standard Chartered in Africa.
It comprises a range of underlying supply chain financing instruments – such as payables finance, receivables discounting and pre-shipment finance programmes – to help smaller firms get paid earlier, reduce the cost of working capital, and invest in growth.
“This US$300mn facility with IFC underscores our shared commitment to strengthening Africa's supply chains and enabling sustainable business growth,” said Dalu Ajene, chief executive and head of coverage, Standard Chartered Africa.
“As a super-connector bank with deep expertise across key trade corridors linking Africa to Europe, Asia, the Middle East and the Americas, we are uniquely positioned to channel capital and innovation into the real economy. By expanding access to supply chain finance, we are helping African companies unlock liquidity, manage risk, and invest with confidence.”
Ajene said the collaboration unites Standard Chartered’s cross-border expertise with IFC’s development mandate to empower businesses – from major corporations to smaller local suppliers – “to engage more actively in regional and global trade, fostering job creation and promoting inclusive growth.”
IFC will provide guarantees for up to US$150mn from its own account, with US$100mn committed as the first tranche under the scheme, to support transactions in both US dollars and selected local currencies.
Over the next three years, the partnership is projected to enable about US$1.9bn in supply chain finance transactions, providing access to finance for firms across Africa.
It aims to support more than 500 suppliers, including small and medium enterprises (SMEs), in both domestic and global value chains, with the potential to indirectly benefit over 1 million farmers.
“Supply chain finance is among the fastest ways to narrow the growing finance gap that businesses, particularly small and medium enterprises, are facing in emerging economies,” said Mohamed Gouled, IFC’s vice president, products & clients.
“By partnering with Standard Chartered to support companies at the center of strategic value chains, we can unlock much-needed working capital at scale for businesses across Africa, including smaller firms and farmers, making supply chains more competitive and boosting job creation.”
According to IFC, global demand for supply chain finance has surged – in 2025, the estimated volume reached about US$2.7trn, showing an 8% increase year-on-year.
Yet supply chain finance has not scaled at the same pace in emerging markets, it says, especially in lower income and fragile contexts, largely because commercial banks tend to focus on developed markets.
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Jendamark Automation’s catalytic converter shrinker machine integrates a 12- segment precision shrinking system, where SEW-EURODRIVE servo gear units and motion control software ensure each can is accurately reduced to predetermined dimensions based on mat weight and component tolerances. (Image source: SEW-EURODRIVE)
Innovative technology for ‘shrinking’ catalytic converters - designed and built in South Africa by Jendamark Automation for the global market - relies on the precision of SEW-EURODRIVE’s highly dynamic servo-geared units and software
Based in Gqeberha in the Eastern Cape, Jendamark Automation is a specialist in advanced automated assembly systems for powertrains, catalytic converters, hydrogen technologies and other automotive components. Yanesh Naidoo, executive innovations director at Jendamark Automation, says that 95% of the locally produced machines are exported and are in operation in Europe, India and the USA.
"The shrinking machine - or ‘shrinker’ - is a core component within our catalytic converter assembly cell," commented Naidoo.
“This cell is a highly automated production environment in which multiple machines, robots and laser measurement systems operate in coordination.”
The process begins with the core of a catalytic converter - a ceramic ‘brick’ or monolith, coated with precious metals such as platinum and palladium, that converts exhaust gases into less harmful emissions. This brick is wrapped in a thick spring-like insulation mat and inserted into an outer casing (or can) of stainless-steel. In this process, there are many variable factors to consider, he explains.
“Because the ceramic monolith is extruded and baked, its diameter can vary slightly - by two or three millimetres in a passenger vehicle converter and up to ten millimetres in a truck converter,” he said.
“This makes the size of every monolith slightly different.”
To secure the monolith inside the casing with the right spring load, the casing itself has to be adapted. This is the key function of the shrinking machine - to reshape the stainless steel casing to the exact diameter required for each brick and mat combination. Shrinking stainless steel to tolerances of 50 microns requires enormous force and control which the shrinker achieves by closing a set of heavy tapered segments around the can.
“For a passenger vehicle converter we use twelve segments, while for a commercial vehicle converter - which is larger - we use sixteen,” stated Naidoo. “We pull a massive steel ring back over those segments and as the ring moves the segments close in, collapsing the can evenly around the monolith.”
Driving that motion are two powerful SEW-EURODRIVE servo motor systems, each connected to precision roller screws that pull the ring from both sides. Synchronizing those drives is critical.
“If one side is pulled just a few millimetres more than the other, this will damage these very expensive roller screws,” he explains. “This is where SEW-EURODRIVE’s technology comes into its own; the drives and controllers keep the two motors synchronised to within very fine tolerances, even at the high speeds we need to hit our 30 second cycle times.”
The speed at which Jendamark Automation’s shrinker operates is one of its critical advantages, Naidoo emphasises, and this has been achieved through its innovative tool changer. He explains flexibility is particularly important in converter production for commercial-vehicles as variants change every few hours. Traditionally, each change required a lengthy manual tool change which would mean two to three hours of downtime.
“This is why we developed an automatic tool change system for the shrinker,” he says. “We have got two cartridges outside the machine, one of which is preloaded with the next set of 16 segments. When the operator hits ‘tool change’ the machine ejects the old set, inserts the new one and locks everything down - all automatically in about 45 seconds.”
That innovation, also powered by SEW-EURODRIVE servo drives, has transformed productivity.
“We have reduced tool changing times significantly, giving our customers more production time per shift, allowing them to produce around 80 additional parts,” he says. “With two or three tool changes a day, the gains are massive.”
The entire catalytic converter assembly cell can contain up to 30 SEW-EURODRIVE servo drives, powering and synchronising multiple machines – from laser measuring systems to robotic handlers. Behind the scenes, Jendamark’s proprietary Variant Manager software orchestrates these movements.
“Every part coming down the line is slightly different, so every 30 seconds a new set of parameters - such as diameters, spring loads and positions - is sent to the drives,” Naidoo continued. “There are no fixed positions so it is completely dynamic, adapting in real time.”
Parallel to this performance, he adds, is an equivalent focus on reliability as customers require minimal downtime to ensure that their processes and products remain viable. He notes that a USA customer, Cummins (through its acquisition of Faurecia’s USA factory), has been running Jendamark’s shrinker for almost six years - during which time it has produced over three million catalytic converters.
“Apart from greasing the screws, there has been no major maintenance and no drive failures at all,” he stated. “That is a testament to the robustness of our overall design and of the reliability of SEW-EURODRIVE equipment.”
The customer was so impressed that it decided to standardise globally on Jendamark’s machines.
“They had two other suppliers’ machines next to ours on the same line,” commented Naidoo. “Now they’re replacing those with Jendamark machines, because of reliability and consistency of quality.”
Phillip Steyn, Branch Manager at SEW-EURODRIVE in Gqeberha, says the project exemplifies how advanced motion control systems enable complex automation.
“Our MOVIAXIS multi-axis servo system, combined with our efficient servo motors and dynamic gearboxes, provides the accurate positioning and torque that this machine needs,” remarked Steyn. “The challenge was to deliver very high torque while maintaining precise synchronisation and feedback at rapid speeds.”
He notes that it is easier to be accurate when machinery is moving slowly but it becomes much more challenging in the context of high speed machines like this one. SEW-EURODRIVE’s control architecture ensures that every motion - from the synchronised pulling of the ring to the positioning of the auto-tool change mechanism - is tracked and verified before the next cycle begins.
“There is a great deal of feedback between the drive and the upper level controller,” Steyn explained. “The system scans the input data - the product types and can sizes - and adjusts torque and position in real time. It is the brain and the muscle working together.”
Naidoo highlights the value of SEW-EURODRIVE’ integrated unit - the motor, gearbox and drive - which is already matched for torque and speed.
