Screening and vibrating equipment supplier Aury Africa intends to boost its productivity this year with the acquisition of a new polyurethane casting machine. The multimillion-rand machine will enable the Boksburg-based company to produce its own polyurethane screening panels, liners and wedges used for coal screening.

Aury Africa MD Mark Houchin tells Mining Weekly that the cost of imports from the company’s main branch in China has become too expensive, owing to the rand:dollar exchange rate. The new machine will alleviate stock issues while saving the company a substantial amount of capital.

The company currently stockpiles a range of imported screen panels for its clients, but Houchin believes that the procurement of the new machine will enable the company to reduce its stockholding.

“Stock is dead money. We can now produce panels specifically suited to a particular mine’s requirements as and when needed.”

Houchin notes that mining companies constantly have to weigh the composite of their coal screen panels, as this influences the production cycle. He notes that polyurethane panels show better wear characteristics, with longer replacement intervals, although the panels have a smaller screening area. Wedge wire panels, however, wear quicker than polyurethane, but provide a larger screening area.

“There is always a trade-off. If you are happy with the efficiency of your screen and want longer life, polyurethane components last longer . . . if you need a larger area to screen more coal quicker, wedge wire panels allow for greater efficiency.”

Houchin adds that mines have to decide whether to clamp down on the recurring costs of having to frequently replace these components.

“The casting machine will ensure that we retain a steady production of screen panels and other consumables used on coal screens and other devices. The drop in the coal price has strained mining companies, which have consequently come to us for solutions to cut consumables costs. The polyurethane panels help in this regard, as they provide a longer workable lifetime than wire screens.”

The modular casting machine, which will run continuously when it is installed next month, will provide Aury Africa with an aggressive edge in the market, as the company will not only produce stock locally but also collaborate with its Chinese factory for bulk supplies.

“While the machine does not use injection molding but hand pouring, we can still produce around 20 panels an hour. This is perfect for our current demand, but should we need to supply a bulk order, we will use our contacts in China. We might take a slight hit in margin, but the casting machine’s modular design will enable us to install annexes as demand for screening consumables grows. We also hope to add an injection-molding machine in the following months, which will allow for the production of about eight panels a minute,” Houchin notes.

Beyond SA

Houchin says while more South African companies have shown interest in the panels Aury Africa provides, the company has also started “dipping its toes” in other African markets – the company currently supplies the Benga coal mine, in Mozambique, with 2 000 screening panels every few months.

“We have had to open a satellite office in the Tete region of Mozambique, as we also supply panels and accessories to mines in the Benga and Moatize regions.”

Aury Africa has further investigated business opportunities in Ghana, where it has noted the need for its products. Although the Ghanaian market remains finite, with only 16 mines in the country, there is no reason to believe that Aury Africa cannot supply these mining operations with products at competitive prices, adds Houchin.

Aury Africa is changing perceptions regarding the quality of Chinese-manufactured products by providing high-quality merchandise that lasts and meets the specifications of its mining clients’ projects, he adds.

“The casting machine will also enable us to build on our favourable reputation in the marketplace,” elaborates Houchin.