Africa-focused vibration equipment supplier Aury Africa has commissioned a hand-cast gravity-pour polyurethane (PU) system to start the local manufacture of PU panels to reduce imports, saving on costs and improving turnaround times.

“Local manufacture will enable us to remain competitive, while upskilling our staff,” says Aury Africa MD Mark Houchin.

The investment, including construction of the room in which the system is housed, the moulds and the ovens, amounts to about R3-million.

Houchin notes that the company previously imported its PU panels from its sister company Aury Tianjin, in Tianjin, China. While the cost of importing panels did not adversely affect the pricing of its products, the volatile exchange rate eroded profit margins, he notes.

Local manufacture will enable the company to produce panels as needed, rather than importing in bulk and carrying unnecessary stock, which will, subsequently, improve efficiency and cash flow in challenging economic conditions caused by the downturn in commodities prices and the subsequent depressed mining market.

The company initially commissioned the PU mould system to produce panels for India-based mining consortium International Coal Venture’s Benga coal mine, in Mozambique. When the mine went into care and maintenance earlier this year, Aury Africa decided to continue with its plans for the PU mould system because of the substantial related benefits.

The new gravity-pour PU mould and drying room is modular, enabling the company to expand its capacity as and when needed. Aury Africa has hired and trained two new staff to operate the system. Although production will start on a small scale, with about 50 panels a day, the company can easily adapt to increases in demand and, if necessary, automate the process for a faster turnaround time.

The new system will be used to manufacture modular wedge wire panels, PU cross-tensioned screen cloths, PU long slots and punch plate screen panels with PU borders in 305 mm × 305 mm, 305 mm × 610 mm and 610 mm × 610 mm. It can also produce wedge wire screen panels with PU borders in 305 mm × 305 mm, 305 mm × 610 mm and 610 mm × 610 mm, and PU panels in 305 mm × 305 mm and 305 mm × 610 mm, including pin and sleeve options. Other screening products can be imported from China, if necessary.

Houchin comments that the new system is only the first phase of the company’s drive to become more self-sufficient and Aury Africa hopes to import an injection-moulding machine from its sister company in the near future.

Aury Africa also offers a hybrid system that allows its PU panels to be installed alongside existing panels. This provides customers with “the freedom of choice to select a supplier of choice”, as they are no longer bound by a patent or a specific structure, says Houchin.

He highlights that Aury Africa is constantly growing its client base. “Even though the mining industry is running leaner, larger players are moving away from their regular suppliers that have traditionally dictated prices. This is where Aury Africa adds real value, as we offer commensurate quality at a better price, which is exactly what the market needs at present.”

Houchin has also been travelling to Zambia, Ghana and Madagascar to establish contact with potential clients as part of the company’s aim to expand its client base in Africa.

To complement its locally manufactured range, Aury Africa intends to focus on supplying a high-quality customer service for existing clients. “Our customers have peace of mind in knowing they can call us at any time and receive helpful feedback within a few hours,” Houchin notes.