Insulated panel and complete construction solutions manufacturer Afripanel, a division of cold room and freezer manufacturer Africhill, will receive a new machine this year that will increase its current production sixfold.

Afripanel MD Jaco Schultz, who is reluctant to divulge the specifics of the output-increasing technology, tells Mining Weekly that he designed the machine over nine months. It is being manufactured overseas and its construction should be completed in the next three months.

“We are confident that no one in South Africa is in possession of this type of machinery. We will be the first company to employ such technology to produce modular units, which are used for mine site accommodation,” says Schultz.

“The machine comprises better technology, compared with what is currently available on the market, and will decrease the need for manual labour and, therefore, increase Afripanel’s productivity rate,” he says.

The company is also in the process of completing the extension of its production plant, which should be completed by the beginning of May.

“We are building another factory at our current premises in Kempton Park, South Africa, that will make use of old and new machinery.

“We hope that the new machinery and the extension will assist in expanding Afripanel’s African footprint, especially in the mining industry, owing to the company’s faster production rate. Increased production can only mean bigger and better opportunities for Afripanel.”

The company is always looking for new ways of improving its business and overcoming challenges in the modular buildings industry, such as transport costs, sourcing a properly trained and highly skilled workforce and the financing of projects.

“Transport is expensive, so we have adapted to include the modern solution of flat-packing our product and then sending it to site, where it is installed. This enables the client to specify the exact size of the building that it requires. “It also allows a truck to transport between eight and ten times more product, which allows one truck to transport up to six modular houses, decreasing logistics costs,” notes Schultz.

He says the reduction in mining activity in South Africa, as a result of concerns about the introduction of nationalisation and the mineral rent tax, which have decreased investment in the mining industry, has prompted Afripanel to seek contracts in other African countries.

“In the rest of Africa, many investors are seeing potential and we have seen and undertaken numerous projects in countries such as Mozambique, the Democratic Republic of Congo and Zimbabwe.”

Afripanel is also working towards improving its product to meet requirements for fire resistance.

“Our product is all steel and insulated with a type of polystyrene, which has a 20 density/ volume (20 kg/m3) and is fire retardant. “The polystyrene will melt but will not burn in a fire, thereby meeting current standards,” says Afripanel marketing and sales manager Suzette Gous.

She notes that the mindset of the construction industry needs to change to adopt quicker solutions, such as prefabricated accommodation. “People still look at sand, brick and stone and believe that is the best way to build; however, we are able to provide solutions that can match the stability and insulation of traditional house-building methods.”

The houses are also hurricane resistant and maintenance free, owing to the aluminium trimmings that are used by Afripanel.

“The materials that the houses are made from also help to save between 30% and 50% energy, which is a big advantage, especially with South Africa currently experiencing an electricity supply shortage,” she concludes.