The impressive facility has a dedicated stretch film manufacturing centre with two Austrian-built five-layer cast film extrusion lines – the first of their kind in South Africa – complemented by a 2 200mm-wide three-layer coextrusion line, an impressive eight-colour gearless flexographic press and a paper core-making plant.
Technovaa is the packaging arm of the Indian Darvesh group. Established over a century ago, Darvesh operates world-class operations in almost every corner of the globe and its investment in South Africa underlines a commitment to enhancing its sub-Saharan business.
‘The entire South African project has been exciting and rewarding,’ remarks chief operating officer, Derek Cranston. ‘Head office has been very supportive and is keen to see us flourish. We have a great product mix and we’re perceived as a quality manufacturer. The first year of business has been excellent, if not a little stressful!’ he quips. ‘Within the first six months we exceeded our monthly production expectations, proving that our promise to supply international-quality stretch films, coupled with excellent service levels and competitive pricing, was right on the money. With the second phase of investments now established, we can pursue a host of promising blue-chip accounts and continue our positive stride into the local and export markets.’
Enhanced capacity
The two five-layer lines have brought the plant’s stretch film capacity to 16 000 tons/annum, making Technovaa the largest stretch film manufacturer in Southern Africa.
‘The second cast film line has paved the way for new product developments, especially for high-end food packaging and a number of industrial applications,’ remarks Derek. ‘Our international business partners run high-speed packing lines and require the best quality films for these processes. That’s where we come in. Our customers get a consistent, trusted product every time.’
Technovaa, Derek insists, is committed to running an eco-efficient production centre. For instance, each line is fitted with in-line edge-trim recycling unit, where cut material is fed continuously to the extruder.
Investment in the three-layer coextrusion line means that Technovaa produces exceptional films for specialised retail and industrial applications.
The towering German-designed structure is armed with superior gauge, thickness and width control, a patented high-output air-ring system and specially- constructed winder. Its ergonomically-designed control panel is easy to use and its low energy and waste specifications ensure an economical and environmentally-friendly package.
It’s a closed loop system with intelligent process control that minimises energy consumption and running costs, highlighting Technovaa’s commitment to reducing carbon footprint.
Smart systems
As well as producing top-class plain films, Technovaa has dived head-first into the full-colour print arena with a gleaming Miraflex eight-colour flexographic press.
This robust powerhouse, packed with smart technology and top-quality engineering, offers maximum output. The rigidity of the central impression drum and drive system provides excellent print quality at a 370m/min.
‘Our new press provides top-quality printing that’s controlled in-house, offering customers a one-stop shop,’ comments Derek. ‘We can also provide product development services and fast turnaround times. We’re putting ourselves in a position where our customers can expect the best.’
Producing the best film for the market requires a perfectly finished product, right down to the carrier core; and, with approximately 400 tons of film producted each month, Technovaa’s taken the step to incorporate an in-house core-making plant, situated in an adjacent hall.
At first sight, the spiral winding line, imported from Germany, resembles a dinosaur-like mechanical skeleton. However, up-close it’s an intricate system of convoluted tube winding via hydraulic-powered arms, with hot-melt edge gluing.
‘Producing cores for our own use makes complete sense,’ asserts Derek. ‘We’re able to make various core sizes to spec as and when needed, helping to control stock levels and quality.’
The company’s hands-on, motivated culture is clearly driven by Derek and his exco team colleagues, Steve Crowley and Atul Vij.
‘Atul, who joined us in April, brings a wealth of experience to the team, having previously developed high-tech packaging applications for local and international blue chip companies,’ Derek explains.
With a projected investment of R250-million over the next five years, there’s still more to come from this enterprising company. ‘Our professional and enthusiastic sales team is committed to making the company a success,’ comments Derek.
The sales team is headed by sales manager, Tracey-Lee Lazarus in KwaZulu-Natal, supported nationally by key account managers – Ken Pinkus in Gauteng and Wally van Rensburg and Neil Swanepoel in Cape Town.
‘We recently opened a branch in Cape Town to complement our growing national footprint and, with the appointment of experienced sales account managers, Manish Datwani in Gauteng and Nischal Maharaj in KwaZulu-Natal, I’m confident that we’ll continue to cement several more top-quality customer relationships,’ explains Derek. ‘Our vison is to become a competitive international company and I’m already pleased with the growth in our local and export customer base. We already manufacture and distribute several tons of film to customers in Kenya, Nigeria, Tanzania and the Indian Ocean Islands. With phase two now complete, sales volumes are expected to increase substantially over the next few months.’
Technovaa Packaging Industries
T +27 031 9404230
