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In The Spotlight

Kinieiro work nears completion. (Image source: Robex)

Energy

After announcing plans for a merger this month with a rival West African gold miner, Robex remains on track to deliver first gold at its Kiniero mine in Guinea this December, as it looks to complete work on the power plant

Robex and Predictive Discovery Limited (PDI) announced plans to merge on 5 October.

In a 6 October presentation to investors, Robex said that power station concrete works at Kiniero are now complete.

It leaves the power station erection and installation of auxiliary equipment still to finish, as well as the signing of an agreement for the supply, installation and operation of a separate solar PV plant.

The main power supply will come from Hyundai Heavy Industries’ Engine Machinery (HHI-EMD), which signed an agreement with Sycamore Mine Guinea SAU, now a part of Robex, for eight gensets for the Guinea mine and to support further work in the area.

HHI-EMD is supplying eight sets of 4MW class gensets to supply stable electricity in the mine region, with the units shipped in three instalments from May 2025.

Hyundai said at the time of the award that it plans to “further expand the supply of power generation equipment to off-grid mining regions” on the back the order.

It underscores the strength of demand among natural resources companies and the conviction that thermal gensets still provide the most robust source of power supply in remote, off-grid regions.

PDI’s key asset is the Bankan project in Guinea, which is advancing towards a final investment decision in 2026 and is currently contemplating its power supply options.

This will also likely incorporate a hybrid model, but built around a thermal power source, with the main source of power generated through a heavy fuel oil (HFO) plant in combination with a solar farm, the company noted in a recent feasibility study.

It again highlights the continued pull of HFO power plants as a dependable source of electricity for critical and remote mining and industrial applications in West Africa.

As well as the Kiniero mine, Robex also operates the producing Nampala gold mine in Mali.

Read more:

New gensets planned for Sadiola mine

Building reliable power for mining operations in Africa

Bankan Gold HFO power project emerges

Vertiv and Nxtra are setting a new benchmark for data infrastructure in Africa

Technology

In a move set to reshape Africa’s data centre landscape, Vertiv, a global leader in critical digital infrastructure, has deepened its collaboration with Airtel Africa through its data centre division, Nxtra

The partnership begins in Nigeria, marking a major step toward Nxtra’s vision of building one of Africa’s largest networks of high-capacity data centres

The initiative underscores Africa’s growing need for robust digital infrastructure to support its rapidly expanding population and digital economy. Drawing from Nxtra’s extensive operational experience in India, the company aims to replicate its success in Africa by strategically establishing modern facilities in key cities.

“Nxtra has been a valued customer for nearly three decades,” said Karsten Winther, President of Europe, Middle East and Africa (EMEA) at Vertiv. “This next chapter in our collaboration demonstrates the power of combining local support in Africa with international manufacturing and innovation.”

The first of these projects, located in Nigeria, will feature a 42 MW facility developed through a four-phase rollout and expected to be fully operational by 2028. Vertiv will provide thermal management systems and uninterruptible power supply (UPS) units with batteries, ensuring energy efficiency, scalability, and reliability.

“As we invest into high-capacity, high-quality data centres for Africa, it was crucial to partner with a vendor who combines global capabilities with a strong local presence,” said Yash Issur, CEO of Nxtra by Airtel Africa. “Vertiv’s extensive multinational expertise, coupled with their established service team in Africa, provides us the reliability and support we need. We’re particularly pleased to name Vertiv as a main vendor for the first project in Nigeria and extend a collaboration ranging from India to Africa.”

Vertiv’s established Nigerian service team will oversee commissioning, handover, and five years of maintenance, providing vital local support to ensure seamless long-term operations.

A vision for sustainable expansion

According to Wojtek Piorko, managing director for Africa at Vertiv, Africa’s “data-hungry” population is a driving force behind the demand for more data centres. “Our collaboration in Africa with Nxtra marks an important milestone in strengthening Africa’s critical digital infrastructure,” he said. “Together, we are bringing proven global expertise and advanced technology into Nigeria and beyond.”

The partnership not only boosts connectivity but also represents a commitment to sustainable growth. Vertiv’s solutions will enable Nxtra to meet the region’s energy and efficiency demands while supporting environmental goals.

Looking beyond Nigeria, Nxtra and Vertiv are already planning future data centre developments in other Airtel Africa markets. The Nairobi-based facility is projected to surpass the Nigerian site in scale, reinforcing the companies’ long-term ambition to establish a continent-wide digital backbone that fuels innovation, drives local economies, and enhances Africa’s global connectivity.

With this collaboration, Vertiv and Nxtra are setting a new benchmark for data infrastructure in Africa, one that blends global expertise, local empowerment, and sustainable innovation to power the continent’s digital future.

Locomotives power Guinea’s progress. (Image source: SimFer)

Logistics

SimFer, the joint venture between the Government of the Republic of Guinea, Rio Tinto, and the Chinalco-led CIOH consortium, has achieved another significant milestone with the safe arrival of the first four CTG locomotives at the Port of Morébaya

These units mark the initial batch of a total of 78 locomotives ordered by Rio Tinto SimFer in July 2024 on behalf of La Compagnie du TransGuinéen (CTG), the organisation established to own and manage the rail and port infrastructure connected to the Simandou mines.

Purpose-built to support Africa's largest integrated mining and infrastructure project, these locomotives will play a vital role in transporting high-grade iron ore from the Simandou mines to the newly developed Morebaya port facilities in Forécariah. The 670 kmTrans-Guinean Railway will link Guinea from east to west for the first time, unlocking new opportunities for trade, agriculture, and passenger transport. The arrival of these locomotives highlights the crucial role of rail infrastructure in advancing the Simandou project.

Chris Aitchison, CEO of Rio Tinto SimFer, said,“This is a historic moment for the Simandou project and for Guinea. These locomotives are a visible sign of the progress made and the future benefits that the Trans-Guinean Railway will bring by connecting communities, facilitating trade and supporting sustainable development across the country.”

Mamoudou Nagnalen Barry, president of the Compagnie du TransGuinéen, stressed: “The TransGuinéen is gradually becoming a tangible reality, and we are proud to work hand in hand with our industrial partners to ensure the full operationalisation of the CTG. We are committed to making the TransGuinéen corridor an important vector of development for local businesses and a catalyst for economic growth and prosperity for communities in Guinea, in line with the Simandou 2040 vision.”

The Compagnie du TransGuinéen (CTG) will oversee the operation of the railway and port, ensuring long-term sustainability under Guinean leadership. CTG is a joint venture between Rio Tinto SimFer and Winning Consortium Simandou (WCS), each holding a 42.5% share, while the Government of Guinea retains a 15% free stake. Following a 35-year operational period, ownership of the entire infrastructure will be transferred to the Government of Guinea, marking it as a transformative national asset.

With the arrival of the first four locomotives and additional deliveries expected in the coming months, the project continues to advance steadily. This milestone reflects continued progress towards the full realisation of the Simandou project, generating opportunities for the Guinean people and positioning the nation as a global leader in high-grade iron ore production.

Liebherr

  • 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. 

  • 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.

  • 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.

  • 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.

Top Stories

Grid List

Energy

Kinieiro work nears completion. (Image source: Robex)

Energy

After announcing plans for a merger this month with a rival West African gold miner, Robex remains on track to deliver first gold at its Kiniero mine in Guinea this December, as it looks to complete work on the power plant

Robex and Predictive Discovery Limited (PDI) announced plans to merge on 5 October.

In a 6 October presentation to investors, Robex said that power station concrete works at Kiniero are now complete.

It leaves the power station erection and installation of auxiliary equipment still to finish, as well as the signing of an agreement for the supply, installation and operation of a separate solar PV plant.

The main power supply will come from Hyundai Heavy Industries’ Engine Machinery (HHI-EMD), which signed an agreement with Sycamore Mine Guinea SAU, now a part of Robex, for eight gensets for the Guinea mine and to support further work in the area.

HHI-EMD is supplying eight sets of 4MW class gensets to supply stable electricity in the mine region, with the units shipped in three instalments from May 2025.

Hyundai said at the time of the award that it plans to “further expand the supply of power generation equipment to off-grid mining regions” on the back the order.

It underscores the strength of demand among natural resources companies and the conviction that thermal gensets still provide the most robust source of power supply in remote, off-grid regions.

PDI’s key asset is the Bankan project in Guinea, which is advancing towards a final investment decision in 2026 and is currently contemplating its power supply options.

This will also likely incorporate a hybrid model, but built around a thermal power source, with the main source of power generated through a heavy fuel oil (HFO) plant in combination with a solar farm, the company noted in a recent feasibility study.

It again highlights the continued pull of HFO power plants as a dependable source of electricity for critical and remote mining and industrial applications in West Africa.

As well as the Kiniero mine, Robex also operates the producing Nampala gold mine in Mali.

Read more:

New gensets planned for Sadiola mine

Building reliable power for mining operations in Africa

Bankan Gold HFO power project emerges

Powering Africa through innovative funding mechanisms

Kamoa-Kakula smelter. (Image source: Ivanhoe Mines)

Construction

Transport sector poised for growth in Africa

Construction

Saint Gobain has announced a new ‘Lead & Grow’ strategic plan, which envisages around €12bn (approx. US$13.95bn) in growth capex and acquisitions globally over the 2026-2030 period
 
With a focus on light and sustainable construction, the group says it is raising its profitable growth trajectory in the years ahead, and aims to increase its exposure to the non-residential and infrastructure sectors.
 
“In the current geopolitical context, Saint-Gobain benefits from the powerful operating model it has established and optimised country-by-country, based on local value chains,” said Benoit Bazin, Saint-Gobain’s chairman and CEO.
 
The group outlined growth plans across major developed regions, including Asia, North America and Europe, but it is also active across the African continent.
 
Its latest investment in Africa is a new cement plant in South Africa, opened this year to support local manufacturing and sustainability efforts.
 
It also dovetails with another of the group's corporate messages in priortising local manufacturing capabilities: Make it Africa, to Build Africa, or MABA.
 
“We will also expand into new growth markets: in infrastructure, particularly thanks to our established leading position in construction chemicals, and in non-residential, where the group holds key advantages,” added Bazin.
 
The widening of the group’s product offer over the past few years has opened up new opportunities in non-residential (including educational and healthcare facilities, hotels and data centres) and infrastructure (transport, energy), the company added in a statement.
 
In the data centre segment, it highlights solutions including focusing on speed of construction, low-carbon partitions and concrete, airflow management and improved thermal insulation.
 
On the infrastructure side, it said it was targeting niche areas in the bridges and tunnels segment, such as technical waterproofing, specialty admixtures, expansion and injection grouts, repair and protection mortars.
 
And on the airports side, it highlighted products for runway reinforcement, fire-resistant and fire safety glass, solar controlled façades, technical flooring and acoustic partitions.
 
Read more:
 
 
 
 
   
 
 

The collaboration combines XCMG's expertise in innovative, eco-efficient technologies with Dangote Group's extensive operational footprint. (Image source: XCMG Machinery)

The latest Volvo wheel loaders comes with standard cutting-edge automation to simplify your workday. (Image source: Volvo CE)

Mining

Epiroc’s Minetruck MT65 S. (Image source: Epiroc)

Mining

Epiroc AB has secured a large order for mining equipment and digital solutions from Asante Gold Corp. for a gold mine in Ghana
 
Canadian mining company Asante Gold ordered a fleet of underground mining trucks, loaders, face drilling rigs and production drilling rigs for its operations at the Chirano Gold Mine, a combined underground and open pit gold mine in southwestern Ghana.
 
The equipment order is valued at around (US$12mn), Epic said in a statement.
 
Asante Gold also ordered a digital situational awareness solution that will increase efficiency by keeping track of the machines and providing near real-time production metrics such as tonnages moved, cycle time and meters drilled. Epiroc will also provide tools, spare parts and service support, it noted.
 
“We are very pleased to support Asante Gold with our top-modern loaders, trucks and drilling rigs,” said Helena Hedblom, Epiroc’s president and CEO.
 
“The digital situational awareness solution will boost operational efficiency as well as safety through improved production monitoring.”
 
Asante Gold ordered a fleet of the Minetruck MT65 S hauler, Scooptram ST18 S loader, Boomer M20 S face drilling rig and Simba E70 S production drilling rig.
 
The machines are part of Epiroc’s Smart series which means that they are automation ready.
 
Delivery of the equipment has begun and will continue for the next few months, the Epiroc statement added.
 
“We are excited to collaborate with Epiroc to upgrade operations and increase gold production at our Chirano Mine,” said Dave Anthony, Asante Gold’s president and CEO.
 
“The Epiroc mine equipment fleet is world class and brings advanced technology, plus reliability. This strategic partnership marks a significant step towards unlocking Chirano’s full potential and we are confident it will generate lasting value for years to come.”
 
Read more:
 
 
 
 

Tharisa Mine begins phased underground expansion to enhance efficiency

Condra jib crane (Image source: Condra)

Logistics

Mr. Guo Shuangqing, assistant chief marketing officer of SF Technology. (Image source: Huawei)

Logistics

Huawei unveiled its SMART Logistics & Warehousing Solution, which integrates leading digital and intelligent technologies to enhance service quality, reduce costs, and increase efficiency across logistics and supply chain operations

HUAWEI CONNECT 2025 recently hosted a transportation summit titled "Creating a Digital & Intelligent Foundation for Comprehensive Transportation and Logistics," bringing together global leaders, key customers, and partners from the transportation and logistics sectors. The event served as a platform to discuss emerging trends in intelligent transformation and exchange innovative practices.

Rapid digitalisation, intelligentisation, and decarbonisation are reshaping transportation, supply chains, and logistics worldwide. Advanced technologies are improving the efficiency and security of critical infrastructure, including ports, airports, railways, and road networks. Multimodal transport and cross-industry integration are also driving substantial growth in the sector.

Delivering the opening address, Ma Yue, vice-president of Huawei and CEO of Huawei's Smart Transportation BU, highlighted Huawei’s commitment to technological innovation. “As a leading global provider of ICT infrastructure and smart devices, Huawei remains committed to technological innovation. By fitting the right technologies to increasingly diversified scenarios, the company helps optimise the flow of passengers, freight, businesses, revenue, and information, laying a robust foundation for industry transformation.” He emphasised the importance of open collaboration in addressing the complexities of upgrading transportation systems and noted Huawei’s work with global partners in supporting over 100 ports, more than 200 logistics enterprises, and Intelligent Transportation Systems across 70 cities. 

Guo Shuangqing, assistant chief marketing officer of SF Technology, shared that his company has developed an air logistics digital twin platform based at China’s first cargo airport. “This platform allows for TB-level data processing with millisecond-fast response time. It fosters smooth collaboration among millions of elements and has successfully managed a cargo throughput of 1.9 million metric tons without any switching errors. SF Technology and Huawei will maximise respective strengths to expand capabilities in coordinating multiple airports, thus leading to a substantial efficiency increase across the entire air logistics sector.”

Dr Rachad Nassar, Huawei's global business & strategic partners director, added, “Huawei is enabling a smarter, safer, and more efficient future for transportation and logistics. With its comprehensive ICT intelligent foundation and its innovative technologies, such as intelligent sensing, broadband connectivity, cloud-based digital platforms, and AI, Huawei is turning concepts like Mobility as a Service and Logistics as a Service into reality—unlocking the full potential of digital intelligence.”

Qiu Shikui, vice-president of Huawei's smart logistics and warehousing BU, explained, “The logistics industry is currently grappling with key challenges such as high OPEX, low efficiency, complex data coordination, and underutilised AI. To address these common needs, Huawei, alongside its customers and partners, has launched the innovative SMART Logistics & Warehousing Solution. Built on the '1+N' architecture, it combines a smart operations cloud with intelligent coordination across logistics parks and yards to provide end-to-end digital and intelligent services. It focuses on platform-based services, digitalized operations management, intelligent allocation, automated relocation, and unattended transportation, enabling secure data collaboration, AI-based planning, and automated logistics yard operations.”

To date, Huawei has supported a massive infrastructure network worldwide, including over 100 ports, more than 200 logistics and warehousing enterprises, 300 urban rail lines in 70+ cities, over 180,000 km of railways, road networks exceeding 200,000 km, over 300 urban transportation cities, and more than 210 airlines and air traffic management bureaus. Huawei continues to collaborate with customers and partners to advance the logistics and supply chain sector globally.

Locomotives power Guinea’s progress. (Image source: SimFer)

Jet refuelling operations on the tarmac (Image source: Adobe Stock)

Finance

Afreximbank leads US$1.35bn facility in US$4bn syndication to strengthen Dangote’s refinery operations and growth

Finance

The African Export-Import Bank (Afreximbank) has announced the signing of a US$1.35bn financing facility for Dangote Industries Limited (DIL)

This forms part of a larger approximately US$4bn syndicated financing arrangement for DIL, Africa’s largest industrial conglomerate, with Afreximbank acting as the Mandated Lead Arranger for the syndication.

This transaction — one of the largest syndicated loans in recent African financial markets — will be used to refinance capital invested in the construction of the Dangote Petroleum Refinery and Petrochemicals Complex, the world’s largest single-train refinery with a capacity of 650,000 barrels per day. The financing will reduce initial operational expenditures, strengthen DIL’s balance sheet, and support its ongoing growth.

Afreximbank’s contribution of US$1.35bn, the largest share among participating banks, highlights its commitment to major infrastructure projects that drive Africa’s industrialisation, energy security, and intra-African trade.

Since the refinery complex commenced operations in February 2024, Afreximbank has continued to provide financial support for crude supply and product offtake, ensuring smooth operations and reinforcing its role in Africa’s most significant refining project.

Commenting on the deal, Benedict Oramah, president & chairman of the board of directors at Afreximbank, said, “With this landmark deal, we once again demonstrate that Africa’s development can only be meaningfully financed from within. It is only when African institutions lead the way that others can follow. The journey to utilise African resources for its own economic transformation is well underway. Through the Bank’s funding support, we are enhancing the capacity of the Dangote Refinery and Petrochemical Industries Ltd to produce and supply high quality refined petroleum products to the Nigerian market, as well as for export to the entire continent and the world. Our energy security is in sight.”

Aliko Dangote, CEO, Dangote Industries Limited, added, “Afreximbank’s contribution to this milestone financing underscores our shared vision to industrialise Africa from within. This refinancing strengthens our balance sheet and accelerates with ease the refinery’s suppy of high-quality refined petroleum products across Africa.”

The syndicated facility attracted strong interest from major African and international financial institutions, reflecting confidence in Africa’s industrial growth and in Dangote’s vision for transforming the continent.

AfDB and Algeria’s Knowledge Economy Ministry partner to scale African startups and SMEs, with fresh funds and policy support

Paycorp invests in UK’s Currency Stream to accelerate FX tech growth across Africa, Asia, the Americas and Europe

Manufacturing

FLS strengthens Delmas site as a global polyurethane hub. (Image source: FLS)

Manufacturing

FLS has completed a significant upgrade to its polyurethane manufacturing facility in Delmas, Mpumalanga, positioning the site as a key global hub for the production of its advanced NexGen wear-resistant material

This development forms part of a wider modernisation programme by FLS, aimed at strengthening supply chains, increasing manufacturing efficiency and enhancing
sustainability across its global footprint.

Brad Shepherd, director service line - screen and feeder consumables at FLS, said the investment at Delmas aligns with the company’s global strategy to standardise and optimise production processes.

“This is a milestone for us,” commented Shepherd. “We are integrating cutting edge technology and modern manufacturing methodologies across all our polyurethane plants, and Delmas is leading the way. The upgrade enables us to respond more quickly and reliably to customer needs across Africa, the Middle East and Europe.”

The centrepiece of the upgrade is the introduction of purpose-built infrastructure to produce NexGen screen media - a polyurethane material developed by FLS to deliver extended wear life, reduced maintenance and improved operational efficiency. In on-site trials, screen panels made from NexGen have demonstrated up to three times the wear life of conventional rubber and polyurethane products, making it a gamechanger for industries that rely on high performance screening solutions.

Warren Walker, head of global manufacturing - polyurethane operations at FLS, explained that Delmas is the first of the company’s five global polyurethane plants to complete this transition. “We have installed new, latest generation polyurethane machines, precision tooling and dedicated preheating ovens for inserts,” he said. “This allows us to significantly increase our output while ensuring consistent quality.”

The facility now includes two trommel screen media stations and three screen media stations, each tailored to produce NexGen products. One of the standout technologies introduced is a programmable auto- calibrating polyurethane machine capable of adjusting material hardness to suit
specific applications.

“The flexibility to produce varying hardness levels is critical,” Walker noted. “It means we can tailor our screen media precisely to the customer’s application, ensuring optimum performance and longevity.”

To complement this, a high capacity polyurethane machine capable of pouring up to 42 kg per minute is in operation at the facility. This system is particularly suited to applications requiring large volume pours, such as flotation spare parts and vertical mill components.

The Delmas facility already benefited from a significant upgrade in 2019, when a state-of-the-art six-axis machining centre was introduced for tooling precision, along with robotic welding systems for manufacturing screen media panel inserts and a CNC controlled spiral welding machine to produce wedge wire products. The latest round of investments builds on this foundation and brings the facility to the forefront of global polyurethane production capability.

Energy efficiency was a key consideration in the new layout and equipment design. “We have incorporated smart energy saving features like individual temperature control on each casting table station,” Walker remarked. “This avoids the need to heat large surface areas unnecessarily and contributes to our carbon reduction goals.”

Further supporting these goals is the installation of 300 kW of solar generation capacity at the Delmas site, completed in 2024. Plans are already in place to expand this by another 500 kW in 2026, along with the integration of a battery energy storage system (BESS), enabling greater energy independence and resilience.

FLS’s offering from Delmas extends beyond screen media manufacturing. The facility is equipped to handle the complete fabrication of vibrating screens, from raw material processing and in-house machining to assembly and factory acceptance testing. This vertical integration allows the company to deliver customised solutions with tighter control over quality and lead times.

Shepherd emphasises that FLS operates both as an original equipment manufacturer (OEM) and a screen media specialist, supplying screen panels for all types and brands of vibrating screens, feeders and trommel screens.

“We don’t just supply products,” he said. “We work closely with our customers through our network of on-the-ground specialists to assess site conditions and select the best screening media for their specific needs.”

He notes that many older processing plants are treating materials that differ from their original design specifications. In these cases, screen efficiency can often only be improved by optimising the screen media. “This is where NexGen makes a real difference,” Shepherd commented. “Combined with the correct aperture design, it allows customers to get more life and better performance from their screens.”

Unlike injection-moulded polyurethane, which can compromise the structural integrity of screen panels, FLS’s proprietary process retains superior mechanical properties, resulting in a tougher more durable product. “We have never used injection moulding because it reduces the quality of the end product,” Shepherd explained. “Our process delivers a product that stands up to the toughest operating conditions and offers lasting value.”

Walker adds that the expansion at Delmas not only supports FLS’s global operations but also contributes meaningfully to the South African economy. “Our commitment to local manufacturing is evident in the scale of our investment and the jobs we have created,” he said. “We have expanded our workforce, prioritised local recruitment and significantly grown our apprenticeship programme.”

A strong focus has also been placed on developing female artisans. In 2024, six women from the local community were recruited into a three year trade apprenticeship programme, receiving training in welding, fitting and boilermaking.

“Our investment during a period of economic uncertainty underlines FLS’s long term commitment to South Africa and to our customers in the broader EMEA region,” said Walker. “We are not just building products – we are building skills, opportunities and partnerships that will power sustainable growth for years to come.”

the partnership aims to accelerate the transformation of West Africa’s manufacturing landscape. (Image source: RusselSmith)

Brady Corporation empowers panel builders with durable, compliant, and efficient labelling systems for electrical clarity. (Image source: Brady Corporation)

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