In The Spotlight
AFC reaches financial close on 119MW power plant, Burkina Faso's largest, to help close its electricity access gap (Image source: AFC)
A major power project in Burkina Faso is to proceed after securing a first US$60mn tranche of a US$300mn corporate loan facility from Africa Finance Corporation (AFC)
The funds will support the development of the 119MW thermal power plant by Aksa Enerji Üretim A.Ş., Türkiye’s largest publicly-listed power generation company.
The project is expected to make a huge dent in accss to electricity in Burkina Faso, a country of 24 million people where only one in five currently have access to power.
“Burkina Faso represents an important milestone in our long-term commitment to Africa,” said Cemil Kazanci, chairman of Aksa Enerji.
“Together with AFC, we are delivering critical energy infrastructure that will strengthen energy security, support economic development and improve the reliability of electricity supply for millions.”
The transaction marks AFC’s first investment in Burkina Faso, but builds on its US$150mn corporate loan facility to Aksa Enerji in 2025, which supported the company’s utility-scale gas-to-power projects in Senegal and Ghana.
This includes Senega’s new 255MW combined-cycle gas power plant designed to use domestic natural gas to deliver more reliable and lower-emission baseload power.
Collectively, these projects have established Aksa as a major partner in delivering large-scale energy infrastructure across Africa.
The Burkina Faso project is expected to transform the nation’s electricity system.
The West African state currently imports 60% of its power supply, leaving homes, businesses and industry vulnerable to supply disruptions and elevated energy costs, constraining industrialisation and economic growth.
Once operational in 2027, the power station will reduce dependence on imported electricity by more than 50% while significantly strengthening domestic generation capacity.
By delivering more reliable, lower-cost baseload power, the project is expected to improve energy security, attract private investment and create a stronger foundation for long-term economic growth, according to the AFC.
Expanding reliable electricity access is a central part of the Corporation’s mission in unlocking sustainable growth across the continent.
“Africa’s path to industrialisation and global competitiveness by 2050 depends on the infrastructure decisions we make today,” said Samaila Zubairu, AFC’s president and CEO.
“Reliable electricity is fundamental to economic transformation. Without dependable power, countries cannot industrialise, businesses cannot grow and communities cannot realise their full economic potential. Aksa shares our commitment to delivering the reliable energy infrastructure needed to power Africa’s industrial growth and long-term transformation.”
Read more:
Nesa Power gets cash boost for C&I power growth
Lobito is a strategic project connecting central and west African markets to the USA. (Image source: AFC)
Africa Finance Corporation (AFC) has announced the financial close of the US$753mn Lobito Corridor Railway Project in Angola
It marks a major milestone for one of Africa's largest and most strategic cross-border transport infrastructure developments.
The project will fund the rehabilitation, upgrade and long-term operation of a 1,300-kilometre rail corridor linking the Port of Lobito on Angola's Atlantic coast with the border of the Democratic Republic of Congo (DRC).
The railway is expected to improve regional connectivity, facilitate trade and strengthen access to international markets for a variety of mineral deposits out of the DRC.
"The financial close of the Lobito Corridor Railway Project underscores AFC's leadership in delivering complex transformational infrastructure that advances Africa's industrialisation and regional integration,” said AFC’s president and CEO Samaila Zubairu.
“As one of the continent's most strategic transport corridors, the project will strengthen regional connectivity, facilitate trade and unlock new opportunities for economic growth across Angola and the wider region.”
AFC acted as co-financial adviser alongside Eaglestone, helping to structure and mobilise financing for Lobito Atlantic Railway S.A. (LAR), the concessionaire responsible for the project.
LAR is a joint venture between construction firm Mota-Engil and commodities trader Trafigura.
The financing package includes US$553mn from the US International Development Finance Corporation (DFC) and US$200mn from the Development Bank of Southern Africa (DBSA), following financing agreements signed late last year.
Eaglestone founding partner Nuno Gil described the agreement as “the culmination of years of work and a defining moment for infrastructure finance in sub-Saharan Africa.”
He also said the deal demonstrated that “complex, multi-lender, cross-border project financings can be structured and successfully closed on the continent.”
Read more:
Africa can benefit from geopolitical change, says Afreximbank
DP World opens Egypt's first integrated logistics distribution centre at Sokhna to strengthen regional trade.
DP World has inaugurated Egypt's first fully integrated Logistics Distribution Centre (LDC) at Sokhna Logistics Park, introducing a new logistics hub designed to simplify access to the Egyptian market while supporting regional and international trade through a single distribution platform
The launch ceremony was attended by His Excellency Dr Mostafa Madbouly, Prime Minister of Egypt, alongside senior government officials and representatives from international businesses. The occasion also marked the first official visit to Egypt by His Excellency Essa Kazim since assuming the role of chairman of DP World. During the event, agreements were signed with the first three international customers that will utilise the new facility.
Situated adjacent to Sokhna Port within the Suez Canal Economic Zone, the Logistics Distribution Centre has been strategically positioned along one of the world's busiest trade routes, providing efficient connectivity to markets across the region and beyond.
The facility delivers an integrated supply chain offering that combines international freight forwarding, port operations at Sokhna Port, warehousing, inventory management, order fulfilment, customs clearance support, transport coordination and a range of value-added services. These include assembly, packaging, repackaging, labelling and product customisation, allowing businesses to manage distribution from a single location while retaining ownership of inventory until products reach their final destination.
His Excellency Essa Kazim, chairman of DP World, said, "The launch of the project marks a new chapter in our long-standing partnership with this dynamic market. Egypt has been one of our most important investment destinations in the region, and today we reaffirm our confidence in its potential to become a global hub for trade, industry and logistics.”
“Egypt's first Logistics Distribution Centre reflects our vision of creating an integrated ecosystem that connects ports, logistics and supply chain solutions, enabling businesses to access local, regional and international markets more efficiently. We look forward to expanding our investments in support of the Egyptian government's vision while strengthening the competitiveness of the Egyptian economy and attracting further investment," added Kazim.
The centre has already secured its first group of international customers, highlighting Egypt's growing importance as a regional logistics gateway.
Among them is a Kenya-based tea exporter serving customers across Africa, Europe and the Middle East. The company, which handles around 1,000 TEUs into Egypt each year, will use the facility as a regional inventory hub to streamline distribution across several international markets.
Another early customer, one of the world's leading consumer goods distributors, will utilise the centre to support operations in eight markets across Saudi Arabia, the Levant and the Horn of Africa. Its activities will be supported by a dedicated temperature-controlled facility located within Sokhna Logistics Park.
A third customer is a German multinational specialising in fibre-optic cables and digital infrastructure solutions. The company will use the logistics centre to strengthen its distribution and re-export operations across Egypt, North Africa and the Gulf Cooperation Council countries.
Mohammad Shihab, executive vice-president, Egypt and Levant, DP World, said, "The launch of the LDC at Sokhna Logistics Park strengthens Egypt's trade and logistics capabilities by enabling businesses to position inventory closer to customers and serve multiple markets from a single regional hub. The integrated model improves efficiency and flexibility while reinforcing Egypt's role as a strategic gateway connecting Asia, Africa and Europe.”
He thanked the Egyptian Government for its support in enabling the project, adding that it will help attract investment, encourage industrial growth and improve Egypt's competitiveness.
By positioning inventory and raw materials closer to manufacturing hubs and end markets, the Logistics Distribution Centre is expected to shorten lead times, improve supply chain resilience and support business continuity. It will also provide local industries with quicker access to essential materials, further strengthening Egypt's position as a regional trade and logistics hub.
DP World has invested more than US$1.4bn in logistics infrastructure across Egypt. Its investments include the expansion and modernisation of Sokhna Port, the development of Sokhna Logistics Park and a new cold chain facility currently under construction. Together with the company's freight forwarding, contract logistics and end-to-end supply chain services, these assets are intended to help businesses improve operational efficiency, lower costs, enhance export competitiveness and expand access to regional and global markets.
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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.
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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.
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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.
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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.
AFC reaches financial close on 119MW power plant, Burkina Faso's largest, to help close its electricity access gap (Image source: AFC)
A major power project in Burkina Faso is to proceed after securing a first US$60mn tranche of a US$300mn corporate loan facility from Africa Finance Corporation (AFC)
The funds will support the development of the 119MW thermal power plant by Aksa Enerji Üretim A.Ş., Türkiye’s largest publicly-listed power generation company.
The project is expected to make a huge dent in accss to electricity in Burkina Faso, a country of 24 million people where only one in five currently have access to power.
“Burkina Faso represents an important milestone in our long-term commitment to Africa,” said Cemil Kazanci, chairman of Aksa Enerji.
“Together with AFC, we are delivering critical energy infrastructure that will strengthen energy security, support economic development and improve the reliability of electricity supply for millions.”
The transaction marks AFC’s first investment in Burkina Faso, but builds on its US$150mn corporate loan facility to Aksa Enerji in 2025, which supported the company’s utility-scale gas-to-power projects in Senegal and Ghana.
This includes Senega’s new 255MW combined-cycle gas power plant designed to use domestic natural gas to deliver more reliable and lower-emission baseload power.
Collectively, these projects have established Aksa as a major partner in delivering large-scale energy infrastructure across Africa.
The Burkina Faso project is expected to transform the nation’s electricity system.
The West African state currently imports 60% of its power supply, leaving homes, businesses and industry vulnerable to supply disruptions and elevated energy costs, constraining industrialisation and economic growth.
Once operational in 2027, the power station will reduce dependence on imported electricity by more than 50% while significantly strengthening domestic generation capacity.
By delivering more reliable, lower-cost baseload power, the project is expected to improve energy security, attract private investment and create a stronger foundation for long-term economic growth, according to the AFC.
Expanding reliable electricity access is a central part of the Corporation’s mission in unlocking sustainable growth across the continent.
“Africa’s path to industrialisation and global competitiveness by 2050 depends on the infrastructure decisions we make today,” said Samaila Zubairu, AFC’s president and CEO.
“Reliable electricity is fundamental to economic transformation. Without dependable power, countries cannot industrialise, businesses cannot grow and communities cannot realise their full economic potential. Aksa shares our commitment to delivering the reliable energy infrastructure needed to power Africa’s industrial growth and long-term transformation.”
Read more:
Nesa Power gets cash boost for C&I power growth
A new figurehead has been appointed to drive forward the development of the proposed US$15bn Abidjan-Lagos highway megaproject
The board of directors of the Abidjan-Lagos Corridor Management Authority (ALCoMA) recently appointed Beninois finance expert Wilfried Lauriano do Rego as board chairman for a two-year term, at its inaugural meeting in Nigeria.
The 1,081 km Abidjan-Lagos Corridor represents one of Africa’s most ambitious infrastructure projects.
It entails the construction of a six-lane supranational highway linking the capitals and major economic centres of Côte d’Ivoire, Ghana, Togo, Benin and Nigeria, while integrating trade and transport facilitation, value chain development and logistics components.
Do Rego’s appointment is in accordance with an intergovernmental agreement, which provides for alphabetical rotation among member states starting with Benin.
Jacques Ayadji, also from Benin, automatically assumes the role of vice-chairperson.
The ALCoMA meeting also outlined actions needed to drive forward the corridor’s medium- and long-term transformation.
The project is expected to become a major driver of economic and industrial development in West Africa by 2030.
The ECOWAS Commission, the African Development Bank Group, ECOWAS Bank for Investment and Development (EBID), the West African Development Bank (BOAD) are currently working together with other partners to mobilise financing.
Various interim subcommittees were also formed during the recent Lagos meetings, including a finance committe, to support ALCoMA in mobilising funding for the highway.
The ALCoMA board also called on other development partners, including the European Union and the World Bank, to support the construction of the road scheme and ALCoMA’s operations.
It also welcomed the AfDB’s ongoing discussions to mobilise catalytic capital of US$500mn and other resources from across the region.
“These resources will be complemented by other bank group financial instruments, including viability gap financing; partial risk and credit guarantees for local-currency bonds; non-sovereign operations, and climate finance through the Global Center on Adaptation partnership (GCA),” an AfDB statement read.
GCA brings together governments, banks and private sector to accelerate climate adaptation projects and mobilise financing.
The AfDB has already provided US$25mn in technical assistance for the project’s preparatory phase.
With feasibility studies completed, theproject now enters its investment phase, paving the way for the construction of a six-lane transnational motorway.
Read more:
Develon launches new excavator for emerging markets
Barloworld Equipment delivers Southern Africa's first Cat 707 WBT trucks. (Image source: Barloworld)
Barloworld Equipment delivers Southern Africa’s first Cat 707 WBT trucks to Northern Cape mining customer
Barloworld Equipment has successfully handed over two Cat 707 WBT (World Build Truck) units to a mining customer in South Africa's Northern Cape, marking the first sale and delivery of the Cat 707 WBT trucks in Southern Africa.
The milestone represents a significant step in expanding the availability of Caterpillar's latest off-highway truck technology across the region, while supporting mining customers with modern, high-performance fleet solutions.
The delivery forms part of a customer-focused fleet replacement strategy designed to align with PDMI Level 9 readiness requirements, ensuring the customer is equipped with machinery that meets evolving operational and safety standards.
Built on the proven Cat 707 platform, the Cat 707 WBT is designed to deliver dependable performance, high productivity and reliability in demanding mining environments. The trucks also feature VisionLink connectivity, enabling enhanced fleet visibility, real-time equipment monitoring and data-driven insights to help optimise operational efficiency and fleet performance.
The successful handover further reinforces Barloworld Equipment's long-standing partnership with the mining sector by providing solutions that support safer operations, improved productivity and future-ready fleet management.
Commenting on the achievement, the company said, "This milestone reflects our commitment to delivering innovative solutions that support our customers’ operational goals while helping them prepare for the future of mining. Congratulations to the Bloemfontein Region teams on making this landmark delivery a success. Here’s to powering productivity, advancing safety, and helping our customers build a better world."
The delivery marks an important milestone for both the customer and Barloworld Equipment, as the Cat 707 WBT enters the Southern African mining market for the first time, paving the way for wider adoption of the platform across the region.
China Road and Bridge Corporation (CRBC) has signed an agreement worth around US$1.2bn for the expansion of Kenya’s Jomo Kenyatta International Airport
The project update was shared by the country’s Transport Minister Davis Chirchir, posting to his X social media account, and later reported by Reuters.
“The project scope includes the construction of a new terminal building and associated support facilities, the modernisation and upgrading of existing infrastructure, the improvement of airside and landside operations," Chirchir said in his update.
The expansion of Kenya’s main gateway airport in Nairobi forms part of national efforts to revitalise infrastructure and open the door to more arrivals.
The project aims to almost triple annual passenger capacity at the airport from around 7.5 million people to 22 million people.
Progress was hit thwarted, however, after the cancellation of a previous agreement with India’s Adani Group following the indictment of its founder in the United States.
Last week, Chirchir also noted that the Kenyan government had appointed Africa's Trade and Development Bank and the Africa Finance Corporation to arrange financing for the project.
As East Africa’s largest economy, Kenya is keen to expand its transport infrastructure, including ports, roads and rail lines, to reassert its position in the region, and to boost logistics and supply chain efficiencies.
In air transport, Kenya hopes to maintain its role as a regional aviation hub in the face of growing competition from countries such as Ethiopia and Rwanda, which are also investing in new airport construction.
While CRBC has yet to formally confirm the award, the company holds strong links in Kenya already.
In February 2026, Kenyan President William Ruto visited the construction site of the Talanta Sports City Project in Nairobi, which is being undertaken by the company.
Talanta Sports City is a 60,000-seat professional football stadium fully compliant with FIFA standards and will serve as the core venue for the 2027 Africa Cup of Nations co-hosted by Kenya, Uganda and Tanzania.
Read more:
Uganda's new international airport
Africa’s first privately-financed sustainable aviation fuel (SAF) plant has secured funding from the Emerging Africa & Asia Infrastructure Fund (EAAIF) and various Middle Eastern investors
The deal expands EAAIF’s footprint into the Middle East North Africa (MENA) region, following its ongoing expansion into Asia.
The US$212mn clean fuels project, located in Egypt’s Sokhna Special Economic Zone, will be owned and operated by Green Sky Capital Limited together with its local subsidiary, SAF Fly Egypt.
EAAIF, a Private Infrastructure Development Group (PIDG) company managed by Ninety One, supported a senior secured loan of US$40mn for the development of the plant.
The transaction marks the first project-financed SAF plant in the MENA region.
The facility is designed to produce 200,000 tonnes per annum of biofuels, including SAF, Hydrotreated Vegetable Oil (HVO), bio-propane and bio-naphtha and will utilise commercially proven Hydroprocessed Esters and Fatty Acids (HEFA) technology to convert waste-based feedstock into high-grade sustainable fuel.
To ensure long-term bankability, the transaction will be anchored by Shell who will purchase the facility’s products on a take-or-pay basis and act as its primary feedstock provider.
Martijn Proos, co-head of emerging market alternative credit, Ninety One, the fund manager of EAAIF, said the transaction arrives at a critical juncture for the global energy market.
“Amid heightened geopolitical volatility and energy market uncertainty, this first-of-its-kind facility provides a practical solution to advancing both decarbonisation and energy security,”he said.
“By acting as the global mandated leadarranger, Ninety One and EAAIF are demonstrating how institutional capital can be mobilised to support the decarbonisation of hard-to-abate sectors like aviation, which is projected to account for 5% of global emissions by 2050 without intervention.”
The project is being developed with the support of regional sponsors, including Al Mana Holding, a Qatari diversified conglomerate, and Vision Invest, a Saudi Arabian infrastructure investor and developer.
Ninety One acted as the global mandated lead arranger and coordinating lender, facilitating the mobilisation of a total debt package of US$142.9mn with a US$40 million commitment from EAAIF and Ninety One’s Emerging Markets Transition Debt (EMTD) Fund.
Ninety One has also mobilised the participation of Qatar National Bank (QNB) via its Egyptian subsidiary, QNB S.A.E, with a commitment of up to US$31.4mn.
The debt financing was completed by The Arab Energy Fund, which acted as co-MLA and global structuring lender committed US$71.4mn to the project.
SAF is estimated to offer up to an 80% reduction in CO₂ emissions, compared to conventional jet fuel, supporting the aviation industry’s target of reaching net-zero by 2050.
The project's strategic location near the Suez Canal offers a direct export route to key demand centres in the EU and UK, which are currently implementing strict SAF mandates.
The transaction also demonstrates strong appetite among regional and international lenders for renewable fuels infrastructure, supporting both energy security and price stability amid heightened global volatility.
“Emerging markets have been transitioning toward renewables and cleaner energy sources for some time, driven by rising energy costs and the need to strengthen energy security,” said Alper Kilic, head of alternative credit, Ninety One.
“This investment highlights the critical role long-term capital plays in scaling next-generation energy infrastructure in emerging markets.”
He added that sustainable aviation fuel is “one of the most compelling – and challenging – decarbonisation pathways” requiring proven technology and strong commercial structures to deliver at scale.
“This project demonstrates how institutional investors can pursue attractive risk-adjusted returns while supporting the real-economy transition, and underscores the growing opportunity for transition debt strategies to finance high-impact assets in hard-to-abate sectors.”
Read more:
Supply chain boost for African businesses
AFC green bond to boost Ivorian solar sector
Vantage Capital, Greenpoint funding to boost SolarAfrica
Jendamark Automation’s catalytic converter shrinker machine integrates a 12- segment precision shrinking system, where SEW-EURODRIVE servo gear units and motion control software ensure each can is accurately reduced to predetermined dimensions based on mat weight and component tolerances. (Image source: SEW-EURODRIVE)
Innovative technology for ‘shrinking’ catalytic converters - designed and built in South Africa by Jendamark Automation for the global market - relies on the precision of SEW-EURODRIVE’s highly dynamic servo-geared units and software
Based in Gqeberha in the Eastern Cape, Jendamark Automation is a specialist in advanced automated assembly systems for powertrains, catalytic converters, hydrogen technologies and other automotive components. Yanesh Naidoo, executive innovations director at Jendamark Automation, says that 95% of the locally produced machines are exported and are in operation in Europe, India and the USA.
"The shrinking machine - or ‘shrinker’ - is a core component within our catalytic converter assembly cell," commented Naidoo.
“This cell is a highly automated production environment in which multiple machines, robots and laser measurement systems operate in coordination.”
The process begins with the core of a catalytic converter - a ceramic ‘brick’ or monolith, coated with precious metals such as platinum and palladium, that converts exhaust gases into less harmful emissions. This brick is wrapped in a thick spring-like insulation mat and inserted into an outer casing (or can) of stainless-steel. In this process, there are many variable factors to consider, he explains.
“Because the ceramic monolith is extruded and baked, its diameter can vary slightly - by two or three millimetres in a passenger vehicle converter and up to ten millimetres in a truck converter,” he said.
“This makes the size of every monolith slightly different.”
To secure the monolith inside the casing with the right spring load, the casing itself has to be adapted. This is the key function of the shrinking machine - to reshape the stainless steel casing to the exact diameter required for each brick and mat combination. Shrinking stainless steel to tolerances of 50 microns requires enormous force and control which the shrinker achieves by closing a set of heavy tapered segments around the can.
“For a passenger vehicle converter we use twelve segments, while for a commercial vehicle converter - which is larger - we use sixteen,” stated Naidoo. “We pull a massive steel ring back over those segments and as the ring moves the segments close in, collapsing the can evenly around the monolith.”
Driving that motion are two powerful SEW-EURODRIVE servo motor systems, each connected to precision roller screws that pull the ring from both sides. Synchronizing those drives is critical.
“If one side is pulled just a few millimetres more than the other, this will damage these very expensive roller screws,” he explains. “This is where SEW-EURODRIVE’s technology comes into its own; the drives and controllers keep the two motors synchronised to within very fine tolerances, even at the high speeds we need to hit our 30 second cycle times.”
The speed at which Jendamark Automation’s shrinker operates is one of its critical advantages, Naidoo emphasises, and this has been achieved through its innovative tool changer. He explains flexibility is particularly important in converter production for commercial-vehicles as variants change every few hours. Traditionally, each change required a lengthy manual tool change which would mean two to three hours of downtime.
“This is why we developed an automatic tool change system for the shrinker,” he says. “We have got two cartridges outside the machine, one of which is preloaded with the next set of 16 segments. When the operator hits ‘tool change’ the machine ejects the old set, inserts the new one and locks everything down - all automatically in about 45 seconds.”
That innovation, also powered by SEW-EURODRIVE servo drives, has transformed productivity.
“We have reduced tool changing times significantly, giving our customers more production time per shift, allowing them to produce around 80 additional parts,” he says. “With two or three tool changes a day, the gains are massive.”
The entire catalytic converter assembly cell can contain up to 30 SEW-EURODRIVE servo drives, powering and synchronising multiple machines – from laser measuring systems to robotic handlers. Behind the scenes, Jendamark’s proprietary Variant Manager software orchestrates these movements.
“Every part coming down the line is slightly different, so every 30 seconds a new set of parameters - such as diameters, spring loads and positions - is sent to the drives,” Naidoo continued. “There are no fixed positions so it is completely dynamic, adapting in real time.”
Parallel to this performance, he adds, is an equivalent focus on reliability as customers require minimal downtime to ensure that their processes and products remain viable. He notes that a USA customer, Cummins (through its acquisition of Faurecia’s USA factory), has been running Jendamark’s shrinker for almost six years - during which time it has produced over three million catalytic converters.
“Apart from greasing the screws, there has been no major maintenance and no drive failures at all,” he stated. “That is a testament to the robustness of our overall design and of the reliability of SEW-EURODRIVE equipment.”
The customer was so impressed that it decided to standardise globally on Jendamark’s machines.
“They had two other suppliers’ machines next to ours on the same line,” commented Naidoo. “Now they’re replacing those with Jendamark machines, because of reliability and consistency of quality.”
Phillip Steyn, Branch Manager at SEW-EURODRIVE in Gqeberha, says the project exemplifies how advanced motion control systems enable complex automation.
“Our MOVIAXIS multi-axis servo system, combined with our efficient servo motors and dynamic gearboxes, provides the accurate positioning and torque that this machine needs,” remarked Steyn. “The challenge was to deliver very high torque while maintaining precise synchronisation and feedback at rapid speeds.”
He notes that it is easier to be accurate when machinery is moving slowly but it becomes much more challenging in the context of high speed machines like this one. SEW-EURODRIVE’s control architecture ensures that every motion - from the synchronised pulling of the ring to the positioning of the auto-tool change mechanism - is tracked and verified before the next cycle begins.
“There is a great deal of feedback between the drive and the upper level controller,” Steyn explained. “The system scans the input data - the product types and can sizes - and adjusts torque and position in real time. It is the brain and the muscle working together.”
Naidoo highlights the value of SEW-EURODRIVE’ integrated unit - the motor, gearbox and drive - which is already matched for torque and speed.
