In The Spotlight
Rolls-Royce powering Africa-Europe maritime bridge. (Image source: mtu Solutions, Rolls-Royce Power Systems)
Rolls-Royce’s Power Systems division is set to supply generators for new fast ferries that will create a rapid maritime bridge between Africa and Europe
The company is supplying a total of eight mtu emergency power generators for two fully-electric fast ferries belonging to the Spanish shipping company Baleària.
From 2027, the ships will cover the 18 nautical miles between Tarifa in Spain and Tangier in Morocco using electric power, thereby opening up the first ‘green corridor’ between Europe and Africa.
According to a Rolls-Royce statement, the project is considered a milestone for CO2-neutral mobility at sea and is supported by an international network of partners consisting of shipping companies, shipyards, port authorities, energy suppliers and other companies.
On behalf of the Spanish shipyard Astilleros Armon, four mtu 20V4000M35S emergency power generators will be supplied for each of the two ships.
The two identical catamarans are fully electric, reach a maximum speed of up to 26 knots, and can accommodate 804 passengers and 225 vehicles.
With an output of 2,840 kilowatts each, the generators will ensure the power supply in case of need – for example, if the ferries’ on-board batteries cannot be charged in port as planned.
Unlike conventional on-board power systems, however, their function goes beyond simply supplying the electrical systems: in an emergency, the mtu gensets can also secure the entire propulsion system of the ferries.
“The project is a prime example of how emission-free shipping and reliable system technology go hand in hand,” said Phil Kordic, senior expert, commercial marine business, at Rolls-Royce Power Systems.
“Our mtu engines make an important contribution to the operational safety and efficiency of these state-of-the-art ships – powerful, lightweight and perfectly tailored to maritime requirements.”
With their high-power density, low weight, and compact design, mtu engines are ideal for use in high-speed ferries.
“For us as a shipyard, the integration of powerful, compact systems is crucial, especially in innovative ship projects such as this one,” said Ricardo Garcia, head of marketing, sales and business development at Astilleros Armon.
“The mtu gensets from Rolls-Royce meet these requirements perfectly and help to provide additional backup for the ferries' electrical systems.”
Delivery is scheduled for the first half of 2026, with the ferries entering regular service in 2027.
Read more:
Rolls-Royce powers Sibanye-Stillwater mine
A renewed surge of hydropower from Inga II signals a defining clean-energy shift for the Kamoa-Kakula mine. (Image source: Ivanhoe Mines)
Ivanhoe Mines has confirmed that the Kamoa-Kakula Copper Complex is now receiving its first 50 MW of clean hydroelectric power from the newly refurbished Turbine #5 at the Inga II dam in the Democratic Republic of Congo (DRC)
The 178 MW unit, which has undergone a full mechanical and electrical overhaul, marks a major step forward in securing long-term renewable power for one of Africa’s largest copper operations.
Installation and commissioning of replacement equipment for Turbine #5 were completed between the third and fourth quarters of 2025. Following synchronisation and energisation in early Q4 2025, the turbine has ramped up to full output and is currently delivering approximately 180 MW of hydropower into the national grid.
Kamoa-Kakula is initially receiving 50 MW of this supply, bringing its total domestically sourced power to around 110 MW. Power deliveries from Inga II are expected to increase to 100 MW in the first quarter of 2026 and later rise to 150 MW once key grid upgrades are finalized.
Ongoing infrastructure improvements are focused on strengthening substations at Inga (SCI) and Kolwezi (SCK). The first component, a resistor bank upgrade at the Inga substation, was completed in May 2025. Matching upgrades at Kolwezi are expected shortly, improving voltage stability to the mine.
A new static compensator at Kolwezi is scheduled for completion in early Q1 2026, enabling power transmission to reach 100 MW. Additional upgrades to filter banks at both substations will be rolled out over the next 18 months, supporting an increase to 150 MW of delivered power during the first half of 2027. By the end of 2027, Kamoa-Kakula is projected to have access to roughly 210 MW of domestically sourced renewable energy.
Updated projections show the copper complex’s total power demand rising from 208 MW in December 2025 to 347 MW by December 2028. Supply will be met through a combination of SNEL grid power, third-party imports, on-site solar generation, and backup generators.
The refurbishment of Turbine #5 was carried out in partnership with the DRC power utility SNEL, engineering firms Gruner Stucky AG and VOITH, and Kamoa Copper’s project teams. Representatives from these organisations recently visited the turbine hall at Inga II to review commissioning progress and mark the return of the turbine to full operation.
Technical disclosures in this update have been reviewed and approved by Steve Amos, Ivanhoe Mines’ Executive Vice President, Projects, who is a Qualified Person under NI 43-101. Further technical information is available in the Kamoa-Kakula Integrated Development Plan 2023 Technical Report, accessible on Ivanhoe Mines’ website and through its SEDAR+ profile.
Prem Rodrigues, vice-president sales and marketing for India, the Middle East and Africa at Siemon. (Image source: The Siemon Company)
The Siemon Company, a global leader in high-performance connectivity solutions for data centres and smart buildings, has introduced Smart Building COMPLETE, a fully unified connectivity and cabling ecosystem designed to support the essential technologies driving today’s intelligent workplaces
Covering everything from Wi-Fi and security systems to AV, access control and sensors, Smart Building COMPLETE provides building owners and operators with a comprehensive, field-proven foundation to plan, construct and manage smarter, more efficient buildings and campus environments.
At the core of Smart Building COMPLETE is Siemon’s advanced PowerGUARD+ technology, delivering extended reach of up to 200 metres. This significantly lowers deployment costs and complexity by reducing or eliminating the need for traditional telecommunications rooms, associated equipment, power, cooling and routine maintenance. Engineered to control heat rise and maintain performance at temperatures up to 75°C, Siemon’s patented, independently verified cabling and connectivity offer the reliability required to deliver uninterrupted power and data to a wide range of connected devices.
Smart Building COMPLETE combines trusted technology with a new suite of intuitive planning and design tools that streamline specification and speed up deployment for customers, designers and consultants. The Cabling Reach Calculator assists users in selecting the right cable type based on real installation conditions and required distances, especially crucial for runs extending beyond 100 metres. The Wired for Wi-Fi tool highlights equipment manufacturer requirements and guides users in choosing the correct cabling solutions for each wireless access point. The Backbone Speed Calculator further supports planning by helping determine the fibre backbone needed for Wi-Fi deployments of any scale.
Sustainability remains a central priority for smart building operators, helping decrease energy consumption, cut operational expenses, reduce carbon emissions and enhance occupant comfort. Smart Building COMPLETE supports these goals through energy-optimising technologies and transparent reporting, assisting operators in meeting green building certification requirements. The solution emphasises transparency through Health and Environmental Product Declarations (HPDs and EPDs) and aligns with leading standards such as LEED, BREEAM, LBC and WELL, ensuring cost-effective, healthy and high-performing indoor environments.
“Modern commercial buildings and campuses must deliver more than just space. They are expected to create safe, efficient, and engaging environments that support the people inside them while maximising facility value for those who operate them. Smart Building COMPLETE, through its PowerGUARD+ technology, extensive application support and a commitment to sustainability, helps building owners and operators create dynamic, future-ready workplaces for a more sustainable tomorrow,” commented Prem Rodrigues, vice-president sales and marketing for India, the Middle East and Africa at Siemon.
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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.
Norwegian renewables group Scatec ASA has started commercial operations at the 273 MW Grootfontein solar power plant in South Africa
Separately, the Oslo-listed company announced that it has signed up EDF Power and Norfund as partners on its flagship 1.1GW solar and battery storage hybrid project, Obelisk in Egypt.
“Obelisk is Scatec’s largest project to start construction to date and combines solar and batteries to deliver stable and cost competitive renewable energy to support Egypt’s growing power demand and energy transition,” said Scatec CEO Terje Pilskog.
Following the transaction, Norfund will own 25% of the Obelisk holding company with Scatec owning the remaining 75%.
EDF power solutions will own 20% of the operating company (SPV), bringing Scatec’s and Norfund’s total economic interest to 60% and 20% respectively with Scatec retaining economic control of the power plant.
Scatec added that it is in “advanced discussions” with additional equity partners, aiming to reduce Scatec’s economic interest in the project further.
In South Africa, the smaller Grootfontein project will generate solid revenues via a 20-year power purchase agreement (PPA).
“Bringing the Grootfontein plant into operation is an important milestone for Scatec and our partners,” said Pilskog.
“As our first project in the Western Cape, and the first solar project to reach COD under REIPPPP Round 5, this achievement reflects the dedication and resilience of our teams and contractors.”
The power plant is expected to generate 700 GWh of clean energy annually, leading to an estimated abatement of 630,000 tonnes of CO2 emissions, making it the largest co-located solar PV cluster in the Western Cape.
Scatec owns 51% of the equity in the project, and partners with H1 Holdings, its local Black Economic Empowerment partner, and the Grootfontein Local Community Trust.
Scatec will also continue to provide Operation & Maintenance and Asset Management services to the power project.
Read more:
Scatec's Kenhardt project earns global recognition
Scatec venture signs Liberia, Sierra Leone solar deals
Scatec pioneers industrial EV adoption on-site in Northern Cape
West Wits Mining has officially commenced operations at the Qala Shallows Underground Mine, marking South Africa’s first new underground gold mine in 15 years
The development represents a major step forward for the company and strengthens the long-term trajectory of the Witwatersrand Basin Project.
A ceremony west of Johannesburg gathered senior government officials, industry leaders, diplomats, and community representatives. Among the attendees were the Minister of Mineral and Petroleum Resources, Gwede Mantashe (or senior departmental delegates), Australian High Commissioner Tegan Brink, Minerals Council South Africa CEO Mzila Mthenjane, as well as investors, partners, and local stakeholders.
During the event, West Wits CEO and Group Managing Director, Rudi Deysel, underscored the project’s significance as a resurgence of confidence in the Central Rand’s geological promise.
“For years, many believed the Central Rand had reached the end of its mining life, but Qala Shallows shows that with rigorous geological work, clear planning and disciplined execution – and strong cooperation between government and business – new underground gold mines can still be developed in this district,” Deysel said.
“The Witwatersrand built Johannesburg and shaped our economy, and it still holds substantial potential for the future.”
Deysel acknowledged the contributions of government partners, lenders, surrounding communities and industry collaborators, crediting them with the successful realisation of the project.
“Together we have brought a new mine to life in one of the world’s most historic gold districts, and today, Qala Shallows starts a fresh chapter for the Witwatersrand and for South African gold mining.”
Development status and production outlook
Since work began in July 2025, construction and underground development at Qala Shallows have progressed smoothly, with all key milestones met within schedule. The project delivered its first ore to surface in October 2025, and all essential underground systems required for the production phase have been completed. Surface ore stockpiles continue to grow and are expected to reach around 30,000 tonnes before the initial gold pour planned for March 2026.
Long-term role in West Wits’ growth plans
Bringing Qala Shallows online transforms West Wits from a developer into an operating gold producer, reinforcing the company’s commitment to South Africa and laying the groundwork for extended expansion within the Witwatersrand Basin Project. The broader project contains a Mineral Resource Estimate exceeding 5 million ounces³, with Qala Shallows acting as the first stage of a phased rollout. Additional development zones such as Bird Reef Central are expected to incrementally support future production targets.
These steps align with the company’s Project 200 vision, focused on achieving annual output of 200,000 ounces through sustainable, disciplined execution.
Upcoming activities
Over the coming months, West Wits will continue underground advancement and surface work at Qala Shallows as it prepares for the first gold pour in March 2026. In parallel, planning and development efforts for later phases of the Witwatersrand Basin Project will continue to move forward.
The African Airlines Association (AFRAA) has announced a major shift for the continent’s aviation sector with the full-scale rollout of Free Route Airspace (FRA) across the Western and Central Africa (WACAF) region as of 30 October 2025
This development follows the positive outcomes of FRA trials that began in November 2023, enabling airlines to design and operate more direct User Preferred Routes (UPRs). The shift to UPRs marks a significant improvement in operational efficiency, allowing pilots to choose optimal flight paths based on real-time conditions instead of adhering to fixed conventional routes. The result is reduced fuel use, faster journeys and lower emissions, enhancing both sustainability and airline performance.
The African Export-Import Bank (Afreximbank) has backed the FRA programme from the outset, supporting its progression within the framework of its Memorandum of Understanding with AFRAA, the International Civil Aviation Organisation’s Global Air Navigation Plan and the work of the Africa-India FRA Planning and Implementation Regional Group.
The full implementation is the outcome of collaboration between air operators and air navigation service providers, who agreed to conclude the trial period during a joint workshop in Dakar, Senegal.
“The implementation of Free Route Airspace in the WACAF region is a game-changer for African aviation,” said Abdérahmane Berthé, AFRAA secretary general.
“This is a testament to what we can achieve through collaboration. By cutting flight times and fuel consumption, we are not only boosting the competitiveness and profitability of our airlines but also making a significant commitment to environmental sustainability.”
Kanayo Awani, executive vice-president for Intra-African Trade and Export Development at Afreximbank, also highlighted the bank’s continued support: “Efficient, safe, and well-regulated air services are critical to facilitating intra-African trade, tourism and connectivity in line with the objectives of the Single African Air Transport Market (SAATM) and the African Continental Free Trade Area (AfCFTA). Afreximbank is fully committed to supporting the full implementation of SAATM and the establishment of an effective and efficient aviation industry through a range of financing instruments, including its aircraft leasing platform as well as trade facilitation interventions.”
The initiative has already demonstrated tangible benefits for the first airlines involved. Six major carriers, Ethiopian Airlines, Kenya Airways, EGYPTAIR, Royal Air Maroc, RwandAir, and ASKY Airlines, received approval to operate UPRs linking 30 important routes. These optimised trajectories are expected to save more than 1,393 flight hours each year, reduce fuel consumption by 5,000 metric tonnes, avoid 16,000 metric tonnes of CO₂ emissions and cut fuel costs by around US$15mn annually.
With the WACAF region now fully accessible for free routing, airlines can file User Preferred Routes from 30 October 2025. ANSPs have also agreed to process new UPR requests within 48 hours. Once administrative updates across the 24 WACAF states are completed, the approval requirement will be removed entirely from mid-2026.
Following the WACAF milestone, attention will now turn to implementing FRA across the Eastern and Southern Africa (ESAF) region in 2026. Plans also include the creation of a digital coordination platform to simplify the interaction between airlines and ANSPs across the continent.
AfDB and Algeria’s Knowledge Economy Ministry partner to scale African startups and SMEs, with fresh funds and policy support
The African Development Bank (AfDB) and Algeria’s Ministry of Knowledge Economy, Startups, and Micro-Enterprises have agreed to deepen cooperation to accelerate the growth of startups and small and medium-sized enterprises (SMEs) across Africa
The announcement came at the close of the fourth edition of the Intra-African Trade Fair (IATF 2025), hosted in Algiers from 4 to 10 September. Leading the Bank’s delegation, Ousmane Fall, Acting Director of the Industrial and Trade Development Department, highlighted the AfDB’s central role in unlocking finance for African businesses. “Supporting small and medium-sized enterprises and startups is one of the key pillars of our work, as defined in the Four Cardinal Points of the Bank group’s new president, Dr Sidi Ould Tah,” said Fall. He added, “The Bank will support SMEs through an innovative approach that combines new financing instruments, advisory services, and policy reforms to promote their emergence across the continent.”
Strengthening private sector engagement
Ahead of discussions with Minister Noureddine Ouadah, the Bank delegation met with Algeria Venture, the state-backed startup accelerator. Both sides agreed to enhance cooperation, particularly by linking Algerian startup funding mechanisms with leading private equity and venture capital funds. They also confirmed plans to jointly take part in the African Startup Conference, scheduled in Algiers from 6 to 9 December 2025, which aims to promote innovation, strengthen networks, and attract investment on a continental scale.
Closing IATF 2025, Minister Ouadah announced the launch of a new investment fund for African startups, an initiative championed by Algerian President Abdelmadjid Tebboune, underlining Algeria’s commitment to prioritising youth and innovation in shaping Africa’s economic future.
The AfDB’s Non-Sovereign Operations team also presented financing solutions for the private sector while pursuing new strategic collaborations. Engagements with firms such as Solewant Group, a Nigerian steel and coatings leader, illustrated the Bank’s interest in high-impact African companies.
Showcasing innovation and entrepreneurship
The AfDB further contributed to several IATF sessions, including one organised with UNDP’s Timbuktoo initiative and the African Union on “Building an Enabling Startup Ecosystem,” as well as a discussion hosted by Afreximbank’s African Research and Innovation Centre. These platforms enabled the Bank to highlight its Innovation and Entrepreneurship Lab and its flagship ENNOVA programme, which helps entrepreneurs expand their operations and access new opportunities.
The IATF Advisory Council, in which the Bank is an active participant, announced that Lagos, Nigeria, will host the fifth edition of the fair in 2027. Reaffirming its commitment, the AfDB stressed that trade, entrepreneurship, and innovation remain central to driving inclusive growth and industrial transformation across the continent.
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.”
