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Rethinking South Africa's wastewater potential (Image source: Adobe Stock)

Wastewater is still too often viewed as the end of a process, something to treat and discharge once it leaves a home, business, mine, or industrial site

In a water-scarce country, that linear view overlooks its value and the consequences of returning it to a connected water system.

South Africa’s rivers and water-transfer systems carry water across municipal, provincial, and national boundaries. Water may be abstracted, used, treated, returned, altered, and abstracted again downstream. The performance of wastewater infrastructure therefore affects far more than the site or municipality operating it.

“Some by-products of wastewater treatment can be used to generate energy that is fed back into the treatment infrastructure, reducing its demand on the grid,” says Kosikee Emma-Iwuoha, associate and water civil engineer at WSP in Africa. “Treated effluent can also be reused for irrigation or, with further treatment, in industrial processes.”

Wastewater is already part of the water system

Discharged water does not disappear from the resource system. Lee Boyd, technical director and water resource scientist at WSP in Africa, says return flows already form part of the water available to downstream users in South Africa’s connected catchments.

“South Africa’s water is reused extensively. Return flows can be abstracted again downstream, where their quality affects domestic users, agriculture, industry, and aquatic ecosystems. Water quantity and quality are connected and should not be managed separately,” says Boyd.

Return flows are incorporated into reconciliation planning in all catchments. However, Boyd cautions that return flows do not always meet the required quality after treatment, and sewer failures can prevent it from reaching treatment works.

Emma-Iwuoha’s earlier career experience includes extending a treated-effluent pipeline to potential users in the Western Cape where he saw firsthand that effective reuse ultimately hinges on reliable collection, treatment, monitoring, and clear end‑use planning.

A disposal mindset sends risk downstream

When the objective is simply to move wastewater through the system and dispose of it, less attention may be paid to the condition of the material entering the receiving environment.

Emma-Iwuoha says poorly managed discharge can overload natural systems, contribute to eutrophication, affect downstream water quality, and create environmental and health risks. The linear model also loses economic value that could support monitoring, maintenance, and further treatment.

The bulk network is central to this problem. Treatment capacity has limited value if sewers leak, surcharge, or release wastewater before it reaches the plant. Upgrades therefore need to cover collection, conveyance, treatment, monitoring, and discharge as one system.

Boyd says investment must also be matched by operational capability: “A treatment works can be upgraded, but the wider question is who will run it, whether there are enough people, and whether they have the skills and support to monitor performance.”

Design should begin with the catchment

Catchment assessments and water quality management plans help define what wastewater infrastructure needs to achieve before the physical solution is selected.

A catchment assessment identifies the downstream communities, industries, ecological systems, risks, and reuse opportunities that may be affected. It helps establish the required capacity and which receiving environments need protection.

“A suitably detailed catchment assessment gives us a better understanding of the risks, needs, and opportunities. The water quality management plan provides the benchmarks for choosing treatment processes, monitoring performance, and responding under normal and emergency conditions,” says Emma-Iwuoha.

Boyd adds that site-level wastewater and surface-water decisions should reflect the condition and objectives of the broader catchment. That depends on reliable evidence, yet monitoring information is often fragmented across government departments, municipalities, mines, industries, laboratories, and other water users.

Consolidating and verifying that information would improve treatment planning and allow problems to be identified sooner. A report received months after a pollution incident may explain what occurred, but it cannot reduce the impact while contaminated water is still moving downstream.

Resilience depends on people as well as assets

Wastewater systems need to be designed for expected growth rather than present demand alone. Government plans, municipal budgets, industrial expansion, urbanisation, and long-term operating requirements influence how much capacity is needed and how soon another upgrade may be required.

Emma-Iwuoha says coordination between government and industry can help prevent infrastructure from reaching capacity shortly after commissioning. Community involvement is equally important because acceptance cannot be assumed simply because a solution is technically sound.

Residents may have concerns about location, odour control, downstream river use, and the implications for health and livelihoods. Engagement needs to address these concerns while explaining the sanitation, environmental, and economic benefits.

Shared data requires similar trust. Boyd says a credible platform that verifies and protects monitoring information where necessary could strengthen catchment-wide planning without duplicating work.

Innovation has to reinforce the fundamentals

Waste-to-energy is one of the most promising opportunities identified by Emma-Iwuoha.

As treatment processes improve, organic material from wastewater can contribute to energy generation and, in suitable applications, create synergies with solid-waste management. It can reduce the energy burden of treatment where the scale, feedstock, economics, and operational capacity support it.

WSP has built capabilities in solid waste management and is expanding its capacity in wastewater treatment and process engineering, supported by expertise in water science, environmental assessment, and civil engineering.

Bringing these disciplines together allows teams to define what needs protection, set the required water quality targets, and translate those requirements into infrastructure that can be funded, built, operated, and adapted over time.

South Africa will not unlock the resilience value of wastewater through technology alone. Functioning bulk networks, skilled operators, verified data, appropriate treatment, credible governance and community support must be considered together.

Planned as a single system, wastewater can support the country’s water security rather than remaining an obligation at the end of a pipe.

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Beyond expanding battery production, the gigafactory is expected to generate significant economic benefits for Morocco.

The African Development Bank (AfDB) Group has approved a €100mn (approx. US$117mn) loan to Gotion Power Morocco to support the construction of an integrated lithium iron phosphate (LFP) battery gigafactory in the Rabat-Salé-Kénitra Free Trade Zone, marking a significant step in the development of Africa's electric vehicle manufacturing ecosystem

In addition to its direct financing, the Bank intends to mobilise up to a further €141mn (approx. US$165mn) from financial partners under the New African Financial Architecture for Development (NAFAD), where it will serve as the Mandated Lead Arranger. The blended financing package is designed to accelerate delivery of one of the continent's largest battery manufacturing investments.

Building Africa's battery manufacturing capacity

The project is being developed by Gotion High-Tech Co. Ltd., a leading global battery producer headquartered in Hefei, China, and listed on the Shenzhen Stock Exchange. Once operational, the facility will become the first fully integrated cathode-to-cell LFP battery manufacturing plant in both Africa and the Middle East and North Africa (MENA) region.

Phase one of the project will deliver an annual production capacity of 10 gigawatt-hours (GWh) of battery cells and battery packs for electric vehicles, with long-term plans to increase output to 100 GWh. The investment is expected to reinforce Morocco's position as an emerging global centre for electric mobility manufacturing and green technology supply chains.

The project also reflects growing investment in battery production as demand for electric vehicles and renewable energy storage continues to expand worldwide. By establishing large-scale local manufacturing capacity, Morocco aims to strengthen regional supply chains while supporting the transition towards cleaner transport and energy systems.

Kevin Kariuki, the Bank group's vice-president for Power, Energy, Climate and Green Growth, said, "Battery storage is the missing link in Africa's clean energy transition. A facility of this scale, powered primarily by renewable energy, strengthens the foundations for the large-scale integration of solar and wind power, which our grids increasingly depend on. This is exactly the kind of project that will deliver reliable, low-carbon energy while creating green industrial jobs and building the resilient value chains Africa needs to sustain its energy transition."

Supporting industrial growth and local value creation

Beyond expanding battery production, the gigafactory is expected to generate significant economic benefits for Morocco. During its initial phase, the development is projected to create more than 600 direct jobs while achieving a 70% local industrial integration rate, supporting skills development and strengthening domestic manufacturing capabilities.

The project is also intended to encourage the growth of local supplier networks and increase value addition within Africa's critical minerals sector, helping retain more economic value from resources that are essential to global energy transition technologies.

Achraf Tarsim, the African Development Bank group's country manager for Morocco, commented, "This gigafactory will be a major catalyst for strengthening Morocco’s industrial competitiveness and for accelerating its emergence as Africa’s manufacturing hub for sustainable mobility industries. It will help foster an African industrial ecosystem for batteries and electric vehicles while promoting the local beneficiation of critical minerals essential to the energy transition."

Advancing Africa's clean energy ambitions

The investment supports the African Development Bank Group's Four Cardinal Points strategic vision by promoting resilient infrastructure, accelerating industrialisation, increasing value addition to Africa's natural resources and strengthening regional integration.

As demand for battery storage continues to rise alongside renewable energy deployment and electric vehicle adoption, projects of this scale are expected to play an increasingly important role in positioning Africa within global clean energy and electric mobility value chains. By expanding domestic battery manufacturing and energy storage capabilities, the initiative is set to support the continent's transition towards a lower-carbon economy while enabling wider deployment of renewable energy technologies.

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Arridex Launches West Africa’s first additive manufacturing hub. (Image source: Adobe Stock)

Arridex has officially commissioned its Omnifactory in Lagos, marking the launch of West Africa’s first multi-technology industrial additive manufacturing facility

The commissioning ceremony was led by Babajide Sanwo-Olu, governor of Lagos state, and brought together senior government representatives, industry stakeholders, members of the diplomatic community and investment delegates participating in the Invest Lagos 3.0 forum.

The Invest Lagos delegation featured participants from the forum’s panel discussion on The Future of Technology and Innovation, where Kayode Adeleke, group CEO of Arridex, highlighted the importance of technology and innovation in advancing Africa’s industrialisation. His insights were shaped by Arridex’s operational experience across sectors including oil and gas, maritime, aerospace, defence, construction and manufacturing.

The Arridex Omnifactory brings together several additive manufacturing technologies within one facility, including Laser Powder Bed Fusion (L-PBF), Cold Spray, Fused Filament Fabrication (FFF) and Selective Laser Sintering (SLS). The facility enables the production of industrial components, spare parts and enhanced part designs for critical industries, while its large-format manufacturing capabilities support the creation of full-scale marine components and other large industrial structures.

The commissioning of the Omnifactory represents the transformation of two decades of accumulated expertise into a dedicated industrial manufacturing platform. Arridex commenced operations in 2005 as an asset integrity company serving Nigeria’s oil and gas industry before expanding its capabilities into maritime, defence, construction, technology and aerospace sectors. The company has achieved zero lost-time incidents across more than seven million operational man hours.

The next chapter of global manufacturing can be written from Lagos

For Nigeria and West Africa, the Arridex Omnifactory addresses long-standing challenges associated with dependence on imported industrial components. Companies operating ageing infrastructure have often faced extended procurement timelines, complex international supply chains and the growing challenge of sourcing legacy parts from manufacturers that may no longer exist. Through the Omnifactory, Arridex will enable these components to be manufactured on demand within Lagos.

Arridex has received Pioneer Status in additive manufacturing from the Nigerian Investment Promotion Commission (NIPC). The company is also the first organisation qualified by the Nigerian Upstream Petroleum Regulatory Commission (NUPRC) for additive manufacturing deployment in the oil and gas sector. In addition, its joint venture partnership with the Defence Industries Corporation of Nigeria (DICON) supports the local production of military-grade additive manufactured components.

Further strengthening its position in the global additive manufacturing ecosystem, Arridex is the first African member of the Additive Manufacturer Green Trade Association (AMGTA). The company is also a Designated Strategic Partner of the Commonwealth Enterprise and Investment Council (CWEIC), with Kayode Adeleke serving on the CWEIC Global Advisory Council.

"Today, I opened West Africa's first multi-technology industrial additive manufacturing facility in Lagos. By producing industrial components and spare parts here in Lagos, Arridex is helping to reduce our dependence on imports, strengthening critical industries and supporting economic growth," commented Sanwo-Olu.

"I commend the Arridex team for their vision and commitment to building solutions that serve not only Nigeria but the wider African continent. Lagos will continue to support investments that create opportunities, grow local capacity and position our state as a hub for innovation and industry."

“We did not set out to build the biggest company, but a resilient one. For over two decades, we have chosen the harder path, and that is to make in Africa what others import, to meet global standards without exception, and to put purpose before profit. The Arridex Omnifactory is where that conviction becomes infrastructure. The name on the door is new, but the work behind it is not. We are not stopping here. By the first quarter of 2027, we will commission the Arridex Mega Omnifactory, which will stand among the largest single-site industrial additive manufacturing facilities in the world. The next chapter of global manufacturing can be written from Lagos. We are building it.” concluded Adeleke.

EBOR strengthens South Africa’s automotive manufacturing. (Image source: Adobe Stock)

The Nelson Mandela Bay Business Chamber has welcomed the official opening of EBOR’s new manufacturing facility in Kariega, describing the development as a significant boost for the region’s industrial landscape and its position as the Bay of Opportunity and a leading manufacturing hub in South Africa

The investment by EBOR, an established automotive component manufacturer specialising in plastic moulded parts and assemblies, demonstrates continued confidence in Nelson Mandela Bay’s manufacturing capabilities and future growth potential. The new advanced facility expands local production capacity, strengthens the automotive supply chain, and contributes to the preservation and creation of sustainable employment opportunities within a key economic sector.

Covering 8,000 sq m, the Kariega facility represents a 60% increase in scale compared with EBOR’s previous operations. The expansion is supported by an estimated R100 million (approx. US$6.1mn) investment in infrastructure, along with a further R45 million (approx. US$2.7mn) allocated towards relocation, upgrades, and advanced equipment. With around 140 employees, EBOR continues to contribute to employment and the development of the region’s manufacturing ecosystem.

Manufacturing remains a vital component of Nelson Mandela Bay’s economy, accounting for approximately 22% of GDP while supporting industrial activity and employment. Investments such as EBOR’s expansion extend beyond individual companies by encouraging supplier development, enabling skills transfer, and strengthening economic resilience across the wider region.

Commenting on the opening, Denise van Huyssteen, CEO of the Nelson Mandela Bay Business Chamber, said the facility highlights the metro’s continued attractiveness as an investment destination despite current economic challenges.

“EBOR’s expansion into a significantly larger and more advanced facility is a strong vote of confidence in the manufacturing strength of Nelson Mandela Bay. It reinforces our positioning as the Bay of Opportunity and speaks directly to the resilience and capability of our industrial base,” she said.

Van Huyssteen further emphasised the importance of ongoing automotive sector investment in supporting regional economic growth.

“Manufacturing remains the backbone of our metro’s economy. When companies like EBOR invest, they strengthen the entire value chain, support local suppliers, safeguard jobs, and enhance South Africa’s competitiveness in the global automotive industry,” she said.

She added that EBOR’s investment demonstrates the continued opportunities available within Nelson Mandela Bay’s industrial sector.

“At a time when economic uncertainty continues to weigh on business confidence, this investment stands as tangible proof that Nelson Mandela Bay remains a strategic manufacturing destination with deep industrial expertise, skilled talent, and established infrastructure. It is precisely this kind of commitment that drives economic renewal and builds long-term resilience in our metro,” Van Huyssteen concluded.

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.

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