Manufacturing

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

Caracol, a global leader in robotic large-format additive manufacturing, and RusselSmith, an ISO-certified provider of innovative asset integrity and advanced manufacturing solutions for critical industries in Africa, have announced a Strategic Partnership to deploy, develop, and commercialise Caracol’s Vipra AM platforms – its robotic Wire Arc Additive Manufacturing (WAAM) technology – in West Africa

This collaboration aims to establish a world-class advanced manufacturing hub in the region, supporting the growth of local industrial capabilities and enabling the adoption of innovative and sustainable production solutions.

Under the exclusive partnership, Caracol and RusselSmith will:

• Deploy Caracol’s robotic large-format Vipra AM technology across key West African markets.

• Develop local expertise and capacity in advanced manufacturing.

• Support commercialisation opportunities across diverse industrial sectors.

• Advance regional industrialisation by providing innovative, scalable, and sustainable manufacturing solutions.

By combining Caracol’s global leadership in robotic WAAM technology with RusselSmith’s regional presence and industry expertise, the partnership aims to accelerate the transformation of West Africa’s manufacturing landscape, enhancing its role as a hub for innovation, efficiency, and industrial growth.

Riccardo Nicastro, global chief commercial officer and managing director of Middle East and Africa for Caracol, said, "The partnership between RusselSmith and Caracol is a testament of commitment towards Africa and its technology and manufacturing independence, agnostically from industries, together we are pursuing the creation of value for the whole Continent."

This initiative marks the start of a long-term collaboration that will bring two Caracol Vipra AM advanced technology platforms to the region, while also fostering talent development, promoting sustainability, and creating new economic opportunities.

Kayode Adeleke, CEO of RusselSmith, stated, "Our exclusive partnership with Caracol represents another bold stride in shaping the future of advanced manufacturing in West Africa. By introducing robotic WAAM technology through Caracol’s Vipra AM platform, we are unlocking new possibilities for industrialisation across the region. This collaboration allows us to build local expertise, accelerate the development of scalable manufacturing solutions, and create opportunities that strengthen Africa’s ability to compete globally. Together with Caracol, we are laying the foundation for a world-class hub that drives innovation, nurtures talent, and delivers sustainable growth for the industries we serve."

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

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Brady Corporation in Africa

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

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.”

SEW-EURODRIVE’s X.e-series industrial gear units deliver high performance and reliability for heavy-duty applications across Africa’s mining and industrial sectors. (Image source: SEW-EURODRIVE)

Operating successfully in Africa demands far more than the delivery of products or technology - it requires a deep understanding of local conditions, proactive skills development and sustained collaboration across borders

While industry sectors such as mining, food and beverage, water treatment and manufacturing share some common operational requirements, each African country presents its own distinct set of challenges shaped by infrastructure limitations, environmental conditions and regulatory variations.

As a leading provider of drive and automation solutions across the continent, SEW-EURODRIVE recognises that local insight and on-the-ground capability are critical to delivering effective sustainable results. The company continues to invest in people development and technical training within its network of African subsidiaries and partners, supporting the long term growth of its customers and the broader industrial ecosystem.

A recent regional workshop hosted at SEW-EURODRIVE’s Johannesburg facility brought together team members from several African countries for intensive product training and inter-regional knowledge exchange. The focus extended across the company’s full suite of advanced technologies, including its modular X.e-series industrial gear units, energy efficient IE3 electric motors, decentralised MOVIGEAR® mechatronic drives and the sophisticated MOVI-C® automation platform.

“Workshops like this are invaluable because they not only upskill our people but also help us connect the dots between what we do in different regions,” remarked Teboho Moloi, business development executive: Africa at SEW-EURODRIVE South Africa. “Our teams face very different realities depending on where they are operating, from remote mining operations in Zambia and the DRC to agro-processing plants in Kenya and Ghana. By sharing technical experiences across these sectors, we enhance our ability to apply the right solution for each unique application.”

Moloi highlights the value of knowledge-sharing in building a robust reference base across industries. “In the sugar sector, for instance, we’ve successfully deployed helical and bevel geared motors on conveyors and mill drives, while in water treatment our compact and corrosion-resistant solutions help ensure uptime in aggressive environments. These learnings are not only relevant to similar applications elsewhere in Africa, but they also allow us to anticipate challenges and fast track
problem solving.”

By equipping its people with the latest product expertise and encouraging collaboration across borders, SEW-EURODRIVE is strengthening its ability to serve Africa’s evolving industrial and mining landscape. The company’s commitment to developing regional capability ensures it remains responsive, reliable and aligned with its customers’ strategic needs.

“Ultimately, our investment in people and technology is what sets us apart,” concluded Moloi. “It is how we grow with our customers - and grow Africa’s industries at the same time.”