Alex White & Company was established in 1913 and joined Astrapak in 2006. The company operates through a powerful group of sales specialists assisted by a dedicated support team and offers complete customer service from design through to distribution of the finished product. Alex White is able to track and monitor usage, assist customers in planning their purchase requirements and monitor stock levels.

Markets served by Alex White

Alex White focuses on the supply of printed packaging to the following markets :

• Horticulture, coatings and agrochemicals
The company has in excess of 75% share of the local seed packet market and also sells directly to seed companies in East Africa, Mozambique, Zambia and Zimbabwe. Heat- sealed sachets are also supplied for the pesticide and fertiliser markets

• Food and FMCG
Alex White is one of very few local companies specialising in the manufacture of in-mould labels - these labels are delivered to various injection moulders who use them to decorate leading brand containers for margarine, ice cream, cheese and yogurt. Alex White is also a leading supplier of cut and stack paper labels designed for the food canning market.

• Beverages
Alex White caters for the ever demanding fresh beverage and prepared meal market. With short order times and minimal shelf life these products require quick turn around and just-in-time delivery of packaging. Alex White is also well equipped to litho print plastic to be used as neck labels, sleeves and clip- on cards.

• Pre- paid vouchers
Alex White’s technology has proven ideal for the needs of the cell- phone industry throughout Africa and the Indian Ocean islands. These vouchers or cards are printed on both sides and are decorated with a number of security and tamper evident features.

Group synergy

Alex White supplies in-mould labels to companies within the Astrapak Rigids Division and many of Marcom’s products for instance utilise these labels for some of the food industries top brands. It compliments and completes the product range that the Astrapak Group is able to offer its current customer base.

Top class premises

Alex White operates from a custom design factory situated in Lea Glen, Roodepoort, west of Johannesburg.

State-of-the-art technology

Alex White has pioneered the technology of litho printing onto synthetic substrates. Commonly known as UV printing, this is the key to its development of in-mould labels and pre-paid voucher products.

During 2005/06 Alex White installed the latest computer to plate technology as well as Swiss made counter pressure punches - this strategy of investment continues and in 2007 a locally made seed packet heatsealer and Swiss made automatic die cutter were commissioned.

The addition of a narrow web press enables Alex White to offer the market a choice of UV- litho, conventional litho and flexo printing options.
In 2007 Alex White had its long standing ISO quality accreditation re- confirmed!

Barrier Film Converters, established in Benoni in 2002 as a greenfields operation, supplies a range of highly specialised barrier co-extruded films, bags and pouches to the food, dairy, industrial, medical and allied industries. The company is situated in Durban and today forms part of Astrapak’s Films Division.

Markets served by Barrier Film Converters

Barrier Film Converters provides a wide range of high barrier films to its focused market segments, based on its state of the art 3 and 5 layer co-extrusion facilities. One of it’s primary objectives is to offer a local alternative to imported films, in particular into the dairy and medical industries.

The company’s major markets include:

• Food form-fill-seal thermoformable base and lidding films
• Dairy form-fill-seal sterilizable films
• Medical form-fill-seal thermoformable base films and retortable dip pouches
• Industrial explosive bags
• Vacuum bags for the meat market
• Fertilizer and chemical industries
• Industrial skin packaging

Group Synergy

The following synergies are enjoyed within the Astrapak Group:

• Barrier Film Converters and Thermopac - both companies service the meat industry with barrier type products and the products produced by the two companies compliment each other.

• Barrier Film Converters and Saflite – the company supplies a range of barrier type lamination film to be used in end user products such as sachets and stand-up pouches.

• Barrier Film Converters and Knilam Packaging - supplies a range of peelable lidding films that seal directly onto PET, PP and aluminium trays.

The company also enjoys the benefits of the Group’s purchasing power and remains a competitive supplier of highly complex and sophisticated films.

Production Technology

Barrier Film Converters offer the following technology:

• Extrusion
Mono-layer as well 3 and 5 layer co-extruded cast and blown films in medium and high barrier structures.

• Slitting
State of the art slitting facilities for films and sheeting from 25 to 300 micron.

• Pouch Making and Bagging
3 sided seal pouch as well as bottom seal bag-making facilities are also available.

Cinqpet , founded in 1997, specialises in the manufacture of PETd (Polyethyleneterephthalate) preforms, jars and bottles.This world-class operation is located in custom-designed premises in Denver, Johannesburg and forms part of Astrapak’s Rigids Division.

Markets served by Cinqpet

Supporting its outstanding competence in the PET market, Cinqpet offers both single-stage and two-step processes for PET conversion.

The innovation driven product range includes containers ranging from 60ml to two litre bottles and jars, high-volume water and beverage bottles, wide mouth jars for food, personal care applications and specialised cosmetic bottles.

Preforms ranging from 10g to 24g with 28mm PCO and 38mm sports and snap-on neck finishes are supplied both locally and into the African continent.

Group synergy

Contributing to the success of the Astrapak Group is the co-operation that is evident between the various operations. Cinqpet produces a range of preforms which it is able to supply sister companies within the Group. The company also benefits from the Groups purchasing power, particularly with respect to raw materials, thereby making it a truly competitive supplier of containers.

State-of-the-art technology

The company has made continual investments in upgrading plant &
equipment – including a purpose-built factory for the operation, new
injection and stretch blow moulding equipment and wrap around labelling machines.

The plant also features automatic palletisers to minimize handling and
statistical process control systems to ensure consistent and excellent
quality, working on ISO 9000/2008 standards.

Cinqpet offers the following technologies:

• Injection stretch blow moulding of PET containers
• Stretch blow moulding of PET preforms
• Application of wrap-around stretch labels
• 2 stage and single stage equipment

In-house design

Cinqpet helps eliminate customers’ on-line problems by taking filling and capping operations into consideration when designing containers.

Reflecting its stature as a global supplier of worldclass
packaging, the design team can develop concepts to increase brand impact on shelf. The designers can receive 3D electronic files via the internet and can produce exact product roll-outs using sophisticated
CAD/CAM systems.

Cinqpet’s close association with international leaders in ISBM technologies like Husky, Sidel , Sipa and Aoki ensures that world-class technical input, support and innovation are applied from concept stage to final product.

The Cinqplast-Plastop operation, situated in Denver south of Johannesburg, was acquired by the Astrapak Group in 2002. The company is now a well-established player in its chosen markets using state-of-the-art technology and offering a wide range of blow and injection moulded products.

Markets served

The core focus is on the home care, personal care and pharmaceutical plastic packaging markets. The injection moulding unit actively complements the container ranges and also supplies closures to other Astrapak companies including Cinqpet. More recently, driven by customer demand, the company has enhanced its’ position in the food and beverage markets and will continue to invest in these growing sectors.

State-of-the-art technology

The constantly upgraded plant includes a variety of multi-cavity machinery all of which is linked to sophisticated closed-loop electronically controlled material feed systems. In addition, production ancillaries include highly automated deflashing, take-out units, leak testing, counting and box-moving equipment. Through these high levels of automation Cinqplast-Plastop ensures that the correct quality of product is consistently supplied to its increasingly evolving markets.

Product development

Cinqplast-Plastop’s in-house Product Development Team’s approach to development extends from concept through product and mould design to include customer filling and capping operations. Onward transport, storage, display, consumer and recycling considerations are also carefully evaluated as part of the overall offering. Product and design proposals can be presented in 3D employing the latest CAD/CAM technology. Rapid prototyping is also accessible through Cinqplast-Plastop’s own unique pilot blow tool facility and 3D growth options. The in-house facilities ensure the strictest of confidentiality plus the fastest response and lead times. The company has upgraded to Pro-Engineering and continues to leverage the benefits of this modern design software.

Toolroom

An in-house toolroom complements the design facilities, further enhancing confidentiality and speed to market through direct control. Leading-edge technology has allowed Cinqplast-Plastop to compete successfully in a number of global rollouts through the exchange of electronic files via the internet. The company has also entered into a number of alliances with key international injection moulding toolmakers, thereby passing on the benefits to the clients.

Decoration Facilities

Cinqplast-Plastop is able to offer a full range of decoration options including four colour UV-printing. New sleeving equipment has also been installed to cater for those customers requiring full body decoration of their containers.

With huge spend on technical innovation, Cinqplast-Plastop Denver will continue to ensure that its people are trained and developed to extract the full benefits from these technologies to meet the needs of an ever increasingly demanding market.

City Pack was founded in 1984 and focused initially on the shrink film market for food and beverage packaging . In March 1997 it became the third major acquisition for the Astrapak Group.

Markets served by City Pack

Thanks to the installation of coextrusion technology, City Pack has moved films into a new era of sophistication and added-value and today is among South Africa's market leaders in the supply of coextruded printed film for the shrink wrapping
of food, beverages and industrial products.

The company's strategy is to move from the supply of commodity to value-added coextruded and printed films particularly for promotional marketing applications. In fact the company's sales slogan says it all:
'We wrap your pack bright and tight !'

City Pack has also entered the form-fill-seal market and is a major supplier of high-quality film which is flexographically printed in up to eight colours for frozen vegetable packaging.

Group synergy and one-stop shopping

Contributing to the success of Astrapak is the synergy that is enjoyed between the various Group operations. This is particularly appealing for multinational customers who can now enjoy one-stop shopping convenience - a typical example is the option to purchase shrink film from City Pack and pallet stretch wrap from Tristar Plastics.

Technological breakthroughs

City Pack is proud of a number of in-house technical developments, including:

• coextrusion film for use in hot-fill form fill-seal packs for extended shelf life food products

• innovative sun block protection within film for light-sensitive products

• a bar code block printing process to prevent bar code scanners reading
through shrink film on multipacks

• a non-stick coextruded outer shrink film for collating four six-packs into a 24-pack.

State-of-the-art technology

City Pack offers the following leading-edge technologies :

• extrusion and coextrusion of polyethylene films

• flexographic printing up to 8 colours

Consupaq is one of South Africa’s leading manufacturers of plastic jars, containers and tubes for the personal care, pharmaceutical and
cosmetics industries.

Entrepreneurial drive, innovative products, listening-based customer service and a dedicated strong team have been key to the company’s success. The company is based in Durban, KZN and became part of the Astrapak Group in September 2005.

State-of-the-art technology

The company employs the latest technology to ensure that it’s ERP and product development systems provide a platform for world-class products to be produced in the shortest possible lead times.

Consupaq designs and develops products and technologies in order to achieve a distinct competitive advantage and now holds numerous
patents. All products can be decorated using the latest technologies, including five-colour silkscreen printing, offset litho printing, hot foiling and tube labeling. In addition, a variety of textured finishes can be offered to further enhance decorated products.

The company has also been the proud recipient of numerous accolades, including Gold and Silver medals at the Gold Pack Awards.

Markets served

Consupaq’s generic product range includes injection moulded jars, thick walled cosmetic jars and a full range of mono and multi-layer
polyethylene tubes.

The company produces a wide range of products for the following markets:
• Cosmetics
• Personal care
• Pharmaceutical
• Ethnic hair care

East Rand Plastics was the second business to be acquired by the Astrapak Group in early 1997. However, the history of East Rand Plastics goes back a further three decades when the company was first established in Brakpan, in the late 1960s, to produce plastic tubing for ice lollies. This initial focus changed in the 1970s when the company commenced production of high-density polyethylene film.
East Rand Plastics continued to grow and during the 1990s equipment was installed to produce multilayer co-extrusions and high quality flexographic printing, setting the company on its current course.

Markets served by East Rand Plastics

The company continued to grow rapidly and today East Rand Plastics' ISO 9001 : 2000 accredited plant is one of South Africa's largest film converters. Priding itself on outstanding production quality, East Rand Plastics produces high-density, low- and linear low-density polyethylene, polypropylene as well as metallocene films, converting them into a range of sophisticated products – from multilayer film structures to superbly decorated and wicketed bags for a range of markets including:

• refuse bags, flat and on-a-roll - in perforated, interleafed and biodegradable product ranges
• packaging for the bakery industry, including printed and wicketed bags, shrink wrap and flimsy bags
• general purpose packaging, such as flat and side-seal bags, form-fill-seal film and tear-off perforated bags-on-a-roll
• shrink films including continuous collation films, shrink sleeves and shrouds (UV stabilised if required)
• agricultural products including heavy-duty fertiliser bags, mulch sheeting and bulk bag liners
• multilayer polypropylene-based heavy-duty sacks
• multilayer embossed tubing for form-fill-seal resin applications
• multilayer lamination sheeting
• tamper-evident form-fill-seal film

World-class technology

Much of East Rand Plastics' success can be attributed to ongoing investment in technology and the establishment of strong supplier partnerships. On the technology front, the company boasts an atmospherically controlled extrusion hall and has continuously upgraded with the best conversion and decorating hardware available.

When it comes to partnerships, East Rand Plastics enjoys many, including close relationships with national and international raw material suppliers, allowing the company to remain abreast of resin technology . The company also liaises closely with all the major international equipment suppliers and by so doing ensures that it maintains it's position at the forefront of printing and converting technologies.

Quality is the key

An important milestone in the company's history was ISO 9001 : 2000 accreditation for its quality assurance system in 1996. The business also operates a carefully-equipped laboratory where quality of manufactured products is tightly controlled. It's here too that new products and applications are developed.

Group synergy

Contributing to the success of the Astrapak group is the synergy that’s enjoyed between the various operations. Close co-operation between the companies that make up Astrapak's Films Division ensures
geographical coverage and an enormous diversity of products and manufacturing facilities.

The company also benefits significantly from the Groups purchasing power resulting in a producer that is able to offer truly cost effective film solutions.

Hilfort Plastics was established in Cape Town in August 1983 and operated as a family-owned, family-managed company for almost two decades until it was purchased by the Astrapak Group during 2005.

Markets served by Hilfort Plastics

Operating from two plants, situated in Cape Town and Bloemfontein, Hilfort Plastics manufactures and distributes rigid plastic containers and closures in capacities from 50ml to five-litres.
The company produces a wide range of products for the following markets:
• Food
• Beverages
• Wine
• Cosmetics
• Pharmaceuticals
• Chemicals

Hilfort Plastics’ entire focus is on rigid plastics packaging, with particular capabilities in the fields of injection stretch blow moulding (PET),extrusion blow moulding (HDPE) and injection moulding of caps and closures. A 6-layer extrusion blow moulder was also recently commissioned for the manufacture of speciality barrier containers for the food industry. In addition Hilfort also has some silk screen printing capability.

In the field of PET, Hilfort has particular competence and is a recognised market leader, offering customers superior products in terms of quality, aesthetics and featuring environmentally-responsible characteristics.

Hilfort Plastics has an excellent reputation within all the industries Served and is noted for its special emphasis on custom design, quality and service.

Accent on innovation

Another accent at Hilfort Plastics is on innovation and the company has produced numerous speciality bottles for a variety of industries. This focus on innovation was further underlined when Hilfort Plastics won the coveted Gold Pack trophy in 2003.

Group synergy

Contributing to the success of the Astrapak Group is the synergy enjoyed between the various operations within the company.
The acquisition of Hilfort Plastics brings a national blow moulding presence to Astrapak’s Rigid Division, adding manufacturing facilities in both Cape Town and Bloemfontein, in addition to those already established in Johannesburg, Pretoria and Durban.
Hilfort Plastics further benefits from Astrapak’s management expertise, capital base and overall purchasing power.

Premises and state-of-the-art Technology

The main business is operated from a 10 000m² facility in Stikland near Cape Town with a second
manufacturing plant in Bloemfontein serving customers in Gauteng, KwaZulu-Natal and the Cape.

Hilfort specialises in the design and manufacture of moulds and preforms and boasts an in-house, state-of-the-art toolroom, featuring the latest CAD/CAM and CNC technology – the company has also installed its’ own rapid prototyping facility for the production of mock-ups and models.

JJ Precision Plastics (JJPP) has been trading in KwaZulu-Natal for over 30 years, initially as a toolroom, manufacturing plastic moulds and press tools. In 1981 injection moulding technology was introduced and JJPP has since grown to become a fully fledged plastics converter with an in-house toolroom.

In 1994, JJPP was closely involved in the formation of Pak 2000, manufacturing tooling for extrusion blow moulded bottles for the petrochemical industry. In addition, JJPP manufactured and supplied all the injection moulded closures for these containers and since these early days has continued to play a critical role in Pak 2000’s success.

Following the early acquisition of Pak 2000 in 1997, the Astrapak Group then took a 70% interest in JJPP in 1999 – this was increased to100% in March 2003.











Markets served by JJ Precision Plastics

In its formative years as a toolroom, JJPP was the supplier of choice to many of South Africa’s major plastics packaging converters. Many early packaging conversions from traditional substrates such as glass and steel to plastic were effected using JJPP’s design and tooling expertise.

During this initial growth phase, conversion of engineering plastics and the manufacture and maintenance of industrial products were also part of JJPP’s key activities.

Today as a wholly-owned subsidiary of Astrapak, JJPP still continues its historical supply arrangements with Pak 2000 as well as with other companies within the Astrapak Group.

The product portfolio has been expanded to include packaging for the food and beverage markets, including spice bottle caps and the well-known pepper and salt grinders. This has recently grown further in the food sector, resulting in the manufacturing of the unique slide top Robertson’s spice closure and the Gold Pack award winning in-mould- labelled ( IML ) Aromat canister.

‘One-stop shop’

JJPP is a ‘one-stop shop’ for customers looking for assistance in developing new, value-added packaging for their brands – the company specialises in taking projects from concept and developmental stages to designing the necessary moulds and tooling to provide an end product that precisely meets the customer’s original brief and specifications – using one team, under one roof.

Group synergy

An important component of the decision to become part of the Astrapak Group in1999 was to improve procurement synergies. Although competitive in terms of technology and expertise, JJPP did not have the financial muscle to source raw materials at the best prices. Now, thanks to the Astrapak Group's buying power, JJPP is highly competitive in every aspect of its business.

State-of-the-art technology

By conducting ongoing research and development
jointly with it’s customers, JJPP prides itself in keeping abreast with global technology developments, while still monitoring and managing costs. Service and quality are key to the ongoing relationships of all JJPP’s customers.
The high level of process knowledge required is actively supported by it’s commitment to providing on-going and well-structured training and
education.

 

Knilam Packaging is a leading supplier of Modified Atmosphere Packaging (MAP) to the perishable produce industry. The extension of shelf-life without artificial preservatives allows for longer distribution lines, reduced wastage, improved product appearance, and greater flexibility for wholesaler, retailer and consumer alike.

Knilam boasts a world-class production facility, advanced technical expertise, product innovation and commitment to staff development. Defined as a food packaging “solutions provider” rather than merely a manufacturer, Knilam prides itself on the unique added benefits it is able to offer customers. Astrapak acquired a majority interest in Knilam in 2004.

Markets served by Knilam

Under its two trademarked brands - FreshWorks™ and SteamWorks™ - Knilam is able to provide packaging solutions across a broad spectrum of applications.

FreshWorks™ is a range of flexible films incorporating the latest innovations and technologies for use in the shelf-life extension of fresh produce. The versatility of the FreshWorks range makes it suitable for use in prepared cut vegetables, salads and fresh convenience products. Transmission and respiration rates are optimised to suit the specific product.

SteamWorks™ is a range of self-venting steam-cook film technologies for convenience (microwave) cooking of vegetables, fish, chicken, ready-meals and convenience products. This technology is revolutionising the way consumers prepare fresh produce and recipe meals, yielding consistent results every time.

Both product ranges can be supplied printed or unprinted and tailored to meet the customer’s requirements, in the format to suit their production requirements:

• Lidding film for tray applications
• Bags
• Pouches
• Reel stock for automated packing processes

In addition, food-grade proprietary anti-mist coatings can be applied to reduce condensation and improve overall pack appearance.

Technical services

Knilam prides itself in being able to offer customers added value by providing :

• Technical support
• Packaging system development & shelf life extension
• Packaging specification development protocols
• Co-ordination of activities & training relating to:
   o Hygiene Systems
   o Factory/Facility Development Consulting
   o HACCP Consulting
   o BRC Implementation
   o Third Party Audits

Group synergy

An important part of the decision to become part of the Astrapak Group was to obtain
access to capital to fund future growth prospects. Access to Astrapak’s capital base,
management expertise and purchasing power enable Knilam to continue on its path of
rapid growth as a leader in the field of speciality packaging for the fresh produce and convenience food markets.

World-class technology

Much of Knilam’s success is attributable to continual evaluation of technical innovations
and its commitment to remaining in the forefront of emerging technologies. It boasts world class technology and a plant that is British Retails Consortium / Institute of Packaging certified.

 

Marcom Plastics was established in 1994 to produce unprinted 175ml and 250ml polypropylene yoghurt containers for the dairy industry.

In 1999 Marcom acquired the assets of Unimould from Plasgroup bringing the company additional capacity and market share.

In March 2004 it was acquired by Astrapak and now forms an integral part of it's Rigids Division, adding thin-wall injection moulding to the Group's already comprehensive range of offerings.

Shalam Packaging of Israel is a shareholder in Marcom and brings to the partnership access to internationally proven technologies.

The company prides itself on its very high level of customer service.














Markets served by Marcom

Marcom has the technology and capacity to produce a wide range of thin-walled injection moulded containers and lids, including tubs for the dairy industry (yoghurt, cottage cheese, etc) and promotional items such as beer cups. It remains South Africa’s only supplier to offer a complete standard and pedestal range of containers for the premium end of the yoghurt market in sizes from 80ml to one-litre.


Cutting-edge technology
Marcom has invested heavily into its core injection moulding technologies through the addition of Nestal equipment. The company is also able to print up to 8 colours via the utilisation of several state-of- the- art offset printers.

Progression into in-mould-labelling (IML) technology that delivers high-quality photorealistic reproduction has allowed for packaging designs to play a vital role in product advertising, marketing and high consumer brand awareness. Furthermore IML allows for high resistance to scratching, humidity, heat, cooling, deep freezing and microwaving – it is perfectly safe and hygienic for use in the food industry because of solvent free colours and chemically-pure film with optimum barrier properties. IML also provides an antistatic, production-orientated surface finish that allows for fast, fully-automated handling.

HACCP and ISO compliant

Vital for customers in the food industry is the peace of mind that comes from Marcom’s strict compliance with HACCP standards. The company
is currently working towards ISO accreditation.

Accent on innovation

The focus at Marcom is to produce innovative and value added products for the markets that they serve – examples include, yoghurt multipacks produced using IML technology, clever yoghurt and topping containers and tamper-evidence for 500g and one kg containers.

In-house platemaking studio

In 2000, Marcom established its own in-house reproduction and platemaking studio, enabling the company to further provide customers with quick and cost-effective turnkey solutions.

Group synergy

Important considerations in the decision to become part of the Astrapak Group were to improve procurement opportunities and to have access to additional funding to facilitate future growth. With access to management expertise, the Groups capital base and buying power, Marcom has truly become highly competitive in every aspect of its business.

Durban-based Packaging Consultants was established in 1972 and purchased by East Rand Plastics in 1994 - it was acquired by the Astrapak Group in 1997 and today forms part of the Films Coastal Business Unit. Initially, Packaging Consultants was committed to the plain and construction film market but later on moved into high-tech eight-colour printing and sophisticated bagging.

In 2004 Packaging Consultants moved to a new purpose-built factory in the eco-sensitive Riverhorse Valley Business Estate. The result of the move has seen a marked improvement in quality and productivity as all processes are now under one roof and run far more efficiently.

Markets served by Packaging Consultants

Packaging Consultants enjoys a substantial share of the building/ construction market and has SA Bureau of Standards and Agrement certification, as well as ISO 9001:2008 accreditation.
In addition to supplying the wide-width (up to 3 200mm) plain sheeting and bag markets, Packaging Consultants serves the six- to eight-colour high-quality print market with either form-fill-seal film in reel-form or bags. The company's major markets include:

• Boutique bags - including patch, loop and punch-out handles
• Form-fill-seal packaging material for confectionery, maize, rice and sugar
• Bags for poultry, maize, pet food and frozen vegetables
• Heavy-duty sacks for agricultural and chemical products
• Printed and plain shrink film
• Reusable bags with rigid handles supplied by JJ Precision Plastics
• Laminated substrates for use in the packaging of rice and frozen vegetables

Group synergy

Contributing to the success of the Astrapak Group is the synergy that is enjoyed between the various operations. Packaging Consultants works closely with other companies in the Group by not only supplying them with film but also sourcing complementary products that truly make the operation a one stop shop for plastics packaging.

Pack-Line Packaging was established in East London in 1997, initially as a distribution company supplying film and other packaging items to the local market. A year later branches were established in Port Elizabeth and Bloemfontein transforming the company into a leading manufacturer and distributor of plastic packaging in the Free State and Eastern and Northern Cape regions.

Markets served by Pack-Line Packaging

With a well-deserved reputation as a 'one-stop packaging shop', Pack-Line Packaging specialises in the manufacture of extruded film products in both reel and bag form – in addition to the extrusion of virgin polymers, Pack-Line Packaging also uses recycled material for a variety of general films.

Key product lines include stretch and shrink film and tubing for a diverse range of uses including pre-packed fruit and vegetables, linen and clothing, confectionery products and an array of industrial applications.

The management team remains committed to flexibility and the delivery of high-quality products on time and at affordable prices and consequently the company has earned an outstanding reputation for reliability in the local packaging market.

Group synergy

Contributing to the success of the Astrapak Group is the synergy that's enjoyed between the various operations. Pack-Line is able to source a wide scope of packaging from within the Group and as a result is able to offer a very diverse range of products, included printed film, to it’s chosen markets. The company also benefits from the Groups purchasing power, particularly with raw materials, making it a truly competitive local supplier.

Manufacturing base

The production plant is East London is constantly being upgraded to world-class-manufacturing standards and offers the following technologies:

• extrusion
• slitting
• bag-making
• recycling

The Packline Management team is steering the company into becoming the preferred supplier of Plastic Film products in the Eastern Cape and Free State Regions.

 

Pak 2000 was established in Durban in 1994 with the express purpose of specialising in blow moulding and decorating plastic containers for the lubricants market. Pak 2000 was among the first
companies acquired by Astrapak.

Markets served by Pak 2000

Since inception, Pak 2000 has specialised in the design, manufacturing, Extrusion blow moulding and decorating of HDPE plastic containers for thepetrochemical industry and is currently the acknowledged market leader.

Containers produced range from 200ml to five-litres. Pak 2000 is striving become a major supplier of 500ml forecourt motor oil containers and to assist customers with the conversion from tin to plastic.

At Pak 2000 the name of the game is adding value. While many companies are capable of blow-moulding plastic bottles and injection moulding auxiliary components, not many are equally adept at high-tech decorating.

Group synergy

Critical to Pak 2000’s success has been its close association with JJ Precision Plastics, another Astrapak group company. JJ Precision Plastics supplies all the closures for Pak 2000’s products and offers access to a fully-fledged toolroom that is seen as vital to the success of the business.
With access to Astrapak’s purchasing power, capital base, and expertise, Pak 2000 has continued to go from strength to strength.

Top class premises and, state-of-the-art technology

Towards the end of 2004, Pak 2000 moved into its new state-of-theart, custom-designed premises in Mahogany Ridge near Pinetown. The technical capabilities of the company were further enhanced with the introduction of new equipment and Pak 2000 can now boast that it has all the ingredients to continue producing world-class packaging.

Pak 2000’s success hinges not only on technology, innovation and high-quality products but also from management’s enthusiastic hands-on approach, professionalism and close rapport with customers in the motor vehicle lubricants industry.

BEE partnership

During 2004 Astrapak sold in excess of 25% of the equity in Pak 2000 to Michael Maziya and Anand Raidoo as part of a Black Empowerment transaction. The transaction has been well received by Pak 2000's customers and should stand Pak 2000 in good stead when competing for new business in the future.

The empowerment partners have taken an active role in the running of the business and will play an important part in the continued success of the company.

Peninsula Packaging was established in Cape Town in 1979 as a satellite company for Johannesburg based East Rand Plastics, primarily to service the large retail chains headquartered in the Western Cape. In the meantime, however, the company has gained an enviable reputation as a leading manufacturer of plastic packaging materials in its own right. Peninsula Packaging was acquired by Astrapak, together with East Rand Plastics early in 1997, and today forms part of the Group’s Films Division.

Markets served by Peninsula Packaging

Peninsula Packaging are widely acknowledged as market leaders
in the manufacture of plain and printed polyethylene films,
sheeting, tubing and bags. These products are primarily used for packaging the following:
• fresh fruit for both local and export markets
• bakery
• general food
• beverages
• industrial packaging
• refuse bags including bag-on-roll, degradeable, interleaved, retail and municipal
• FMCG

Of prime benefit to customers is Peninsula Packaging's ability to react swiftly to JIT orders – this particularly important for those customers whose harvests or catches are unpredictable ie. fruit and fishing.

Group synergy

Contributing to the success of the Films Division is the synergy that is enjoyed between the various operations that give customers an ever-widening choice of products and services. Through its diverse production capability Peninsula Packaging has enabled the Group to offer its customers a far wider range of products than would otherwise be possible from one production facility.

World-class technology

The extensive product range produced by Peninsula Packaging is supported by advanced flexographic printing facilities including one eight-colour, three six-colour and two four-colour presses.The business also boasts comprehensive bag-making facilities, catering for all manner and types of bag – from wicketed through to side-sealed bags. All products can be supplied in a fully bio-degradable form where required.

Plastech was founded in East London in 1993 by Charley Harnden and soon became a recognised regional supplier of rigid plastic packaging. Both Charley and the company have received numerous business awards and accolades and are well established in the Eastern Cape as producers of high-quality plastic containers and closures. Two other related packaging companies, PrintTech and PETech, were later founded forming the PlasTech Group. The Group prides itself in providing exceptionally high, enthusiastic and passionate levels of service! Astrapak acquired a majority share in Plastech in February 2007 and by so doing expanded the national footprint of its Rigids Division to include the Eastern Cape.

Markets served

Plastech focuses on small plastic containers for the health and personal care, homecare , beverage and industrial markets. In addition to being in a position to offer polyolefin and PVC products, PETech also supplies an extensive range of PET bottles to the beverage and related industries.



As an added advantage, PrintTech is also able to add value by decorating containers which broadens the company’s ability to provide a more comprehensive in-house service.

Technology

In addition to the conventional extrusion blow moulding and injection moulding processes, the Group also utilises various state-of-the-art, single-stage PET machines to reinforce their regional dominance in the PET market.

Group Synergy

Astrapak have long recognised the potential of the Eastern Cape and Plastech forms a sound base for the Rigids Division to grow and leverage their position as a major supplier of plastic packaging into the region.



As part of a major Group, Plastech also benefits from improved raw material procurement, access to up to date technology and marketing synergies allowing the company to become much more competitive in every aspect of their businesses.

Continued emphasis on service, quality, technology and particularly innovation will see Plastech growing from strength to strength.

Plastform, located in the Western Cape, was founded in 1980 as an independent company and in 2006 became a part of the Astrapak Group of companies. It has continued to grow to become one of South Africa’s leading packaging suppliers of thermoformed plastic products.

Whilst Plastform is already ISO 9001:2000 and AIB (Silver status) certified, the company is currently pursuing attainment of ISO 22000 as well as HACCP certification during the course of 2010.

Markets Served

Plastform supplies a diverse range of customers throughout South Africa and abroad specialising in the following markets:
• Dairy - yoghurt, cheeses and creams
• Desserts
• Prepared meal trays
• Salads, fresh fruit and vegetable trays and punnets
• Vending and drinking cups
• Fast food, delicatessen and catering

Technology

In order to maintain their leading market position as a supplier of quality products only state-of-the-art equipment is employed including :

• Extrusion lines capable of producing polystyrene, polypropylene and ABS sheeting

• A large number of thermoformers enabling both
in-mould and post-cut trimming techniques.

• Printing capabilities of up to 9 colours on cups and 6 colours on lids via dry offset printing technology. Partnering with design houses and plate makers both locally and abroad has seen rapid advances in the realization of ‘near identical’ photographic
reproduction.

During the course of 2009 Plastform completed a major factory re-layout aligning itself with international best practices and by so doing has provided a platform to exceed future food safety and thermoforming processing requirements. An example of this can be seen in the development and installation of a world first fully automated and integrated granulation system.

Product development and innovations

Plastform’s commitment to innovation as a key driver to sustainability and client partnering is evident in its latest market offerings. Current prototype developments include radical offerings which were previously not realizable in a thermoforming environment. Enabling subsequent optimum commercialization is supported by the companies continued commitment towards World
Class manufacturing and international best practices. This combination is regarded as one of the vital building blocks in providing clients with optimum solutions and support – this will continue to support Plastform’s influence as a formidable force in the marketplace.

Group Synergy

Although Plastform has a sound reputation in its core markets, it takes full advantage of all expertise and resources in the Astrapak fold to build upon core competencies and deliver ever improving standards of quality, service and innovation.

Since its inception in 1966, Plastop has been regarded as an innovative and quality supplier of rigid plastic packaging components.
Plastop was acquired by Astrapak in 2002 and today forms part of the Groups Rigids Division.

Markets served

Plastop has matured into a leading supplier of injection blow moulded containers specialising in the personal care and pharmaceutical markets. The company places strong emphasis on using state-of-the-art technology and this is complemented by its international affiliations with Alcan Wheaton and Weener Plastics, both of whom are industry leaders in their respective chosen markets.

Plastop now looks forward to further developing its presence within it’s vibrant chosen market sectors and actively pursues its vision to be the preferred supplier therein.

Production facility

Plastop based based in Ekandustria, BHS operates from an air-conditioned plant containing high levels of automation and closed-loop process that are comparable with the best in the world. In addition, the on-site toolroom has been upgraded and takes care of new mould construction and maintenance. Further to being ISO 9001:2008 accredited and compliant to the OSH ACT (BS OHSAS:18001-2007), Plastop has embarked on World Class Manufacturing ensuring best practices in maximising performance in the following areas:

• Reduction in lead times (increase in On Time and in Full (OTIF) delivery
• Maximise speed of the innovation process
• Optimise operations costs
• Leader in meeting customer expectations
• Manage the business in global terms with local focus
• Excellence in selected core-competencies
• Improve business performance visibility

For WCM to be successfully implemented organisations need commitment to the process to be directed from the top leadership and filtered to the lower organisational strands. Implementation of WCM begins with a focus on foundation practices of Teamwork, Visual Performance Measurement and 5S/housekeeping.

Plastop seeks to further develop its presence within its chosen markets and actively pursues its vision to be the preferred supplier therein.

Core competencies

Manufacturing processes
• Injection blow moulding
• Injection moulding

Clean-room facility
• Injection blow moulding
• Injection moulding

Roll-on ball manufacture
• Injection moulding
• Welding
• Grinding/lapping
• Washing/sizing/sorting

Decoration
• UV-silkscreen printing
• Labelling
• Pad printing

Other
• Assembly (closure, ball and cage)
• Closure lining

Product development and innovation

Plastop makes use of in-house CAD/CAM and rapid prototyping in order to provide a complete product development and innovation service to its customers. Direct control over these processes facilitates the fastest possible turnaround times and ensures the strictest possible confidentiality.

 

Plastop KwaZulu-Natal (Pty) Ltd was established in 1996 and was acquired by the Astrapak Group in 2002. Originally born out of the need for Unilever to have a supply base close to their Maydon Wharf personal care factory, Plastop relocated part of the Bronkhorstspruit factory to Durban.

Situated in Prospecton, 20km from Maydon Wharf, Plastop KwaZulu- Natal (KZN) is well positioned to supply product at very short notice to Unilever.
The operation is housed in a fully air-conditioned factory with automated material handling to its injection moulding, extrusion blow moulding and injection blow moulding conversion processes. All of the processes are controlled via the ISO 9002 quality management system thus ensuring continued supply of high quality products.

Markets served

Plastop KZN offers world class quality products designed to be aesthetically appealing, yet practical and functional to meet the needs of Unilever's personal care market. The range of injection blow moulded jars, extrusion blow moulded lotion and shampoo bottles and injection moulded closures are come in a variety of shapes, colours and finishes to suit the changing and fashion driven personal care market.

Technology

To maintain the position as a premier supplier of quality packaging, it is vital that the manufacturing processes are in keeping with worldclass manufacturing practices. To this end, Plastop KZN has invested in state-of-the-art technology for all of its processes. The combination of world-class processing equipment and precision built moulds results in high quality moulded packaging products.

Design and technical support

In close association with leading toolmakers, both locally and internationally, Plastop KZN is able to offer packaging solutions to meet the discerning needs of the personal care market. The company prides itself in long and established technical co-operation agreements with both mould and technology leaders in the USA.

PlusNet / Geotex, a Randfontein based manufacturing company, originated in 1995 to supply profile yarns to the plastic textile industry. Today PlusNet / Geotex is a fully integrated production facility that produces innovative products for the agricultural, commercial and civil industries.

The majority of the company was acquired by Astrapak in 2007 and today forms part of the Group’s Industrial Division.

Main Markets serviced by Plusnet / Geotex

1. PLUSNET : RANGE OF AGRICULTURAL & DECORATIVE SHADENET

A wide range of agricultural shade netting which is tailored to improve spectral transmittance, thus optimizing production outputs. A full range of site screening, dune, mining rehabilitation and decorative nets, privacy screens and ground sheets are included in the PlusNet product portfolio.

2. GEOTEX : FIBRES FOR CONCRETE REINFORCEMENT

Geotex fibres is a new generation product that has fast replaced steel in concrete. This product is a polypropylene based fibre with additives to increase the adhesion of the fibre to concrete. The advantage of these specialised fibres are that they are lighter and safer to work with than steel fibres and mesh, whilst at the same time delivering equal if not better performance in terms of crack prevention, improved ductility and avoidance of spalling.

3. BOPHA : RANGE OF HDPE SKI-ROPE

A range of HDPE ski-ropes used for cargo netting, general outdoor uses etc. The product range includes ropes of 2mm, 5mm, 7mm, 8mm, 10mm and 12 mm diameters - merchandised in either in pre- or bulk packs.

PlusNet / Geotex prides itself on offering innovative products and new developments are constantly in the pipeline.

PlusNet / Geotex has achieved higher levels of business with its well proven reputation for quality and service and maintaining the ISO 9001 : 2000-standard.

Group Synergy

The company is able to benefit from Astrapak’s buying power particularly when it comes to the sourcing of raw materials - this enables Plusnet / Geotex to remain exceptionally competitive in the specialised markets within which it operates.

Saflite Packaging was established in Cape Town in 1997, specifically to take advantage of the fast-expanding market in stand-up pouches (Doypacks). The Astrapak Group purchased a majority shareholding in 1999 with the balance being acquired in 2009.

Markets

In Saflite's short history, this innovative company has taken a sizeable share of the stand-up pouch market. The company, through it’s outstanding production versatility, offers gusseted, large format and square bags as well as shaped pouches, with the capability of inserting zippers and/or spouts.

The company’s most recent innovation, the ASTRAPOUCH, is packaging technology which was developed entirely in-house, initially for the South African wine industry. It has now successfully been launched and sold into the UK, Australia, Sweden and Russia. There is also strong interest from the US, New Zealand and Asia.

The ASTRAPOUCH is based largely on its environmental credentials and has been selected as the required packaging for wine tenders issued by the government backed liquor control bodies in Sweden and Finland.

Other key benefits include:

• High impact graphics, which maximizes decoration on-shelf presence and branding
• Faster chilling time than bottles and easier to store in a fridge
• Light and comfortable with cut out handle and low profile press tap
• High barrier properties suitable for premium wine remaining fresh for up to a month once opened
• Ideal for no glass situations, the pouch is easy to handle, cheaper to produce and requires less space when transported.

This innovative pouch is not only a South African and world first, but has an audited 85% reduced carbon footprint when comparing the 1.5 litre pack with two 750ml glass bottles. It is already recognized as a game changer for retailers and producers, with a development of a whole new segment.

In 1997 Emcape-Thermopac was the very first company to be incorporated into the fledgling Astrapak Group. A year later, in 1998 , it merged its operation with Blista Pac and the company then became known as Thermopac.

Markets served by Thermopac

Thermopac specialises in the production of rigid thermoformed PET, RPET, BPET, PETG, PP, HIPS and HDPE plastics packaging and supplies mainly the fresh and prepared food, bakery and confectionery industries. The company also produces some containers for pharmaceuticals, cosmetics and some general industrial applications. In addition, Thermopac also extrudes plastic sheeting for the general thermoforming market.

Serving many of South Africa's 'blue-chip' companies, Thermopac offers a JIT service on a range of custom-moulded and 'off-the-shelf' packs.

Thermopac's service excellence ethic is proven by the company's numerous 'Supplier of the Year' awards from food and pharmaceutical industry customers.

Helping South Africa's exporters

There's no doubt that countries in Southern Africa are increasingly regarded as the bread basket for wealthier countries to the north. Today, many of Thermopac's products carry fresh produce from South Africa and its neighbouring countries to leading retailers in Europe on a daily basis.

Meeting the environmental demands of international customers is just one of the reasons behind Thermopac's move to replace PVC packaging with PET and RPET.

Group synergy

Contributing to Thermopac’s success is the synergy of the Astrapak Group of specialist plastic packaging companies. Internally sourced lidding film can be sealed to Thermopac trays for tamper evidence, oxygen permeability and MAP barrier applications.

State-of-the-art technology

Adding to the positive aura that surrounds this dynamic company has been a continual upgrading of plant and equipment, of which the investment in a state-of-the-art German extruder to process PET is a prime example.

World-class production

To ensure world-class products for its discerning customers, Thermopac continually benchmarks itself against international standards of production efficiency. The company has aligned itself with companies in the UK and Denmark with which it enjoys various technology-sharing arrangements.

The company has also instilled a company culture of continuous improvement through its “World Class Manufacturing” program and boasts the latest BRC packaging hygiene standard.

Tristar Plastics, specialising in pallet stabilization and related products for the industrial packaging sector, was acquired by Astrapak in 1998. But the company's history goes back to 1989 and the installation of an extrusion line that saw the first production of the blown stretch and shrink films that became Tristar's trademark products.

Markets served by Tristar Plastics

Tristar Plastics is widely acknowledged as a market leader in the manufacture of high-quality shrink and stretch film products,
specifically for blue-chip companies in the cement, brewing, milling, retail and mining industries. The company's market success is maintained through developing integrated partnerships with customers in order to provide effective packaging solutions.

Here are just a few examples:

• three-layer coextruded cast stretch film, offering high yield and strength, cost-effectiveness and crystal clear clarity
• blown film extrusion for the stretch wrap and shrink film markets
• latest technology tri-stretch hoods for pallet stabilization to
replace conventional shrink shrouds
• specialised types of stretch films designed to meet individual
customer's requirements to achieve cost-effective and efficient product stabilization.

Outside of it’s core markets, Tristar has also developed a variety of innovative products such as the Tri-lex Agrifilm range comprising of Tri-Feedwrap for silage wrapping and mulch films for cotton and tobacco, as well as ventilated banana bunch covers to provide protection and to improve banana crop yields.

Group synergy

Contributing to the success of the Astrapak Group is the co-operation that’s evident between the various operations. Tristar Plastics, for instance, is able to supply the Astrapak Group companies with film products to meet their pallet stabilization requirements. The company also benefits from the Groups purchasing power, particularly on raw

materials, allowing it to become a truly competitive supplier of cost effective and innovative film products.

Exports

Tristar is constantly expanding its export portfolio, particularly into neighbouring countries in Southern Africa. With the installation of an additional three-layer cast film line, Tristar Plastics are able to target a blue-chip customer base in Africa that has traditionally been supplied
from Europe. The quality of the products offered, coupled to the efficiency of the manufacturing process, will ensure that Tristar Plastics' vision of expansion into Africa becomes a reality.

World-class technology

Much of Tristar Plastics' success is attributable to continual evaluation of technological innovations and its commitment to remaining in the forefront of such emerging technologies. The company's ongoing investment in sophisticated equipment includes:

• state-of-the-art lines for blown and cast films

• a fully-automated three-layer cast film line for the production of stretch wrap and other high-tech film applications. This computerised line –complete with robotics – results in high-quality products being made at high speed in a safe and efficient manufacturing environment.

Award-winning packaging

Tristar Plastics is an multi award winning company with a silver status gold pack award for its Tri-stretch Hood developed concept that replaced the traditional pallet shrink shroud and has received numerous supplier of the year awards for its innovative supply strategies in pallet stabilisation films. The company also enjoys 'preferred supplier' status to many of South Africa's leading companies in the industrial, chemical, retail, packaging and beveraged industries.

Ultrapak was established in East London in 1983 and initially concentrated on the manufacture and supply of plastic packaging for general trade. In 1991 the company made a strategic decision to focus the business on two core products namely printed wicketed bread bags and laminated sheeting for form, fill and seal liquid packaging. The plant is ideally situated for national supply and is well serviced by road, rail and sea. The company was acquired by Astrapak in 2004 and today forms part of the Groups Films Division.

Markets served by Ultrapak

Ultrapak focuses on the bread, milk, juice and fruit packaging markets which it services with distinction due to its committed hands-on management philosophy.

In 1986 Ultrapak pioneered the development of laminated sheeting for form, fill and seal liquid sachet packaging. Ultralam®, as the product is called, is widely used by the dairy, fruit juice and water industries as a reliable packaging option for their products.

Ultrapak holds a very strong position in the milk and juice sectors due to its understanding and dedication to this market - a great deal of this expertise comes from a detailed knowledge of the products, clients, the equipment used and the everyday challenges that these producers face. For over 21 years, Ultralam® has been the benchmark for quality.

Ultrapak also prides itself in being a supplier of top quality printed and wicketed bread bags to the major and independent bakeries in South Africa.

Quality and technology

The sophisticated East London manufacturing plant boasts ISO 9001:2000 certification and is dedicated to the production of retail food packaging.

Arguably one of finest packaging plants in the country, the housekeeping standards are of the highest order.

Ongoing investment in new equipment, including the recent addition of an eight colour state-of-the-art printing press will ensure that Ultrapak is particularly well suited to remain as a competitive force in the film industry.

Based in Ekandustria, this joint-venture between Astrapak and Weener Plastic Packaging Group of Germany is a highly focused manufacturer of 1.4” (35.6mm) hollow polypropylene roll-on balls.

Weener, the world’s leading manufacturer of hollow plastic balls, was the natural choice to partner Plastop - who had already been manufacturing hollow balls for almost 20 years – when they commissioned their new factory in early 2005.

Despite their apparent simplicity, the manufacture of these balls is highly complex and involves a number of processes as well as the need to operate within very tight tolerances.

The balls are one-piece extrusion blow moulded and offer great strength and a reduction in material weight over previous balls.

The state-of-the-art plant incorporates high-speed vision-inspection equipment, thereby ensuring that the hollow plastic balls that are produced meet the stringent Quality Control requirements needed
to ensure that each ball functions and dispenses the product from within the roll-on correctly.


The layout of the plant facilitates good workflow with an emphasis on safety. This is further supported up by a sprinkler system and digital
camera surveillance.

Ongoing investment in the various equipment required to manufacture and finish balls is allowing Weener-Plastop to further boost their output in order to meet rapidly growing market demand.