PHOTO: The Schoeller representatives at the opening of the toolroom, Stefan Scheuerer (sales director for Africa) and Peter Bruckbauer (technical manager at Schoeller Allibert Germany), flank Ian Victor, managing director of MCG Industries, at the launch event in November

MCG INDUSTRIES made a major investment in tool maintenance capability at the tail end of 2015 which is enabling it to greatly improve its ability to keep its moulds performing optimally, as well as service moulds to OEM standards.

In a project with an estimated value of R7-million, MCG installed what is effectively an entirely new toolroom at its plant in Malvern, Johannesburg. The new CNC milling machines, lathes, spark eroders and wire cutting systems give it the capability to service its large moulds, specifically crates for SAB, one of its largest clients.

Four highly skilled mould makers and two assistants are employed in the 600m² toolroom.

MCG has been supplying crates to SAB for well over two decades and most of the moulds employed to date have been supplied by Schoeller of Germany. MCG has had an on-going technology agreement with this internationally reputed tool manufacturer, which has specific expertise in the production of large moulds for the crate sector. Schoeller was the supplier of the first fully automated crate manufacturing plant in the country, at what was then Mega Hitec in Olifantsfontein, in 1992.

“MCG is able to supply and maintain moulds from Schoeller or other mould manufacturers. Customers can then have these moulds serviced at our mould shop where we can guarantee the repairs according to OEM standards,” said an MCG spokesman.

“Our independent Schoeller technician signs off on the work done to the moulds, which gives the customers peace of mind. Furthermore, we have the capability to run these moulds – especially the larger moulds which require machines of 1000 tons or more clamp force – in-house and, with the mould shop across the internal road at our plant, if anything goes wrong, our mould shop personnel are close by.

“Once service or maintenance work on moulds is completed, all customers are guaranteed the work is done according to the OEM specification,” he added.

“SAB has been asking for this setup for some time. We decided to address the issue, as it adds massive benefits for both customers and suppliers, such as SAB. Uptime during peak seasons is critical and if maintenance is done according to OEM standards, there is less of a chance for downtime, moulds in good condition produce faster and better quality products,” said Ian Victor.

The toolroom has the capability to build smaller, less complicated moulds, but as most crate moulds today are very complicated, MCG will continue have such tools built in Europe.

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