Riaan Swart is not your usual accountant – well at least the image that the profession portrays. The image of a stuffy, stereotyped, older gentleman wearing a pressed white shirt, spectacles, a green visor and sitting under some intense light immersed in calculation is not what you get when you walk into Swart’s shared office in Parow Industria, Cape Town. Instead, you get the look of a normal engineering office where the company is either involved in processing metal or is machining products or both. All have the same, unfussed look about them with either tooling or metal components being the chief decoration in the office. There is no room for smartly polished imbuia desks or expensive carpets that cover the entire office. These would be ruined with shop floor footprints on the first day that they were fitted.
Currently Chantex are machining the main frame structural work for a mining company. The 36 ton main frame has dimensions of 5m by 5m by 5m and is part of what is called a crawler used in huge mud-sifting operations. These crawling machines can weigh over 250 tons and stretch over three storeys tall. Final assembly of the crawlers is done on site
Swart did work as an accountant before taking up the opportunity to buy Chantex Heavy Machining from his father-in-law in 1999. The company was a general engineering shop at the time but as soon as Swart took ownership he knew he had to make the company services and offerings stand out from the rest of the many engineering companies that offered similar services in the Western Cape area. And this he has done successfully.
“I was not cut out to be stuck in an office working with figures for the rest of my career. Figures and accounting practices have been a great background for me while running the three companies that make up the Chantex Group. It is so easy to get involved in the engineering aspect of the business and neglect the cash flow that before you know it trouble is staring you in the face. Luckily I have the experience to broadside any of those negatives. And engineering has become my passion.”
The work involves about 200 tons of fabrication, intricate structural assemblies and mechanical components, shop detailing, heat treatment, machining and assembly. For the fabrication phase, the team is using advanced measurement and alignment technology in conjunction with line boring machinery to obtain tolerances of less than 0.05mm over a length of 5 metres
“Chantec Manufacturing had industrial conveyor system manufacturing as its main product line. Most of the machining of components was done inhouse and any sheetmetal requirements were processed by a company named Servmat, which was established in 1995. We would acquire this company in 2008.”
“The machining of components, large and small, is still very much part of the mix, but we sold off the industrial conveyor system manufacturing side in 2012 to a company that operates in the same industrial complex as us. We have continued to have a great relationship with them and we do take care of the majority of their requirements,” said Swart.
“Every business owner wants his company to stand out from the rest but it is not always easy to do so. It’s like going to a game reserve. If you want to see the special sightings you have to work hard for them. It is no good visiting a reserve and expect the animals to come rushing out of the bush to see you. You will soon be disappointed.”
A big advantage that Chantex Heavy Machining has and one that makes it stand out from the rest is that it has big equipment to machine big and heavy components
“On the boring mill side we have two Scharmann CNCs and two Wotan CNCs. The one Scharmann has specifications of XYZ 5 000mm by 2 000mm by 1 780mm, a rotating chuck table size of 3 000mm by 2 500mm, a maximum weight of 35 tons and a spindle diameter of 130mm.”
“There are many companies that run on offering small to medium size machining but very few that offer the large component machining services. And this is the area of engineering that we have concentrated on and have built our reputation on. We believe that nobody in the Western Cape has the capacity that we have, especially if you consider the number of large vertical and horizontal lathes, boring mills, machining centers and milling machines that we have. Altogether we offer CNC boring, milling, slotting, turning and shaping.”
“A couple of our vertical lathes can accommodate components up to 25 tons with a maximum XY of
2 800mm by 2 000mm. On the horizontal lathe side we can machine up to 6 000mm between centres and swings of 2 000mm (in the gap), 900mm (over the bed) and 700mm (over the saddle). This machine can also accommodate up to 8 tons of metal.”
“On the boring mill side we have two Scharmann CNCs and two Wotan CNCs. The one Scharmann has specifications of XYZ 5 000mm by 2 000mm by 1 780mm, a rotating chuck table size of 3 000mm by 2 500mm, a maximum weight of 35 tons and a spindle diameter of 130mm.”
“The other Scharmann has specifications of XYZ 4 000mm by 3 000mm by 2 200mm, a rotating chuck table size of 3 000mm by 2 500mm, a maximum weight of 30 tons and a spindle diameter of 180mm.”
Chantex Heavy Machining believes that nobody in the Western Cape has the capacity that they have, especially if you consider the number of large vertical and horizontal lathes, boring mills, machining centers and milling machines on the shop floor
Chantex Heavy Machining offer CNC boring, milling, slotting, turning and shaping
“The latest innovations in metalworking might be related to CNC automation, robotics, 3D printing, software, tooling and quality inspection. Equally newly patented technologies for controlling chatter and vibration during milling, turning and boring operations promise to drastically reduce production time and increase machining performance.”
“Beyond specialising in certain processes, machine shops also typically specialise in certain volumes. Even if the machining processes are the same, running both small and large-volume jobs can become too complex for some shops to manage. Making one really high-quality part and making 100 000 high-quality parts require very different thought processes and switching between the two can be a challenge, not to mention figuring out a schedule that can handle both types of jobs at the same time.”
“However, when it comes to precision machining of large and complex components many companies are constrained by the dimensional and weight limitations of the machines that it has at its disposal. Additionally, there will be those that have maybe one large capacity machine but that is it. If that machine breaks down then it could be out of action for weeks and even months.”
“That is why I mentioned that we have two Scharmanns, for example. If one breaks down then we can move the component to the other Scharmann or even one of the other boring mills. Not many have this ability in South Africa and it makes us stand out in a crowd.”
“One of our fascinations with large-format machine tools has little to do with their capabilities, but everything to do with the logistics involved with getting them up and running. Once that is done the attraction turns to the loading and unloading of components, especially if the machine is setup in a limited space situation, and of course machining to tight tolerances.”
Machining large components is Chantex Heavy Machining’s speciality
Sister company Servmat Steel Service Centre has recently added a DNE fibre laser to its capabilities. The DNE 6kW fibre laser has a bed size of 4 000mm by 2 000mm. The company can cut up to 16mm stainless steel on this machine and cuts most metals on it
“Currently we are machining the main frame structural work for a mining company. The 36 ton main frame that is 5m by 5m by 5m is part of what is called a crawler used in huge mud-sifting operations. These crawling machines can weigh over 250 tons and stretches over three storeys tall. Final assembly of the crawlers is done on site. The work involves about 200 tons of fabrication, intricate structural assemblies and mechanical components, shop detailing, heat treatment, machining and assembly. For the fabrication phase, the team is using advanced measurement and alignment technology in conjunction with line boring machinery to obtain tolerances of less than 0.05mm over a length of 5 metres.”
“We are machining two of these main frames that are part of a new generation crawler that has been designed by a local company. They are the main contractor. You can call them monster ROV mineral dredging crawlers.”
“The challenge is not the machining of the components of the main frame – but rather getting them on and off the boring machine. We don’t do any welding, fabrication or assembly. Only machining and we like to keep it that way.”
Smaller component machining
“A completely separate company, but part of the same group, does all our smaller component machining. It is even housed in a different building in the complex. When I say smaller component machining, we have just installed a Sino SP1530 high-rigidity heavy cutting double column machining center that was supplied by WD Hearn Machine Tools. This machine can accommodate components XYZ travels of up to 3 100mm by 1650mm by 800mm and a table weight of 7 tons.”
Servmat also offers punching services with a Trumpf TC600L 3kW combination punching laser cutting machine
Servmat has five Amada HFB press brakes. All are 7-axis machines and the largest is the Amada HFB 3204 which is a 320 ton machine that has a 4 000mm width. We also have a 170 ton, 130 ton and 100 ton machine with widths of 3 000mm and the smallest machine is the Amada HFB 50-12 that has a 50 ton force and 1 250mm width
“In this company we also have a Leadwell V-50L vertical machining center and a Leadwell LTC 25iXX turning center. Both were supplied by WD Hearn Machine Tools.”
“We call this a CNC production site but there are also requirements for one-off smaller type components. We are not a company that operates in a one-cent a component better scenario and stay away from the large production runs. In fact we are not set up for that type of work.”
“There is a strong discipline of keeping the companies separate, all with their ‘own set of books’. However, there certainly is cross-over in the industries that the two companies work in but not as much as one would think. Chantex Heavy Machining has always been involved in the mining and shipping industries where there is a regular call for larger components to be machined but it is not limited to these two industries. Our niche is heavy engineering and clients come looking for us because they know we have a versatile heavy engineering operation.”
Components moving through the factory
The Amada HFB 3204 which is a 320 ton machine that has a 4 000mm width
“We are ISO 9001:2015 certified and we have all the normal quality inspection equipment that you would expect in a company like ours. This includes a CMM arm and CMM machine. Currently we employ 15 staff in Chantex Heavy Engineering and three in Chantex Machining.”
Solar power
“I don’t have to repeat all the power problems South Africa has had. Suffice to say we have invested heavily in solar and battery back-up power to get clean and pure power and obviously keep us up and running. It is still work in progress.”
“Sure, it is great to keep the lights on and run the computers but running of the machines is a problem, which is not what you want. Solar power systems are exposed to various sources of electrical disturbances, including lightning strikes, grid fluctuations, and equipment malfunctions. These disturbances can lead to power surges, which can damage the panels, inverters, and other critical components of the system.”
“Luckily our solar company is still trying to contain or stop the power surges efficiently.”
Servmat offers sheet and plate steel services
“The third company in the Group is Servmat Steel Service Centre, also located in the same complex in Parow Industria. Established in 1995 the company celebrates its 30-year anniversary next year. I think we were the second company in Cape Town to acquire a laser machine.”
“A couple of our vertical lathes can accommodate components up to 25 tons with a maximum XY of 2 800mm by 2 000mm. On the horizontal lathe side we can machine up to 6 000mm between centres and swings of 2 000mm (in the gap), 900mm (over the bed) and 700mm (over the saddle). This machine can also accommodate up to 8 tons of metal.”
The third company in the group – Chantex Machining – have just installed a Sino SP1530 high-rigidity heavy cutting double column machining center that was supplied by WD Hearn Machine Tools. This machine can accommodate components XYZ travels of up to 3 100mm by 1650mm by 800mm and a table weight of 7 tons
“The company is a service centre processing sheet and plate but not your normal steel service centre as it is integrated with the other two companies through the Group. A client can therefore get his laser cutting and bending done and also get his machining requirements done while he is in the same complex.”
“We have recently added a DNE fibre laser to this company. The DNE 6kW fibre laser has a bed size of 4 000mm by 2 000mm. We cut up to 16mm stainless steel on this machine and cut most metals on it.”
“We also have two Balliu LD slab lasers that cut our plate requirements up to 20mm, a Trumpf TC600L 3kW combination punching laser cutting machine with Sheetmaster that processes material up to 6mm and five Amada HFB press brakes. All are 7-axis machines and the largest is the Amada HFB 3204 which is a 320 ton machine that has a 4 000mm width. We also have a 170 ton, 130 ton and 100 ton machine with widths of 3 000mm and the smallest machine is the Amada HFB 50-12 that has a 50 ton force and 1 250mm width.”
Chantex Machining also makes use of a couple of Leadwell CNC machines
Owner Riaan Swart with production manager Tom Sterland
“Guillotining is done on our Amada GX that process material up to 8mm thick and 4 000mm wide. Additionally we have a Weber polishing/grinding machine, a Euromac Digibend bracket bending machine, a folding machine and a Boschert corner notching machine.”
“A strong current customer base is found in various industries, including but not restricted to machine building, fabrication, agricultural and wine, architectural, automotive, marine, decorative, signage, shop fitting, mining, rail and offshore engineering.”
“The company has a 25-strong staff complement and stainless steel, mild steel and aluminium is stocked.”
For further details contact Chantex Heavy Machinery on TEL: 021 931 1385 or visit www.chantex.co.za or Servmat on TEL: 021 933 3153 or visit www.servmat.co.za