As the demand for secure and scalable data storage and processing reaches unprecedented heights, Hitech-Gregfor have kept apace.
“When you visited us 10 years ago at our Laser Park factory, Amada had just installed a flexible manufacturing system that includes material storage and handling, a fiber laser, a punch/laser combination machine and a panel bender. It was all to do with productivity and efficiencies for capabilities at the time. Little did we know what it would lead us to,” explained Hitech-Gregfor’s MD Henry Bushney.
“The business has gone from a racking business and diversified into being one that offers a complete data centre integration solution, where you walk into a data centre that is fully populated with cabinets, containment, cable trays, power, cooling, gensets outside and more that is either manufactured by ourselves or we source what is needed. Lithium-ion batteries for example. It’s a full turnkey solution, including civils and mechanical aspects, which makes it a really intense solution that we offer.”
“One of the standouts, which is in keeping with our automation ambitions, is the Amada Ventis 3015 AJ 4kW fiber laser, which has been automated with a ASFH 3015G tower storage system for material storage and material handling. The tower has 10 shelves and can store up to 2 tons of material per shelf. This allows for long, continuous operation with no interruption in loading/unloading of material.”
“Behind it comes our technical team, which includes the design around it, the structural and mechanical engineers to sign off the infrastructure operations, and those that clean site, as well.”
“Clients are different. Some do bricks and mortar and others want a modular setup. Where possible we manufacture everything in-house and then we will put it together, we do all our levels of testing up to 5, depending on the project and client requirements.”
“Because it is manufactured on a modular basis, we can easily dismantle the whole system, wrap it, and then construct it again on-site.”
“That is a very simple description of what we actually do.”
Introduced in 2021 the Brevis 1212 AJ fiber laser provides the versatility of a production-quality laser in a compact design. The Amada Brevis 1212 AJ compact 3kW fiber laser is suitable for high-mix/low-volume production, with a maximum sheet size of 1 250mm by 1 250mm
“Many of the data centre clients that we deal with have been growing their businesses to include data storage solutions that are interconnected with all their facilities. Often these facilities require significant upgrades and improvements to expand their capacity. The enhanced facilities have to meet data centre site requirements with supporting power solutions – all of which have to be configured to fit into a very limited space and accommodate a restricted on-site installation time.”
“Because the modular units are built off site, we then have to manage the complex logistical project of delivering and rigging the weighty units by road, possibly using specialised trucks and air-suspension loading trailers, and then lifting them into place on-site with specially hired large cranes.”
“Apart from the physical requirements, we are expected to offer stability and reliability under all environmental and power supply conditions, in a robust prefabricated structure. We install the latest power distribution and protection technologies to optimise the performance of any installation while keeping personnel and equipment safe. Adequate load handling capabilities are essential, as well as ease of operation and maintenance.”
New Amada press brakes have also been arriving regularly and Hitech-Gregfor now have a bank of Amada HG, HDS, FBD & RG machines. The more recent arrival of a few HRB 1303 press brakes takes Hitech-Gregfor up to 15 Amada press brakes
“The solution that we are expected to offer is total integration into one system with an approach intended to protect the data centre from the repercussions of inconsistent power supply and the ongoing load shedding, or power blackouts, that South Africa has become accustomed to. The turnkey solution usually includes medium voltage switchgear and in many cases Lithium-ion battery combinations.”
“We have our own basic design which is an integrated design with advanced cooling, power, monitoring and security features for our customers. But many of the POP (point of presence) containers are also custom designed. As we have said before the container will include all the electronic equipment needed and the other necessary equipment. It could even include a raised floor to accommodate a water-cooled system which connects directly to integrated cooling within each equipment rack.”
“The modular design of these data centres allows for rapid deployment and scalability. Additionally, the use of modular construction takes into consideration the environmental impact of the data centres, as they can be easily disassembled and relocated if necessary.”
Hitech-Gregfor have recently installed an Amada ENSIS 3015 6kW fiber laser that has been paired with an Amada MPL 3015 C manipulator that incorporates a shuttle table function
“The data centres are equipped with the latest cooling and power management technology, allowing them to operate at maximum efficiency and reduce energy consumption.”
“POP containers are deployed to areas that generally speaking do not have the city infrastructure setup. They act as a fibre distribution centre for anything between 10 000 and 15 000 users. The fibre work, which we have been very successful in, could include trenching or overhead cabling, all of which we do.”
“More often than not there will be a number of these POP containers placed in an area and then they all have to be linked and secure. Some of these container housings are now incorporating solar panels as well. Besides the security aspects, a big influencing factor is that the containers have to be configured to fit into a very limited space and accommodate a restricted on-site installation time.”
“Due to the nature of our business, on-site installation time is generally limited to final assembly and cable connections only.”
“We have also decided to invest in five hand-held laser welding systems from Hugong HGLW and supplied by TRM Supplies because of the potential it offers in our shop environment that we operate in. Manual fiber laser welding will never replace the traditional MIG and TIG welding processes. Each individual unit has its own closed enclosure so there are no safety issues.”
Expansion – new custom built manufacturing facility
“Although we work to a modular format some of our container requirements are large and this was becoming a major headache for us. Our 18 metre long containers were very difficult to manoeuvre at the old factory and we also had limited manufacturing space with no room to expand.”
“When we started the business there were three partners involved – myself, Rogers Naidoo and Hein Vorster, who was CEO at the time.”
“Hein was very influential in making our ‘Lights-Out’ project a reality. He wanted to keep sheets and parts moving with automation. However, he decided to emigrate to Australia in 2020 and Rogers and myself purchased his shareholding and became equal partners.”
“We knew that if we wanted to grow, we had to expand our capabilities and capacity. So in 2023 we found a site in Kya Sands, Gauteng, which we purchased, that only had 1 000m2 of office space on it and we put our plans into action.”
A partial view of Hitech-Gregfor’s 17 000m2 facility
“As we had a greenfield situation, we could custom design our space for manufacturing while at the same time upgrade the office space. We have built a 17 000m2 facility which now also includes a spray booth and shotblasting capabilities. We used to outsource spray painting and shotblasting so you can imagine what the cost of transport to and from the supplier was that we are now saving.”
“At our previous factory the ‘Lights Out’ flexible manufacturing system dominated the factory. It does include the Amada MARS storage system, a centrally located material ‘hub’ that provides storage and distribution of raw materials and blanks on demand. The system includes an automated material handling conveyor and pick-and-place system which consists of 14 vertical sections with each section divided into 12 shelves. Each shelf is capable of holding two tons of material that is stored according to client preference and production. Additionally, it includes the Amada Acies 2515 punch laser combination machine, the Amada EP 2500 AL panel bender and the Amada FOL 3015 AJ fiber laser. Now this flexible manufacturing system, still working on a ‘Lights Out’ basis, takes up a relatively small area of the factory.”
“We also have another 7 000m2 of land to expand into.”
“At our previous factory the ‘Lights Out’ flexible manufacturing system dominated the factory. It does include the Amada MARS storage system, a centrally located material ‘hub’ that provides storage and distribution of raw materials and blanks on demand. The system includes an automated material handling conveyor and pick-and-place system which consists of 14 vertical sections with each section divided into 12 shelves. Each shelf is capable of holding two tons of material that is stored according to client preference and production. Additionally, it includes the Amada Acies 2515 punch laser combination machine, the Amada EP 2500 AL panel bender and the Amada FOL 3015 AJ fiber laser. Now this flexible manufacturing system, still working on a ‘Lights Out’ basis, takes up a relatively small area of the factory.”
“As it is a recent build, we have been able to maximise and incorporate all the latest technologies that are currently available to run a manufacturing plant of this size. For example, we have 5 000 solar panels on the roof which gives us 1 megawatt of energy that is divided into two 500kVA phases to give us maximum performance and savings.”
New Amada equipment
“With all the space that is now available to us we have been able to streamline and maximise production time and add new equipment and we have purchased a number of systems, lasers and press brakes from Amada since we moved in.”
“One of the standouts, which is in keeping with our automation ambitions, is the Amada Ventis 3015 AJ 4kW fiber laser, which has been automated with a ASFH 3015G tower storage system for material storage and material handling. The tower has 10 shelves and can store up to 2 tons of material per shelf. This allows for long, continuous operation with no interruption in loading/unloading of material.”
“We have also installed an Amada ENSIS 3015 6kW fiber laser that has been paired with an Amada MPL 3015 C manipulator that incorporates a shuttle table function. The combination of the two machines provides a flexible automation solution that reduces unnecessary machine downtime due to manual material loading.”
Joint owners Henry Bushney and Rogers Naidoo
Press brakes
“New Amada press brakes have also been arriving regularly and we now have a bank of Amada HG, HDS, FBD & RG machines. The more recent arrival of a few HRB 1303 press brakes takes us up to 15 Amada press brakes that we have working for us.”
“We have kept buying the same model machines because of what we are processing and for operator friendliness.”
Amada Brevis 1212 AJ compact fiber laser cutting machine
“The Amada Brevis 1212 AJ compact 3kW fiber laser is loaded with a diverse range of machine features to support high-speed processing, easy material loading, with a footprint and capacity to efficiently accommodate small cell manufacturing.”
“Only introduced in 2021 the Brevis 1212 AJ fiber laser provides the versatility of a production-quality laser in a compact design. It features reliable, high-speed laser cutting, simple material loading, and an optional rotary index to process 3D material such as tube or pipe. Engineered for manufacturing flexibility, the machine is suitable for high-mix/low-volume production, with a maximum sheet size of 1 250mm by 1 250mm.”
“The machine gives us a bit more flexibility with cutting smaller components.”
Hitech-Gregfor has gone from a racking business and diversified into being one that offers a complete data centre integration solution, where you walk into a data centre that is fully populated with cabinets, containment, cable trays, power, cooling and gensets outside
New direction – investment in 5 Hugong HGLW hand-held laser welding systems
“We have also decided to invest in five hand-held laser welding systems from Hugong HGLW and supplied by TRM Supplies because of the potential it offers in our shop environment that we operate in. Manual fiber laser welding will never replace the traditional MIG and TIG welding processes.”
“As we bring more and more processing operations in-house you have to look at new services to make you more productive and produce more. On the sheet side we are now processing 100% of our requirements. Combine this with the fact that we have broadened our product base, in keeping with this trend we have added more manufacturing services.”
“We now have five units. Each individual unit has its own closed enclosure so there are no safety issues.”
“Handheld fiber lasers, commonly used for welding, cutting, and cleaning, are Class 4 laser devices, which are the most hazardous type and can cause immediate, irreversible damage to eyes and skin. Because these devices are portable and often used in open workshops rather than enclosed cabinets, they present significant safety risks.”
“All this capacity growth has also seen our staff numbers spike. We now have 235 staff as compared to 110 at the previous facility. Another positive for us.”
Hitech-Gregfor’s new facility in Kya Sands, Gauteng
About
Hitech-Gregfor focuses on the provision of data centre infrastructure, communication cabling and managed services. Since opening its doors in 1992, Hitech Gregfor’s offerings have evolved and grown beyond the initial production of manufacturing steel products, such as 19 inch enclosures used to house server equipment, UPS battery enclosures and small electronic enclosures. Today the company offers aisle containment solutions, enviro rack solutions (computer room in a rack), data centre infrastructure, auditing of current infrastructure, precision cooling and power management, integrated security incorporating camera monitoring and access control, environmental monitoring and preventative maintenance, modular containerised data centres, communication cabling – auditing of current infrastructure, installation of new environments, incorporating structured copper and fiber solutions and the maintenance thereof, managed services and preventative maintenance.
For further details contact Hitech-Gregfor on TEL: 011 794 1724 or visit www.hitech-gregfor.co.za
