Mission-critical security component manufacturer TruSeal, based in Krugersdorp, Gauteng has been active in the security products sector since 1974. The company manufactures and distributes a wide range of security seals and tamper-evident bags used across the transport, logistics, retail and cash-handling industries.

With a focus on supplying the local market, TruSeal is a South African manufacturer with international standards capable of meeting the demands of chain-of-custody operations, where verification of integrity is paramount.

Grant and Brent Cramer became owners of the business in 2009 and have run the business hands on since, running all aspects from operations to sales.

TruSeal is a top South African manufacturer and supplier of premium tamper-evident security seals and bags

Says Brent Cramer: “During this time we have developed patented security technologies for the top cash-in-transit, security, retail and banking companies to protect their assets against theft, pilferage and contamination.”

“We also realised that we need to be in a position where if a customer requests a specialised type of lock or pin that we are then able to go to our workshop and cut, bend or weld it ourselves.”

“Our aim with these latest developments in respect of the various machining purchases is to bring all the manufacturing of the different metal security components we use to make our PVC tamper-evident bags in-house into our Johannesburg factory, so that we can control the quality, reduce costs and rapidly prototype and develop new security products so we don’t keep our clients waiting.”

TruSeal recently installed a 6kW Bodor fiber CNC laser cutter with a 2.5m x 1.5m bed, supplied by Spectrum Machine Tools Africa

“We used to import many of our bag components but when Covid came along and the associated shipping issues arose, we realised that we needed to start doing a lot of our own component manufacturing in house.”

“We work with around 20 to 30 different base products that then get further customised as per customer requirements – and this can be anything from colour to size and breaking strength variations – so the number of different combinations can run into the 100s.”

“We will always keep a large quantity of stock on hand in our warehouse which puts us in a position so that if a client requires a product urgently, they can place the order in the morning and we can have the product out for delivery that afternoon. Custom-made bags and personalized laser-printed seal orders are quoted based on lead time,” explains Grant Cramer.

“As these are mission critical products, we need to closely control quality and stock holding to make sure our clients are getting consistently good quality when they need it. Bad quality products or products out of stock can lead to large financial losses and even death in some cases for our clients,” continues Brent Cramer.

Components cut on TruSeal’s new 6kW Bodor fiber CNC laser cutter – the purchase was made to control components they make from beginning to end and to also be able to speed up the time it takes to prototype and test new products. Soon to arrive is a Durma AD-S 30135 4-AXIS bending brake with 3m bending width and 135 ton bending force

“For imported products we plan very far in advance so if there are any disruptions in the supply chain, our clients don’t feel it. Things like delays, harbour issues, wars, closed shipping lanes and so on shouldn’t be the client’s problem, so we work hard to alleviate this.”

In-house machine shop growth
“The reason for now opening the sheet metal section with the 6kW Bodor fiber CNC laser cutter with a 2.5m x 1.5m bed and the Durma AD-S 30135 4-AXIS bending brake with 3m bending width and 135 ton bending force, is to be able to control all the components we make from beginning to end and to also be able to speed up the time it takes to prototype and test new products when our clients pick up a problem and need a new security solution fast. Both of these machines were supplied by Spectrum Machine Tools Africa. We know our components and the software you get with these machines these days makes adopting the technology and putting it to use much easier.”

“We will also use these new machines to manufacture our latest patented security solution launching this year to deal with the massive problem of coal and raw material theft from tipper trucks during transit. Clients lose millions each day due to theft and pilferage when transporting coal and precious raw materials and we are looking to put a halt to that.”

Large rolls of PVC bag material are cut with TruSeal’s state-of-the-art Zünd G3 L-2500 digital CNC cutter. The Swiss-made machine features a table length of 2 500mm and a width of 1 800mm, accommodating a variety of material thicknesses

“Our aim is to grow and develop our offering throughout South Africa and Africa as we are committed to our clients and to the country and to fighting back against the theft and disruptions that are terrorising businesses on a day-to-day basis in South Africa.”

TruSeal’s catalogue of products is extensive and plastic seals form a large part of its production output. Within this segment, TruSeal manufactures the FX seal and the TL seal as standard models. The THL seal is supplied in both a regular form and in a tear-away version. The TH series extends this range further, supported by the TX variant. Its LR line is offered in three lengths – short, long and extra-long – covering different applications. The Pitbull seal is specifically made for fire doors and cargo applications, while the TM seal is part of the general-purpose line. Collectively, the plastic seal category covers more than 40 product configurations in varying sizes and locking strengths.

Alongside plastic seals, TruSeal also supplies barrier seals. This range includes bolt seals and cable seals that are used to secure shipping containers, trucks and other transport equipment, each designed to meet international cargo-security requirements.

TruSeal have also invested in a Chen Hsong JM200-MK6e moulding machine to manufacture a variety of its plastic seals

The metal seal product range contains the Dominator seal, the ACME Metal T seal and the TruGuard seal. These are suited for industries requiring a metallic closure with higher resilience than plastic alternatives. Each type is supplied with variations in length and design depending on use case.

Padlock seals form another important product category. These seals incorporate locking mechanisms designed for single-use applications where padlock functionality must be combined with tamper evidence.

Meter seals form another line item and these seals are widely applied in utilities where electricity, gas or water meters need to be secured against interference.

The company also continues to supply lead seals, a long-standing technology. The lead seal product line includes the seals themselves, the associated sealing wire, and the sealing pliers required to apply them. These products remain relevant in specific industries where traditional lead sealing is still used.

For larger vehicles and freight protection, TruSeal supplies a tautliner seal. This is designed for truck curtainsider applications, providing evidence of access to the load area. TruSeal has a Bambu Lab 3D printer and are currently carrying out research and development into patented designs specifically for these types of products.

TruSeal’s catalogue of products is extensive and plastic seals form a large part of its production output

Another substantial division of the business is dedicated to security bags. TruSeal manufactures and sells a large range of different re-usable security bag types. These include clear casino bags, barcode-sealed bags, padlocked bags, custom-made bags, rifle and handgun bags, bulk bags, tamper-evident bags and security labels. Padlock bags and gun bags are produced in sizes that support cash-in-transit and security service needs. Tamper-evident bags are available in numerous different variants, covering both cash handling and document protection. Clip seal and wire can also be used to seal bags adding further choice within this segment.

In addition to its bag and seal portfolio, TruSeal supplies security pouches, key bags, cash bags and envelopes. Heavy-duty bulk cash bags form part of the company’s supply to the cash-in-transit sector, while other bags serve retail and banking requirements.

High-volume injection moulding
TruSeal has invested in Borche and Chen Hsong JM200-MK6e moulding machines to manufacture a variety of its plastic seals. The machines feature a high-speed servo-hydraulic toggle-range injection moulding line known for efficiency, precision and energy savings with a clamping force of 200 tons. They have a relatively small shop floor footprint and are designed for rapid clamp movements, injection, and ejection. The machines are ideal for high-throughput production and also feature user-friendly PLCs.

Another substantial division of the business is dedicated to security bags. TruSeal manufactures and sells a large range of different re-usable security bag types

Large rolls of PVC bag material are cut with TruSeal’s state-of-the-art Zünd G3 L-2500 digital CNC cutter. The Swiss-made machine features a table length of 2 500mm and a width of 1 800mm, accommodating a variety of material thicknesses. Its modular design enables easy switching between blades and its PLC and integrated software provide a material database and job queue management. It also features interchangeable tooling options for working with a range of different materials.

TruSeal’s model allows it to provide standardised, high-volume items while also meeting requests for customised solutions. All its products are designed for a defined sealing requirement rather than as a general-purpose solution.

TruSeal’s longstanding presence in the South African market has made it a central supplier in its niche and the company’s focus remains on reliability in supply and breadth in offering, rather than limiting itself to one category of product.

For further details contact TruSeal on TEL: +27 11 762 1040 or visit www.truseal.co.za