The installation of this state-of-the-art machinery is a cornerstone of Siyaka’s newly launched production facility at Dube TradePort in Durban. This investment is more than a routine upgrade; it’s a statement of intent. Siyaka has spent over a decade cultivating strategic partnerships with industry giants BOBST and COMEXI, leveraging their printing and converting technologies to enhance its production capabilities.

The new additions at Siyaka’s Dube TradePort facility cement the company’s commitment to cutting-edge automation, sustainability and connectivity – three pillars it sees as non-negotiable in the evolving packaging landscape.

Jessica Busa, head of special projects at Siyaka, believes this move is both timely and necessary. ‘We’re not just keeping up with industry trends – we’re setting them,’ she asserts. ‘Brands today demand packaging that is not only aesthetically striking but also sustainable and efficiently produced. Our latest investments help us deliver on all fronts.’

The BOBST rotogravure press is a powerhouse in its own right. Renowned for its precision, efficiency and ability to handle an array of flexible materials, it offers Siyaka an edge in delivering high-quality packaging with reduced set-up times and minimal waste. ‘With the market shifting towards environmentally responsible materials, this press gives us the agility to experiment with and perfect sustainable substrates,’ Jessica explains. ‘The demand for eco-friendly packaging is no longer a niche concern – it’s a necessity.’

Equally impressive is the COMEXI dual laminator, which integrates advanced coating and laminating technologies that enhance durability while ensuring superior print integrity. ‘For us, packaging is more than a container – it’s a conversation between brands and consumers,’ she adds. ‘With these machines, we’re able to craft that dialogue with greater clarity, vibrancy and responsibility.’

Backbone of operational excellence

Siyaka’s investments are about cultivating a future-ready approach. The Dube TradePort plant, where these machines are housed, represents a blueprint for modern manufacturing. More than just a production hub, it is a think tank for packaging innovation, where automation meets human ingenuity. The facility’s strategic location within the Dube TradePort Special Economic Zone allows Siyaka to streamline logistics, enhance supply chain efficiencies and ensure that its products reach customers across southern Africa with speed and reliability.

To support this next-level production capacity, Siyaka has meticulously designed its plant and machinery infrastructure to maximise efficiency, sustainability and reliability.

At the core of the facility’s engineering excellence is its dual pneumatic system. Equipped with the latest specifications of variable speed drive (VSD) compressor units, Siyaka’s setup ensures that air feed is adjusted based on operational demand, significantly improving energy efficiency.

‘VSD units require a larger initial investment, but the long-term benefits in terms of cost savings and sustainability make them the clear choice,’ Jessica explains. The dual pneumatic system features a ring main, allowing for immediate backup capabilities, better temperature control and an extended lifespan of the utility infrastructure.
Siyaka’s investment into a high-spec thermic oil and boiler system underscores its forward-thinking approach to industrial efficiencies. Featuring state-of-the-art thermic oil pumps across the feed and return lines, the system supports a production environment that incorporates world-class printing and laminating equipment.

Engineered with planned expansions in mind, the facility exceeds industry standards by integrating thermic oil utilities that ensure optimal performance and operational continuity. ‘This is about more than just efficiency – it’s about long-term sustainability and creating a plant that aligns with global best practices in manufacturing,’ Jessica notes. The ergonomic and aesthetic finesse of the facility also reflects Siyaka’s dedication to both form and function.

Another critical investment is Siyaka’s dual chiller system, which incorporates the latest automation technology to optimise cooling efficiency. ‘These chillers operate using real-time data analysis, which allows for predictive maintenance and early detection of potential issues,’ Jessica explains. With built-in tracking and diagnostic capabilities, the system minimises downtime and maintenance costs, ensuring uninterrupted production.

The environmentally sustainable design of the chiller system also aligns with Siyaka’s broader corporate responsibility goals. ‘Operational excellence can’t come at the cost of sustainability. Our chiller system ensures that we maintain peak efficiency while reducing our carbon footprint,’ she adds.

Future-forward manufacturing

Siyaka’s philosophy is rooted in evolution, and that evolution is powered by an unrelenting focus on customer needs. ‘The market is shifting rapidly, and the companies that survive will be those that anticipate change, not just react to it,’ Jessica notes. ‘By integrating smart technology, AI-driven quality control and sustainable practices, we’re ensuring that our customers remain ahead of the curve.’

The company’s commitment to progress extends beyond its production lines. Siyaka’s emphasis on skills development and technical training has fostered a highly competent team capable of optimising these sophisticated machines to their full potential. A dedicated staff complement of trained technicians ensures that customers receive seamless after-sales service, reinforcing Siyaka’s reputation for reliability.

‘Our approach has always been holistic,’ Jessica states. With an unwavering commitment to quality, innovation and customer-centricity, Siyaka is setting new industry benchmarks. Its latest technological advancements position it not just as a supplier, but as a partner in progress for brands looking to push their packaging potential to new heights.

As the industry continues its rapid transformation, one thing is certain – Siyaka is not merely keeping pace, it’s defining the tempo. ‘We’re in an era where packaging needs to be smarter, greener and more efficient,’ she reflects. ‘And at Siyaka, we’re making sure that future is now.’

Beswick boosts Siyaka’s efficiency with BOBST and Atlas Slitters

Siyaka has taken a bold step forward with the installation of a BOBST rotogravure press – courtesy of Beswick Machinery – marking a milestone in its commitment to efficiency and high-quality flexible packaging.

According to Riaan Hopley, Beswick Machinery’s web-fed and flexibles product specialist, the final commissioning and training for the BOBST machine was completed during October last year.

‘This rotogravure press is designed for sustainable production with maximum uptime and ease of operation,’ Riaan explains. One of its standout features is TAPS (Total Automatic Pre-register Setting), a patented one-touch system that ensures full registration in just four minutes with minimal material waste. The BOBST Registron system delivers high-speed, high-accuracy printing with exceptional efficiency, while the MPI (Multi-Purpose Inking System) allows for a wide range of inks and solvent blends, offering easy cleaning and quick maintenance with lower ink waste. The Twin Flow Technology Dryers further enhance efficiency by 30%, ensuring uniform drying, reduced energy consumption and minimal ink skin effect.

To further elevate its operations, Siyaka also added two Atlas slitting machines, which were fully commissioned and operational by July 2024. ‘The new slitters offer Siyaka utmost flexibility in terms of applications and substrates, along with efficiency and ease of operation – all in a very compact package,’ Riaan notes. ‘The fully electric operation eliminates any risk of hydraulic oil contamination in the slit reels, and thanks to a robust yet sensitive tension control system, coupled with the in-house designed and manufactured “ball lock” rewind shafts from the Jagenberg Group, the finished slit reels from these machines are of unparalleled quality.’

Riaan applauds Siyaka for investing in state-of-the-art BOBST and Atlas equipment, emphasising that these additions will enhance its printing and converting capabilities with unmatched precision, efficiency and reliability. ‘With its advanced technology and minimal waste, this press is poised to be a game-changer for Siyaka’s operations,’ he adds.

Bruce Beswick of Beswick Machinery extends his appreciation, stating: ‘We sincerely thank Siyaka for their valued and continued support and wish them every success. We also commend them for these strategic investments, which we know will serve both them and their customers superbly for many years to come.’

COMEXI EVOLUTION: Siyaka’s laminating powerhouse

Siyaka’s latest investment in flexible packaging technology has been further bolstered by the addition of the COMEXI EVOLUTION laminator. A key part of the company’s ongoing expansion strategy, this state-of-the-art machine is set to elevate production efficiency, versatility and sustainability.

Juan Manuel Miranda, COMEXI’s area manager for Africa, underscores the significance of this partnership: ‘Siyaka and COMEXI share an 11-year history of collaboration and we are honoured that they have once again placed their trust in us. The EVOLUTION is a cutting-edge laminating machine that adapts to evolving production demands, making it a perfect fit for Siyaka’s dynamic growth.’

The EVOLUTION is engineered to provide exceptional flexibility, allowing Siyaka to integrate a range of lamination and coating technologies in response to market needs. ‘This machine starts as a standard laminator but can be upgraded to incorporate solventless, solvent-based, water-based, cold-seal and heat-seal laminations,’ Juan explains. ‘It can also perform triplex lamination in a single pass and apply coatings to diverse materials such as paper, aluminium and plastic – giving Siyaka an unparalleled competitive edge.’

One of the standout features of the EVOLUTION is its AI-driven efficiency and user-friendly design. ‘We’ve built this machine to maximise productivity while minimising downtime,’ Juan continues. ‘The latest-generation automation ensures fast changeovers and seamless cleaning through a trolley exchange system, streamlining operations and boosting overall efficiency.’

COMEXI, a leader in the flexible packaging industry with over 70 years of innovation, is confident that the new installation will drive Siyaka’s success. ‘This investment will significantly enhance Siyaka’s application portfolio, reduce waste, lower energy consumption and improve turnaround times,’ Juan affirms. ‘With over 4 500 COMEXI installations worldwide, we know that our technology is a game-changer for converters looking to future-proof their operations.’