South African Bulk Terminals (SABT), a BidFreight business unit, recently installed a 140 m opposing energy chain system from igus to better manage the cables that support the operation of two of its large ship loaders.
Carrying an 11 kV power supply as well as control and fibre optic cables, the new cable management system is proving its worth by significantly boosting productivity and availability of the loader, ultimately providing a safer work environment for workers on the machine. Made of specially developed igus polymers, the energy chains are strong with the ability to withstand millions of bend cycles while carrying and protecting the cables with little need for further maintenance or servicing. The design and layout of the energy chain system also prevents accidental damage to the critical cable, and its no-lubrication requirement eliminates the risk of contamination of the bulk foodstuffs loaded and offloaded from ships every day.
According to SABT’s Houzair Dawood, the opposing energy chain configuration ensures smooth, controlled travel over the full 140 m length. Energy chains are like moving conduits and instead of dragging across walkways as the old system did, the cables are protected, guided and supported throughout the ship loader’s travel path. “The system eliminates manual handling and significantly reduces wear on expensive power and data cables,” says Houzair.
He adds that the change has been transformative for SABT’s shipping department. “Previously, two workers were needed: one to open the covers and ensure the potentially dangerous high-tension cable could pass through freely, and another stationed on the ground floor to operate the machine using separate control cables. It was a legacy system that was no longer efficient or as safe as it should have been. By contrast our new energy chains are trouble free, ensure ease of operation and does not require any additional effort in terms of moving the cables.”
Using energy chains instead of cable reels or simple drag chains has improved functionality and monitoring capabilities, making it possible to add sensitive fibre optic and control cables. These cables support CCTV cameras, enabling immediate control and rapid response to events observed in real time. The cameras also provide visual checks, confirmation, and a record of loading events.
According to Houzair, this has translated to measurable operational gains. Faster repositioning of ship loaders translates directly into improved vessel turnaround times.“The system is significantly more efficient and productive, allowing us to deliver better service to clients and reduce ship turnaround times.”
igus technical sales consultant, Vishay Sudamma explaines: “SABT previously operated with an 11 kV cable dragging across a walkway, creating an arrangement that was both cumbersome and potentially hazardous. This led to discussions around replacing the system with a safer, more reliable solution from igus. SABT was already familiar with the company’s technology, having installed an energy chain system on another machine in 2018. That installation had performed reliably for several years with minimal maintenance, making igus a natural choice for the new application.”
To find the right system, igus collaborated with the team to understand their requirements, expectations and operating parameters. “For this application, the design incorporated our reliable 4040CR series e-chain, one of the longest opposing systems of its kind globally. The roller links enable reduced pulling/pushing forces, while increasing the operating life of the e-chain system. It was designed to manage the cables in a controlled system, with the ability to add cables and other infrastructure as needed.”
igus managing director, Ian Hewat explains that after the energy chains were commissioned the impact was immediate. “Previously, if you wanted to start the machine, you had to get people on various posts to oversee the cable. Now, you put on the siren, press Go, and within 30 seconds, the machine is operational.”
Hewat says that the project shows the ability of engineered cable management solutions in heavy industrial environments. What was once a persistent operational challenge has become a global benchmark, with long cable runs safeguarded by opposing energy chain systems that protect critical power and data infrastructure while improving safety and productivity.
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| www: | www.igus.co.za |
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