Energy chains transform Durban ship loader productivity South African Bulk Terminals (SABT), a business unit of BidFreight, has installed a 140 m opposing energy chain system from igus to improve the management of cables used in operating two of its massive ship loaders.
C arrying an 11 kV power supply, as well as control and fibre-optic cables, the new cable management system at SABT is proving its worth by sig- nificantly boosting the loader's productivity and availability and providing a safer work environ- ment for workers on the machine. Made of specially developed igus polymers, the energy chains are strong and can with- stand millions of bending cycles while carrying and protecting cables with minimal need for maintenance or servicing. The design and lay- out 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 for energy and data carriers; instead of drag- ging cables across walkways as the old system did, the cables are protected, guided and sup- ported 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 trans- formative for SABT's shipping department. “Previously, we needed two workers, with one person required to open covers and ensure free passage of the potentially dangerous high-ten- sion cable, while the other stood at the bottom floor using separate control cables to operate the machine. 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 and ensure ease of operation that does not require any further thought or effort in terms of moving the cables.” The use of energy chains in place of cable reels or simple drag chains has also improved functionality and monitoring, enabling the ad- dition of sensitive fibre-optic and control cables for CCTV cameras, enabling immediate control and response to events observed on the cam- eras. The cameras also provide visual checks, confirmation and record-keeping of loading volumes. This has translated into measurable op- erational gains according to Houzair. Faster Houzair Dawood and King Banda, operations and engineering leaders for South African Bulk Terminals (SABT) at the Port of Durban.
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 commis- sioned 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 or so, the machine is operational.” He says the project demonstrates the capabilities of engineered cable management solutions in heavy industrial environments, such as demanding port environments. What was once an ongoing operational headache has become a global benchmark, with long cable runs protected by opposing Energy Chain systems that prevent damage to critical power and data infrastructure while enhanc- ing both safety and productivity. https://www.igus.co.za/
repositioning of ship loaders translates directly into improved vessel turnaround times. “It’s a lot more efficient and more productive, which means we can offer our clients a more efficient service and quicker ship turnaround times.” According to igus technical sales consultant Vishay Sudamma, SABT had an 11 kV cable that had to be dragged onto a walkway. It was unwieldy and potentially dangerous, and plans were discussed to replace it with igus’ safe, trouble-free system. SABT was already familiar with igus technology, having success- fully implemented an energy chain system on another machine in 2018. This has operated reliably for years without requiring constant maintenance and was therefore viewed as a potential solution. To find the right system, igus collaborated with the team to understand their require- ments, expectations and operating parameters. “So, for this application, the design incorporated our very reliable 4040CR series e-chain, for what is one of the longest opposing systems of its kind globally. The roller links reduce pulling/
igus technical sales consultant, Vishay Sudamma, points to a section of the 140 m opposing energy chain system installed at the Port of Durban.
16 ¦ MechChem Africa • July-August 2026
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