SATI Beyond The Bunch 3rd Quarter 2025

SATI Research Booklet

Quarter 3

BEYOND

2 0 2 5

FOCUS ON: Packaging

LUCENTLANDS

CLAYTON SWART

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www.servatec.co.za

Tel: 021 5

BEYOND

A SATI PUBLICATION

About Beyond the Bunch This quarterly publication aims to serve as a science-based resource for the South African table grape industry. Each edition explores a topic or questions raised by industry, with links to related additional reading. Submit your topic or questions Producers and industry stakeholders are encouraged to suggest scientific or technical questions or topics of interest. We will strive to address as many of these as possible.

Email tarryn@satgi.co.za to submit your request.

Content Disclaimer SATI does not take responsibility for

accuracy or validity of information supplied by advertisers. Views expressed are those of the partner and may not reflect our organisation’s views. Contact denene@satgi.co.za to feature your brand.

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518 1156

email: info@servatec.co.za

THE PHYSICS OF PACKAGING Packaging profoundly impacts table-grape quality. Delivering the best possible product to market requires an understanding of the relevant principles and practices.

BY ANNA MOUTON

DEWALD KIRSTEN | LUCENTLANDS

BEYOND THE BUNCH • 4 • QUARTER 3 • 2025

Maintaining table-grape quality after harvest rests on three practices: lowering temperature to slow respiration and senescence, controlling humidity to reduce dehydration, and applying SO 2 to prevent decay. Packaging can help or hinder these processes – figuring out how starts with a grasp of the relationship between temperature and humidity.

Temperature and humidity

Vapour pressure deficit Water vapour pressure is the pressure exerted by the water molecules in water vapour. Vapour pressure in air reaches its maximum when the air is saturated with water vapour. The difference between the maximum possible vapour pressure in saturated air and the actual vapour pressure is the vapour pressure deficit. Water vapour tends to move from areas of higher vapour pres sure to areas of lower vapour pressure. The intercellular spaces in berries and stems have a high vapour pressure because they are saturated with water vapour, while the air outside the fruit is almost always unsaturated. This difference drives water loss from bunches. Warm bunches lose water faster than cold bunches because the vapour pressure of water increases with temperature. For example, the vapour pressure of water at 35 °C is more than nine times greater than that of water at 0 °C. When hot fruit is first put into a cold room, the bunches lose water rapidly because a) the fruit has a higher temperature than the room and b) the air inside the fruit is saturated, but the cold-room air isn’t. Reducing the temperature difference as fast as possible helps limit water loss. However, bunches will continue slowly losing water even after reaching cold-room temperatures because the plant tissues are saturated, and the cold-room air isn’t. The lower the rel ative humidity in the cold room, the more water the bunches will lose. Continuous cooling during transport is necessary not only be cause shipping containers are imperfectly insulated but also to remove the heat generated by the living and respiring fruit.

Absolute humidity is the amount of water vapour in grams of water per mass or volume of air. Warm air holds more water vapour than cold air, so absolute humidity is usually interpret ed with the aid of charts or calcula tors that account for temperature. Relative humidity is more useful be cause it expresses the amount of water vapour as a percentage of the amount in saturated air at a given temperature. Air is saturated when it contains the maximum possible water vapour. For example, at sea level, a cubic metre of cold-room air at 0 °C can hold about 5 grams of water vapour, whereas a cube of pack-house air at 25 °C can hold about 24 grams of water vapour. The practical implication is that cool ing reduces the water-holding ca pacity of air. Excess water vapour will condense into droplets on surfaces or suspended in air. This is why con densation forms on cold grapes when they’re brought into a warm room on a humid day.

Forced-air cooling Table grapes experience the largest vapour pressure deficits during forced-air cooling because a) they are at their warmest relative to the cooling air and b) the high air velocity strips the boundary layer from the bunches. To minimise moisture loss, the vapour pressure deficit must be reduced as fast as possible by rapid cooling and humidifying the cooling air.

BEYOND THE BUNCH • 5 • QUARTER 3 • 2025

Ventilation

ADOBE STOCK

Where does SO 2 fit in? SO 2 is highly effective at preventing postharvest decay when it’s present at the correct concentrations. Too little SO 2 won’t control decay organisms, and too much can damage fruit. Although other SO 2 -release systems exist, this discussion will focus on SO 2 sheets designed to be placed inside liners. The sheets generate SO 2 from the reaction of sodium metabisulfite with water. Different sheets have different SO 2 -release profiles, but all are subject to similar consider ations regarding temperature, humidity, and ventilation. The direct effect of ventilation is obvious – increased air circulation reduces SO 2 concentrations, sometimes to levels below the effective threshold. The indirect effect of more ventilation is to lower humidity. Lower humidity re Ventilation – air movement – is central to packaging performance because it’s pivotal to temperature and humidity levels. The relationship between these factors explains a familiar packaging conundrum: trying to balance rapid cooling with optimal humidity. Let’s start with temperature. Fruit can be cooled by conduction or convection. Conduction involves the direct transfer of heat from a warmer object to a cool er object or environment. For example, grapes inside a non-perforated liner cool by conduction. With convection, a cold gas or liquid flows around a warm object, carrying the heat away. For example, perforated packaging can allow cold-room air to cool grapes through convection. Convection generally cools fruit more efficiently than conduction, so venti lation is a crucial consideration in packaging design. Unfortunately, moving air doesn’t only carry heat away. It also removes the layer of moisture around the berries and stems. In still air, the moisture lost by the fruit will be concentrated in the boundary layer – the air immediately adjacent to the bunch. The boundary layer reduces the vapour pressure deficit and slows moisture loss. Convection strips away the boundary layer and maintains a high vapour pressure deficit, which keeps pulling water from the grapes. On the other hand, less air movement increases the relative humidity around bunches. This increases the risk of condensation asso ciated with cold-chain breaks. Cold-chain breaks cause the grapes to lose more water because warmer air has a higher water-holding capacity than cooler air. Once cold temperatures are re-established, the cooler air can no longer hold the extra water, which condenses onto the packaging and the bunches.

Poor ventilation increases the risk of condensation on the grapes.

duces SO 2 release by sheets but also inhibits decay-caus ing organisms. In contrast, less ventilation allows SO 2 accumulation. Less ventilation also promotes higher humidity and increases SO 2 release, further raising SO 2 levels inside the liner. Ex cessive humidity or, even worse, free water can trigger SO 2 spikes, leading to phytotoxicity. SO 2 is attracted to water and can dissolve in condensation on bunches, causing unsightly bleaching of berries. Less ventilation can also result in higher temperatures. Higher temperatures accelerate SO 2 release by sheets, as well as potentially increasing fruit sensitivity to SO 2 dam age. Faster SO 2 release can also prematurely deplete the sheets, leaving the fruit unprotected.

BEYOND THE BUNCH • 6 • QUARTER 3 • 2025

PACKAGING UNPACKED Table-grape packaging is a system in which all the components must work together to maintain quality and prevent decay.

BY ANNA MOUTON

From inside to outside, table-grape packaging can include a bunch carrier, a SO 2 sheet, a moisture-absorbing sheet, a shock-absorbing sheet, a liner, and a carton. The performance of each component will affect the overall success of the system. The influence of packaging on ventilation is critical. Too little ventilation increases the risk of SO 2 damage and excessive humidity. The latter contributes to berry split and decay, especially if cold-chain breaks cause condensation. Too much ventilation increases dehydration, leading to mass loss, berry drop, and stem browning, and lowers SO 2 levels, reducing decay control.

DEWALD KIRSTEN | LUCENTLANDS

BEYOND THE BUNCH • 7 • QUARTER 3 • 2025

Bunch carriers Pre-packaging grapes in bunch carriers is con venient for retailers and consumers. However, bunch carriers can impede airflow, especially if their perforated area – the total area of the perforations as a percentage of the total liner area – is too small or stickers or labels cover the perforations. If the bunch carrier is poorly ventilated, the SO 2 reaching the bunch may be insufficient to con trol decay. Inadequate airflow will also hinder cooling and increase humidity, elevating the risk of condensation during cold-chain breaks. Dr Mduduzi Ngcobo’s doctoral research found significantly faster cooling of bunches in open top or clamshell punnets compared with carry bags. He speculated that the soft carry bags deform, allowing the liner to collapse and cold air to channel between the liner and the carton, rather than move through the liner perforations. The rigid punnets, on the other hand, press the liner against the carton sides, creating less op

SATI

The bunch It’s worth remembering that berries and stems are packaged naturally – they are covered in epidermis and a cuticle. These outer layers limit water loss and repulse invading pathogens. Differences in skin and cuticle char acteristics impact the optimal choice of man-made packaging for each cultivar. Berries lose water more slowly than stems because berries have a less water-permeable surface and a smaller surface-to-volume ratio. Therefore, cultivars with relatively more stem area or more exposed stems – looser bunches – will be more sensitive to moisture loss. Unfortunate ly, their stems are also more visible, so any desiccation or browning is easier to spot.

portunity for cold air to bypass the liner. Although table grapes in punnets were better ventilated, they didn’t lose significantly more mass than those in carry bags during a 35-day storage period. However, bunches in punnets did have more stem de hydration, especially in the open-top punnets. It should be noted that Ngcobo didn’t use forced-air cooling in his trials. Forced-air cooling would likely have improved ventilation and cooling rates of the carry bags. The perforated area of liners was also smaller than current industry standards – more on this below. An industry-funded project led by Dawie Moelich investigated the rela tionship between vents in punnet lids and the development of decay. The results confirmed that poor ventilation of the punnet led to insuffi cient SO 2 levels and increased decay. Moelich demonstrated that a minimum total lid vent area of 15 cm 2 for 500 g punnets and 7.5 cm 2 for 250 g punnets reduced decay during cold storage. Vents are less effective when confined to the edges of the punnet lids. SO 2 is about twice as heavy as air, so it tends to sink rather than move sideways. Therefore, vents in the top of punnet lids improve SO 2 penetration.

Sheets Moisture- and shock-absorbing sheets and SO 2 sheets can reduce ventilation, especially if they block perfora tions or holes in other packaging components. However, the SO 2 sheet should be large enough to distribute SO 2 evenly over all the bunches. Moisture- and shock-absorbing sheets also lower humidity and can reduce SO 2 levels. When placed above the SO 2 sheet, the moisture-absorbing sheet will have a greater effect on moisture. When placed below the SO 2 sheet, it will have a greater effect on SO 2 levels.

BEYOND THE BUNCH • 8 • QUARTER 3 • 2025

Liners

Liners are essential to curtail moisture loss from bunches. However, unperfo rated liners slow cooling and increase humidity, predisposing the grapes to all the problems already discussed. For example, Stefan du Plessis’ mas ter’s research showed that an unper forated liner reduced stem browning but increased SO 2 damage in Red Globe. The unperforated liner also increased berry split and promoted decay in Thompson Seedless. The solution is perforating liners so that they restrict but don’t prevent venti lation. The optimal perforated area differs from cultivar to cultivar. Ngcobo measured the ventilation in cartons with unperforated, microper forated, and perforated liners. He in cluded three perforated liners: 54 x 2 mm, 36 x 4 mm and 120 x 2 mm. The liners contained Regal Seedless grapes in carry bags, shock-absorbing sheets, moisture-absorbing sheets, and SO 2 -re lease systems. Cooling rates were similar for unper forated and microperforated liners, probably because Ngcobo didn’t include forced-air cooling, limiting airflow through the microperforations. He also didn’t see a significant dif ference in cooling time between the different perforated liners. However, at the time he was conducting his trials, the total perforated area of lin ers used by the South African industry was much smaller than it is today. For example, current SATI-funded trials on packaging are testing 96 x 5 mm, 112 x 4 mm, and needle-scarred micro perforated liners.

Ngcobo reported that the relative humidity inside the perforated liners corresponded to that of the cooling air. Lower humidity inside perforated liners helped prevent condensation. A related paper by Dr Mulugeta Delele and co-au thors described the modelling of airflow and heat transfer in table-grape packaging. They reported that partial or complete cooling of bunches, either as bulk grapes or in carry bags, before placing them in liners, greatly reduced total cooling time. Partial cooling before placing the grapes in an unper forated liner achieved a high relative humidity without SATI

subsequent condensation. For perforated liners, mois ture loss can be limited by maintaining a high relative humidity of the cooling air. Marius Leuvennink and Dawie Moelich, while at Ex periCo, researched grape cooling in a forty-pallet commercial cooling tunnel. They reported that grapes in 4.5-kg cartons cooled nearly 38% faster in 36 x 4 mm liners than in unperforated liners. Cooling times in 9.0-kg cartons were more than 35% faster in 36 x 4 mm liners than in unperforated liners.

BEYOND THE BUNCH • 9 • QUARTER 3 • 2025

Cartons

cardboard made from primary fibres is stronger than cardboard made from recycled fibres. Cartons must be vented to allow air circulation, but vents reduce strength. In a review by Drs Matia Muka ma, Alemayehu Tsige, and Linus Opara, the authors cite research finding that vent and hand holes can reduce carton compression strength by 20%–50%. They also cite work by Dr Tobi Fadiji and co-authors, who reported that a 2%–7% increase in carton venti lation leads to an 8%–12% decrease in the buckling load. Vents reduce carton strength more when closer to the vertical corners of the carton. Cooling is affected by the total vent area, and the shape, size, and position of vents. During precooling, airflow is predominantly horizontal, but during ship ping, it’s vertical. Airflow is also faster during precool ing than shipping. Moelich and Leuvennink measured the performance of different cartons in simulated pallet stacks. They found that deeper (127 mm) 9-kg grape cartons cooled about 30% faster than shallower (118 mm) car tons. However, deeper cartons increase the cost of packaging material and reduce the number of car tons per pallet stack, which increases shipping costs. The authors also reported that integrated airflow channels in the base of 4.5- and 9.0-kg cartons re duced cooling time by up to 44%. The advantage of the channels is that carton size and numbers per pallet stack are not altered.

SATI

Carton design is a compromise between strength, ventilation, and cost. Weak cartons increase the risk of deformation, collapse, and fruit damage. Poorly ventilated cartons impede cooling, both before and during shipping. No one reading this needs to be told why cost matters. The discussion below focuses on corrugated card board, as this is by far the most common material used for table-grape cartons. Corrugated cardboard is strong, lightweight, print able, and cost-effective. However, corrugated car tons lose strength over time when under load, espe cially when exposed to high humidity. A review by Drs Pankaj Pathare and Linus Opara cites research showing that a load-bearing box can lose 35% of its original strength in 10 days and 45% in 100 days. The strength of cartons depends on the cardboard thickness and material. As Klaus Thieltges explains in an article in Volume 1:1 of the SATI Technical Bulletin,

DEWALD KIRSTEN | LUCENTLANDS

All the packaging elements interact to determine the cooling rate of the pallet stack.

Pallet stacks Carton design interacts with the stacking patterns on pal lets and in containers, which influence how much fruit fits in a container and, therefore, the shipping cost. Stacking patterns also modify airflow, the efficiency and uniformity of cooling, and energy use. As pallet footprints are standardised, the relationship be tween the carton and the pallet dimensions determines

the possible stacking configurations. Different stacking configurations affect the alignment of carton vents and, therefore, airflow. A larger number of smaller cartons in a stack will also have a higher carton surface area per unit of fruit, re sulting in less efficient use of space and more barriers to airflow.

BEYOND THE BUNCH • 10 • QUARTER 3 • 2025

Delele and co-authors investigated airflow within and around a stack of grape-filled cartons. They reported that only some cooling air penetrated the stack, resulting in appreciably slower cooling of cartons in the centre. Their results align with other research, which shows that cooling efficiency decreases with increasing stack size. Leuvennink and Moelich measured cooling profiles in a forty-pallet commercial cooling tunnel. They saw signifi cant increases in cooling time the further pallets were away from the cooling coil, and on the inside compared with the outside of the pallet stack. They also observed rapid cooling of grapes in 36 x 4 mm liners inside 4.5-kg cartons located on the delivery-air side

of the pallet. In some cases, berry temperatures dropped below zero within 3–5 hours of forced-air cooling. At the time, the 36 x 4 mm liners were a recent introduction. Leuvennink and Moelich ‘s results confirmed the uneven cooling of fruit in pallet stacks, a phenomenon known to cold-storage operators but previously unquantified in the 36 x 4 mm liners. The authors recommended that pallets of different packaging types shouldn’t be mixed in cooling tunnels, as this leads to different cooling rates and increased risk of chilling injury and freezing when very low set points are used. Lower set points were commonly used with unperforated liners.

Packaging design tools

Initially, Tsige will work with real packaging to obtain the necessary data for constructing a mathematical model. He will study each packaging component separately before combining them in the model. Once he has a model, he will validate it by compar ing its predictions to airflow and cooling in the real world. The model can then be used as a tool to test and improve packaging.

Until recently, packaging evolved by trial and error. Thanks to computing advances, researchers can now model the performance of different packaging con figurations, enabling them to test multiple iterations virtually before undertaking the trouble and expense of real-life trials. The review by Mukama and co-authors lists numerous recent studies that apply computational fluid dynam ics to packaging and cooling systems for fruit. Much of this work has been done at Stellenbosch University.

This year sees the start of an NRF-fund ed project on table-grape packag ing led by Dr Alemayehu Tsige, senior researcher in the Packaging and Cold Chain Research Group in the Department of Horticultural Science at Stellenbosch University. Tsige aims to help the industry solve problems related to non-uniform air flow and temperature distribution during table-grape export. He will also investigate SO 2 dynamics during different handling stages. The other aspect of the project is how pack aging impacts space utilisation and energy efficiency.

ADOBE STOCK

Acknowledgements The following specialists provided technical inputs. • Dr Johan Fourie. ExperiCo Agri-Research Solutions. • Dawie Moelich. SATI. • Dr Alex Tsige. Department of Horticultural Science. Stellenbosch University.

BEYOND THE BUNCH • 11 • QUARTER 3 • 2025

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BEYOND THE BUNCH • 12 • QUARTER 3 • 2025

NUUS VAN ONS VENNOTE

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druiwe. Hierdie velle is ontwikkel met behulp van gevorderde gelamineerde plastiekmembrane en is beskikbaar in dubbel-vrystelling en enkelstadium opsies, almal vervaardig van volledig herwinbare PET (harskategorie 1). Elke laag van die Servafresh-vel is presies bedek met voedselgraad-kleefmiddels en natrium meta bisulfiet (Na 2 S 2 O 2 ) , wat ’n konsekwente en doeltref fende SO 2 -vrystelling verseker. Hierdie formulering bied ongeëwenaarde beskerming teen bederf en help om vruggehalte vanaf oes tot mark te be waar.

Maar hoe presteer dit teenoor die huidige bedryfsstandaard SO 2 -velle? Hier is wat onafhanklike navorsers ExperiCo gevind het: “ Die unieke vlakke van SO 2 wat deur die Servafresh vel vrygestel word tydens beide die vinnige en stadige vrystellingsfases, kan die bewaring van tafeldruiwe tydens opberging aansienlik verbeter. Die vinnige vrystellingsfase is veral voordelig tydens geforseerde lugverkoeling – wanneer SO 2 vinnig uit druiwekartonne onttrek kan word – terwyl verhoogde stadige vrystellingsvlakke bederf oor langer opbergingstye help onderdruk. Hierdie voordele is duidelik waargeneem tydens vergelykende effektiwiteitstoetse. ”

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Servafresh SO 2 -velle is beskikbaar by alle groot verspreiders.

Vir meer inligting, kontak asseblief: Dr. Willie Opperman Selfoon: +27 83 633 1830 E-pos: willieo@servatec.co.z a

Servatec (Edms) Bpk Eenheid A2, Hi Park Saxenburgweg, Blackheath, 7580. Kaapstad Tel: +27 21 518 1156

www.servatec.co.za

BEYOND THE BUNCH • 13 • QUARTER 3 • 2025

FURTHER READING

CONTACT US FOR CONTENT ENQUIRIES: Submit your topic or question. tarryn@satgi.co.za

CONTACT US FOR SPONSORSHIP ENQUIRIES: Feature your brand. denene@satgi.co.za

Publications and dissertations:

l Delele MA, Ngcobo ME, Opara UL and Meyer CJ. 2013. Inves tigating the effects of table grape package components and stacking on heat and mass transfer using 3-D CFD modelling. Food and Bioprocess Technology (6) pp2571–2585. l Dodd M, Cronje P, Taylor M, Huysamer M, Kruger F, Lotz E and Van der Merwe K. 2010. A review of the post-harvest handling of fruits in South Africa over the past twenty-five years. South African Journal of Plant and Soil 27(1): 25th Anniversary Edition 1983-2008 pp97–116. l Du Plessis SF. 2003. Effects of packaging and postharvest cooling on quality of table grapes ( Vitis vinifer a L.). (MSc thesis. Stellen bosch: Stellenbosch University.) l Fadiji T, Ambaw A, Coetzee CJ, Berry TM and Opara UL. 2018. Application of finite element analysis to predict the mechanical strength of ventilated corrugated paperboard packaging for handling fresh produce. Biosystems Engineering (174) pp260–281. l Fadiji T, Berry TM, Coetzee CJ and Opara UL. 2018. Mechanical design and performance testing of corrugated paperboard packaging for the postharvest handling of horticultural produce. Biosystems Engineering (171) pp220–244. l Fadiji T, Coetzee CJ, Berry TM and Opara UL. 2019. Investigating the role of geometrical configurations of ventilated fresh produce packaging to improve the mechanical strength —Experimental and numerical approaches. Food Packaging and Shelf Life (20) p100312. l Leuvennink M and Moelich DH. 2004. Factors affecting table grape cooling with specific reference to bag perforations, box position in the pallet stack, and the avoidance of low tempera ture damage. SA Fruit Journal (Dec 04|Jan 05) pp20–22. l Moelich DH and Leuvennink M. 2006. Cooling rates of grape boxes as influenced by box depth and use of integral air-flow channels. SA Fruit Journal (Aug|Sep 06) pp74–79. l Mukama M, Ambaw A and Opara UL. 2020. Advances in design and performance evaluation of fresh fruit ventilated distribu

tion packaging: A review. Food Packaging and Shelf Life (24) p100472. l Ngcobo ME, Opara UL and Thiart GD. 2012. Effects of packag ing liners on cooling rate and quality attributes of table grape (cv. Regal Seedless). Packaging Technology and Science 25(2) pp73–84. l Ngcobo MEK. 2013. Resistance to and moisture loss of table grapes inside multi-scale packaging. (Doctoral dissertation. Stel lenbosch: Stellenbosch University.) l Ngcobo MEK, Delele MA, Opara UL, Zietsman CJ and Meyer CJ. 2012. Resistance to and cooling patterns through multi-scale packaging of table grapes. International Journal of Refrigeration 35(2) pp445–452. l Ngcobo MEK, Delele MA, Opara UL and Meyer CJ. 2013. Perfor mance of multi-packaging for table grapes based on cooling rates and fruit quality. Journal of Food Engineering 116(2) pp613– 621. l Ngcobo MEK, Delele MA, Opara UL, Thiart GD and Meyer CJ. 2012. Heat transfer and external quality attributes of ‘Regal Seedless’ table grapes inside multi-layered packaging during postharvest cooling and storage. In II All Africa Horticulture Con gress (1007) pp189–195. l Nieuwoudt T. 2015. Packaging of table grapes for exports from SA: A comparative study. (MSc thesis. Stellenbosch: Stellenbosch University.) l Pathare PB and Opara UL. 2014. Structural design of corrugated boxes for horticultural produce: A review. Biosystems Engineering (125) pp128–140 l Stringer CJ. 2024. The financial impact of postharvest packag ing on export table grapes focusing on shelf-life and fruit losses. (Doctoral dissertation. Stellenbosch: Stellenbosch University.) l Thieltges K. 2014. Packaging for table grape exports: how to choose a semi-chemical fluting for optimum corrugated carton performance. SATI Technical Bulletin 1:1 p7.

SATI-funded projects

Moelich DH. 2010. Optimisation of punnet packaging to reduce decay during cold storage of table grapes. Report available from tarryn@satgi.co.za.

This list isn’t complete. We recognise that other resources may be available.

BEYOND THE BUNCH • 14 • QUARTER 3 • 2025

By Servatec bring ons innoverende SO gasvelle vir die moderne druiweboer 2

Kontak ons gerus vir meer inligting Vervaardig deur Servatec Pty Ltd

Willie Opperman 083 633 1830 willieo@servatec.co.za

Lyal McPherson 079 517 3270 lyalm@servatec.co.za

www.servatec.co.za

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