Demm Engineering & Manufacturing magazine by Adrenalin Publishing Ltd

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Measuring up

Manufacturing NZ’s largest HDPE pipes. ❏ Food processing technology update ❏ Packaging & Labelling ❏ Maintenance Matters: what’s new in fastenings ❏ Raising awareness of machinery safety

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CONTENTS Editors

note

A whole lot of shak’n With Christchurch continuing to endure severe aftershocks as I write this, it’s timely to remind ourselves that for most engineering and manufacturing firms in the city it’s still business as normal – or at least as normal as possible under the circumstances. FrankPKS New Zealand is one such company going full steam ahead. It is likely to serve Christchurch well with its high density HDPE pipes as the rebuild of the city’s infrastructure ramps up over coming months. Following a considerable investment in new tooling machinery last year, the company has since gone on to produce two-metre internal diameter pipe. It’s an interesting tale – and Jenny Baker has the full story in this issue. Also this month we have a special feature on Machinery Safety. Again, timely, considering that in the past six months, 12 employers have been prosecuted and fined more than $365,000 after employees suffered a range of injuries through improperly guarded machinery. Most recently, a Wellington firm was fined $16,000 after an employee accidentally amputated four fingers while cutting steel. Aday after the accident a fixed protective guard was installed on the machine involved. The Department of Labour has decided it’s time for a shake-up – and not before time either.

Product Watch Aroundup of new technologies and services designed to increase the productivity, efficiency and safety of the engineering and manufacturing sector.

Food Processing

What’s new on the technology front in food processing equipment? Read how Ultra High Pressure (UHP) processing technology secured a multi-million dollar avocado export deal.

Packaging & Labelling

Aquick roundup of news and new technologies, including a new line of ethylene adsorption packaging shelf life extension products.

Pipes Measure Up For Rebuild

Christchurch manufacturer FrankPKS has undergone considerable upheaval following the Canterbury quakes – but still manages to make New Zealand’s largest HDPE pipes. Jenny Baker has their remarkable story. Glenn HBaker editor@demm.co.nz

Maintenance Matters

The most recent developments and thinking in the world of maintenance including an update on the latest fastenings and adhesives.

Machinery Safety Atimely feature considering that the Department of Labour has launched a threeyear project on the safe use of machinery.

Industry Watch & Coming Events Supported by:

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AdvertiSinG Frank Atkinson, Email: frank@adrenalin.co.nz publiSHer: Cathy Parker, Email: cathy@adrenalin.co.nz editor: Glenn Baker, Email:editor@demm.co.nz deSiGner: Email: rob@adrenalin.co.nz circulAtion MAnAGer: Kim McIntosh, Email: kim@adrenalin.co.nz

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PRODUCT WATCH Edit o choi r's ce

ANEW innovative mini spraybench unit for manufacturing and maintenance workshops, released by dust and fume extraction specialist Egmont Air, is the perfect solution for in-line spray-stations, linear production lines, or as a touch-up or trial-spray extraction booth for offline or maintenance applications. “The spray-booth regulations are considered onerous by many companies that require a spraypainting facility for painting and/or gluing of small parts and components,” says Cameron

Safe, compliant mini spray-bench solution Prestidge from Egmont Air. “The mini spray-bench provides a fullycompliant solution.” This extractor has been designed to provide three primary functions: • Safe capture of overspray from painting or gluing processes. • Protection of the operator’s breathing zone from harmful gases. • Compliance with spray-booth legislation and the facilitation of safe operating procedures. Clean air is drawn past the operator at 0.5m/s – the optimum airflow ratio to achieve extraction of

excess overspray and harmful gases without disturbing the spray pattern required for a perfect paint finish. Parts are placed on the turntable which can be rotated so all sides of the objects are painted evenly. Concertina filter-paper captures the sticky paint or glue overspray and the clean air then passes through the flame-proof rated fan and discharges out the top of the unit. The discharge outlet has a simple square flange for ducting connection; ducting (supplied separately) and clean-air must discharge vertically to atmosphere. The unit comes complete with flame-proof rated fan, single-stage filtration, turntable and can be quickly assembled on-site by two people in one hour. Dischargeducting, two-stage filtration, spray-guns and control-boards are available separately. Egmont Air has a big range of ready-to-go spray-booth systems, especially designed for engineers, machinery dealers and woodworkers requiring a simple but effective spray-booth solution. It includes both dry-media and wet-booth options so the best unit

July 2011

can be offered for any application where a generous quantity of overspray is created. Dry-booths provide an economical solution for most engineering and machinery painting applications – with a lower initial investment, inexpensive operation, ease of filter disposal, and quiet, trouble-free operation. Wet-booths offer a superior filtration method for high-volume paint users, gluing applications and increased fire protection safety. Contaminated air passes through three separate water-veils to remove all paint particulates. The water is then drained off through a paint separator where solids are collected for safe disposal. Full professional advice is available from Egmont Air’s technical department, along with a free on-site consultation to evaluate your particular application. Egmont Air also stocks smaller bench models for spraying of parts and small components. All spray booths come complete with EXE flame-proof rated motors and certification. Go to www.demm.co.nz/enquiry quote:

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D110702

PRODUCT WATCH

Thermal imagers for all diagnostic applications the slightest temperature difference. The imagers measure temperature from minus 20 degrees Celsius to plus 600 degrees on Ti models (minus 20 to plus 150 on TiR models) and feature a high temperature colour alarm on the industrial models and low temperature or dewpoint colour alarm on the building models. Fluke’s IR-Fusion technology captures infrared and visible light images and simultaneously

displays them fused together to better diagnose issues. It features multiple viewing modes and lets users manipulate images right on the camera’s display. P3 Series thermal imagers have optional interchangeable wide-angle and IR-Fusionenabled telephoto lenses to cover any application. Go to www.demm.co.nz/enquiry quote: D110703

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The model Ti27.

BASED on the award-winning Ti32, the P3 Series of thermal imagers from Fluke adds four additional products – providing high-performance imagers for any budget. The P3 Series includes the Ti32 and TiR32 models, plus the new Ti27 and Ti29 for industrial, electrical, mechanical, and process applications, and TiR27 and TiR29 for building inspection, energy audit, weatherisation, and building maintenance. All models are specifically designed to work in even the harshest environments and provide superior image quality with one-handed, easyto-use interfaces. The new family of imagers features industry-leading thermal sensitivity, the largest total pixel image count (76,800 pixels for the Ti32/TiR32 models) and superior spatial resolution that, combined with the 9.4 centimetre diagonal, full VGA-colour LCD displays, provides sharp, clear images to make it easy to spot even

PRODUCT WATCH

Lifting bags shift rocks following quake

The bag in action in Australia

AVERSATILE lifting bag traditionally used to position everything from pipelines to machinery was employed in a dramatically different role recently. The Kevlar-reinforced Enerpac product was put to work shifting heavy rocks during clean-up and reconstruction after the Christchurch earthquake. The bag was used by Geotech ground engineering contractors to dislodge potentially dangerous boulders above the Evans Pass Road that crosses the steep hills between Christchurch and the Port of Lyttelton. The large rocks had been loosened during the devastating February earthquake and were threatening to fall onto the roadway below. “Geotech came to us with a problem,” recalls Garry Millar, managing director of Enerpac distributor Gino Hydraulics.“The contractors were

July 2011

using big lever crowbars to move the rocks so that they could position jacks behind them. “The bars and jacks were cumbersome and difficult to use on the precipitous hillsides where the contractors had to lower themselves down on ropes and harnesses. “We supplied an Enerpac LB-14 lifting bag with an 11.7 tonne lifting capacity and told them to bring it back if it wasn’t working for them. They didn’t bring it back, they love it. “Compared to the combined weight of levers and a jack, the lifting bag weighs just 5.5 kg, so they could easily swing it down the hill into position,” he said. Geotech powered the lifting bag with a 100 psi air compressor running off a diesel generator. The bag was deflated, positioned behind the boulder to be moved, then inflated, dislodging the boulder from its surrounding earth. “The airbag is very light and easy to handle, especially on the rockface,” says Nigel Gualter, GM of Geotech.“Its narrow profile allowed us to address any boulders where there was a gap wider than 28mm or about the thickness of a crowbar. We just pushed the airbag into the crevice, slowly inflated the bag, and watched the rock move. If required, we then packed the rock in its new position, deflated the bag and took another bite until it was released. “We found that even if the bag could only get a corner behind the rock, we could work the rock out very successfully. We could unleash 11.7 tonnes and move anything that was going to shift. It also kept the guys away from the fall zone. “The airbag has now become an essential part of our kit and is first to go into the toolbox.” Enerpac offers nine sizes of low clearance lifting bags and their controls for lifting, pushing, pressing or moving loads safely and smoothly. The bags use compressed air up to 116 psi (8 bar) or water to

achieve load capacities ranging from 27 to 656 kN. Enerpac New Zealand territory manager Neville Stuart says the big advantages of lifting bags include easy access to restricted spaces, such as those around awkwardly shaped loads or loads in confined spaces, for example. Restricted access situations can range from beneath vehicles and machinery being replaced, recovered or repositioned, to pipeline trenches and around resource and exploration equipment. The bags can also tolerate restricted surface pressure, which is useful when they are lifting from softer surfaces in trenches and tunnels, for example. Go to www.demm.co.nz/enquiry quote: D110704

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Techspan on social media PLASTICS and printing technologies supplier Techspan has recently joined the online social media zone with its own Facebook page and YouTube channel – where you’ll find news and information about the latest in plastics and printing technologies. Image galleries, videos and news stories are also featured. Techspan released its new e-commerce website during 2010 (www.techspanonline.com), which made it quick and easy for customers throughout the Pacific Rim to access pricing and purchasing online. Its news page is also a blog site, so customers can interact with comments or ask specific questions about any new technology they are interested in. Go to www.demm.co.nz/ enquiry quote: D110704a

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PRODUCT WATCH

Above-ground diesel tanks

NOW you can reduce the risk of environmental contamination, thanks to fibreglass double-wall above-ground diesel tanks. Rusting steel tanks can be costly. Arusting fuel storage tank can cost thousands of dollars in environmental clean-up costs. The problem is that condensation, humid air and salt are constantly eating away at older steel tanks, often causing dangerous rust leaks. Internal rust damage is the hardest to detect and not visible until it’s too late. Greentank above-ground diesel tanks are the permanent solution to tank rust and leakage problems. Made from double-wall fireretardant fibreglass, these tanks are

Compressed-air for industrial tools, processes

rot, rust and corrosion-resistant. They are totally weatherproof and secondary-contained by virtue of the double-wall construction. They therefore don’t require costly containment bunding and are guaranteed to provide long term trouble free service with a 25 year limited warranty. Greentank fibreglass aboveground diesel tanks are ERMA approved and suitable for home heating and commercial heating applications – as well as industrial boilers and furnaces, backup generators, transport depots, waste oil collection, farm fuel and biodiesel. Go to www.demm.co.nz/ enquiry quote: D110705

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THE cost-effectiveness and reliability of the Air-One range of electrical reciprocating compressors makes it ideal for companies that require intermittent compressed-air for industrial tools and processes. The Air-One compressor range is economical, easy to install and simple to use. With a small footprint and ‘plug ‘n’ play’ installation, Air-One reciprocating compressors are ideal for on-off load applications including automotive shops, panel beaters, wood-working, general manufacturing, agriculture, air-tools, construction and rental markets. Single stage reciprocating air compressors have long been regarded as the most economical choice where low-medium pressure air is required for intermittent or fluctuating loads. With a cooler operating temperature, low noise and V-belt drive, the Air-One provides high efficiency operation. The compressors range in size from 2kW to 11kW and provide a reliable compressed-air source for industrial markets by operating at low speeds – preserving component life. With a solid cast iron construction and multiple piston options, the Air-One range is robust and requires only routine maintenance and service. Go to www.demm.co.nz/enquiry quote: D110705a

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PRODUCT WATCH

All-electric injection moulding costs by up to 25 percent as the parts can be transferred to sterile packaging immediately after production. At a recent demonstration, the machine, fitted with a SR 80 sidewithdrawal robot was able to produce disposable polystyrene cups in cycle times of 3.5 seconds. The AX350-1400, with a 3,500kN optimised double toggle clamp,

GERMANcompany Krauss Maffei has added two new all-electric small injection moulding machines – the EX 200-1400 and the AX350-1400 – to the already comprehensive range of small, medium and large machines within the EXand AX‘all electric’ series. The EX200-1400, with a 2,000kN clamping force, is a high performance machine designed for the production of precision parts where high shot

weights and material throughput in a short cycle time are necessary. The unique Ztoggle ensures quick mold movements on the clamp side, while the direct-acting plasticizing and injection drive guarantees maximum process accuracy. The fully enclosed drives and water cooled motor ensure an ultra-clean production environment. The machine also cuts manufacturing

efficient servo motors and smoothrunning mechanical parts can save energy consumption by up to 60 percent. It is designed for high precision moulding for the electrical, electronics, medical and automotive market sectors. Go to www.demm.co.nz/enquiry quote:

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D110706

High speed multi-gas detector THE Altair 4X is a new highspeed, robust multi-gas detector designed for use in confined spaces,

mining, oil and gas and across general industry. The device utilises MSA proprietary X-cell high speed sensors (<15 seconds) and incorporates all the Altair family features, such as: robust design with 20-metre drop/impact testing; IP 67 waterproofing; 24 hour run time; ‘man down’ alarm to signal no movement such as unconsciousness; instant alert panic alarm to signal “help needed”; datalogging – as well as MSATick mark to confirm function and a triple alarm system (sound, vibration, visual). The Altair 4X is available in charcoal grey or Extreme Glow Lime (glow in the dark) reinforced body armor. Go to www. demm.co.nz/enquiry quote:

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D110706a

Supplying New Zealand industry with pallet racking, Longspan general shelving and much more.

… contact us on 09 377 9135 or visit our website www.victorindustries.co.nz/www.novalok.co.nz

July 2011

Multi-purpose terminal blocks

WAGO’s range of new multipurpose, Cage Clamp S rail-mounted quadruple deck terminal blocks is now available. The innovative design of these terminal blocks, which can

be used for connecting electric devices from motors to sensors, allows for a set of terminals to supply power to a number of motors or 3-wire sensors with the added benefit of space saving. Ease of installation results in valuable time savings as the tightening of screws is not required and also means no annual maintenance. Go to www.demm. co.nz/enquiry quote: D110706b

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The right choice in lubricants

PRODUCT WATCH

Recycling used tungsten carbide cutting tools RECYCLING, ‘going-green’ or ‘environmentally-friendly’ are today’s buzzwords when it comes to new technologies or developments in manufacturing. With increasing pressures and competition from lowcost-countries, local manufacturers may find the task to become an environmentally-conscious shop daunting. However, there are many different approaches to improve operations which not only reduce the carbon footprint, but can generate extra cash and reduce production costs. For example, when an operator replaces a carbide insert, about 95 percent of the carbide is still intact and capable of being recycled. Of this carbide, tungsten comprises 75 percent of the content. Tungsten is a finite resource with the interesting ability to be recycled infinitely, reducing our reliance upon mining of this rare earth element. The tight supply of tungsten has been keeping upward pressure on the price of the metal. Recent rule changes in China’s new ‘Five Year Plan’ might alleviate some of the supply issues this year as the quota for tungsten production has been raised to 87,000 tonnes from 80,000 tonnes last year. However, in the long run, the rule changes cap new production growth at an average eight percent a year. This holds immense power over the market because approximately 85 percent of global tungsten output in 2010 came from China. According to the Tungsten Investing News, the price of tungsten APT (ammonium paratungstate) as of January 2011 had risen 81 percent since year over year, from US$185 per MTU to its

then current price of $335 per MTU. The effect of rising tungsten prices is causing concern generally across the tooling sector, and recycling is attracting considerably more attention from carbide tip producers to damp down high carbide prices, ensure security of supply and reduce consumption of non-renewable raw materials. Sandvik Coromant is one of the most proactive cutting tool manufacturers in this area. Internal calculations, based on international standards, have shown that production of tools from recycled material consumes up to 75 percent less energy than production from virgin materials. It also reduces CO2 emissions by roughly 40 percent. No comprehensive studies have been undertaken to determine how cutting tool recycling impacts chemical consumption and water pollution, but it is widely accepted that these areas benefit as well. There is no difference in quality between cutting tools made from recycled or virgin materials. Most Sandvik Coromant customers are not concerned whether the tools they buy are made from recycled or virgin materials, though some consider tools made from recycled materials superior because of their positive impact on the environment. Avery small percentage perceives these tools as inferior, due to misperceptions about recycled goods.

Recycling program

the used carbide, it is both a wise financial and environmental choice. One example of a cutting tool recycling program is Sandvik Coromant’s Coromant Recycling Concept (CRC), launched in 1996. As part of the Sandvik Group, the CRC has access to three regional recycling facilities. The Chiplun facility in India, built in 2007, specialises in zinc-process recycling. Wolfram Bergau, a Sandvik-owned company in Austria, operates a chemical-process recycling plant. In the US Sandvik Coromant contracts to provide chemical-process recycling at a Pennsylvania plant. Sandvik Coromant’s CRC offers a comprehensive, easy-to-use and freeof-charge service to its customers that also includes solid carbide tools. Using CRC, all used hard metal materials of any brand are collected in boxes placed by the machine tool. Sandvik New Zealand offers free collection boxes for its customers, while it is recommended that there should be two in place at each lathe, milling machine, drill or machining

Today there is no excuse for not recycling your carbide as almost every major cutting tool supplier has a program in place. With many of these suppliers actually buying back

www.nz.sew-eurodrive.com

INDUSTRIAL DRIVE TECHNOLOGY

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Geared motors Industrial gear units Drive electronics Drive automation July 2011

n o i at

v o nn

The first step D1of5-Jul11

centre; one for inserts and one for solid carbide tools. Once full, the contents are transferred to a transport box provided by Sandvik, which is then picked up by your nearest representative and returned to the Coromant manufacturing plant for recycling. More and more customers are becoming increasingly aware of the need for recycling of carbide products in the light of increasing consumption of non-renewable materials, and the growing take-up is encouraging. With its initiative “Turn your trash into cash”, Sandvik is currently offering $18/kg of scrap carbide, allowing participating companies to not only reduce the environmental impact of manufacturing, but also to make some extra money by cashing in on the recycling concept. Article by Peter Rollauer, Sandvik Coromant Australia. Go to www. demm.co.nz/enquiry quote:

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D110708

PRODUCT WATCH

Keeping an eye on safety IN the event of a hazardous eye contamination, time is of the essence. Left untreated, even for a few seconds, exposure of the eye to chemicals, toxins and foreign bodies can lead to serious eye damage. Sperian Protection recognises the importance of the initial treatment in minimising work related eye injuries, and has developed a range of delivery systems and devices which provide optimal emergency eye care in the workplace. Utilising Eyesaline, a preserved, buffered, saline solution which is superior to tap water or water with a preservative, Sperian Protection offers a range of emergency eyewash stations and personal products which deliver flushing fluids to decontaminate the eye area.

It can be easily and affordably placed near most workplace hazards. The unit is self contained, and features a patented nozzle strap that is easily removed to activate flushing, leaving the hands free to hold the eyelids open. Alarge fill hole and lockable fill cap simplifies cleaning and refilling, and reduces the risk of possible tampering.

The Sperian Fendall Pure Flow 1000 emergency eyewash station delivers a contaminant-free and physiologically correct saline solution from factorysealed cartridges. This patented system Simple is self-contained and to install does not require and operate, any plumbing. The the Sperian cartridges remain Portastream II sealed until activated, emergency eyewash and take less than five station offers versatile minutes to replace. portability and 15 minutes They also last at least four times longer than other of uninterrupted flushing primary, self-contained eye washers – without costly plumbing. The station features a unique nozzle design, which

delivers a soft ‘ribbon’ of Eyesaline and features a fluid pressure balancing system that provides a constant fluid flow rate and stream height for the entire 15-minute flushing period, as required by ANSI Z358.1-2004. Available in factory-sealed bottles, the range of

Personal Eyewash Products from Sperian can deliver drops or an irrigating stream of solution. Each bottle features an easy open tamper-resistant top and extended-flow nozzles. Sperian’s personal eyewash solution is available in a 473ml or 946ml bottle, as well as a single wall mount station or double wall mount station for the 946ml bottle (pictured). Go to www.demm. co.nz/enquiry quote: D110709

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PRODUCT WATCH

Linear actuator champions rolling nut principle

Nozdrive actuators were originally designed for solar panel tracking movement.

A NEW performance level has been reached using trapezoidal screws and nuts. Until now trapezoidal screws were limited

because of their poor efficiency. The resulting friction/heat allowed a duty cycle of a maximum of 40 percent (that is, ten minute duty

cycle, only four minutes of actual operation). The new Nozdrive linear actuator has the rolling nut principle that allows the turns of thread to roll onto and into each other and not slide over each other, resulting in a distinct improvement in performance. The duty cycle is now up to a maximum of 80 percent while still using trapezoidal screws and nuts. Afurther benefit of this rolling motion is the diameter differences between nut thread and spindle thread – allowing a larger reduction ratio without the use of an additional gearbox. Nozdrive linear actuators can handle 10/25/50 kN static load, 3mm/s linear speed using a TR30x6 spindle and steel nut, with strokes of 600/800/1000mm respectively – and they can be manufactured to your drawings. As trapezoidal thread is used instead of ball screw; steel nuts instead of bronze; and because efficiency is improved through the selection

First passivated canister air sampling service

FOLLOWINGa major investment in equipment, Hill Laboratories now offers New Zealand’s first and only passivated canister air sampling service. “The canister sampling service we’re now offering was previously only offered by overseas laboratories and we’ve introduced this technology to the New Zealand market,” says Hill Laboratories’ air quality laboratory manager, Dr Ian Graves.“It is such a huge leap forward in terms of technology, cost savings and ease of use for air sampling that Hills wanted to help our customers gain access to it. “Users of the canister sampling service no longer

July 2011

need to go through the timely and costly exercise of calibrating a pumpfor sample collection. Plus, vinyl chloride can be collected and analysed from the same sample as less volatile, chlorinated VOCs, which also saves a lot of time and money for the user compared to sorbent tube sampling,” explains Dr Graves. Hill Laboratories, through its five labs located in Hamilton and Christchurch, tests over 5000 air samples each year. Dr Graves says since launching the canister sampling service in March, the new technology has especially appealed to environmental consultants working on contaminated sites with vapour issues. Glenn Veart, MDof Air Resource Management in Henderson, was one of the first consultants to use the service and says “the canisters make the whole sampling process cleaner, easier and quicker than methods we’ve used in the past. The cost of the service is justified in the quality and speed of sampling and the accurate analysis received through Hills.” Hill’s canister sampling service has been accredited by International Accreditation New Zealand (IANZ). The canisters can be used for testing soil vapour, sub-slab and vapour intrusion, ambient air, and grab samples. Go to www.demm.co.nz/ enquiry quote: D110710a

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of smaller motors, these Nozdrive actuators will find applications further afield than the solar panel tracking movement they were specifically designed for. Go to www.demm. co.nz/enquiry quote: D110710

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The actuator has the rolling nut principle that allows the turns of thread to roll onto and into each other, resulting in better performance.

Ultra high purity adsorption dryer THE new Boge Dseries are adsorption dryers that still utilise the traditional twin tower system, however each tower contains a cartridge that contains preand after-filtration as well as the desiccant media. Whilst one tower adsorbs humidity, the other one regenerates the desiccant. Saturated compressed air leaving the compressor enters the inlet of one of the towers via a water separator which collects water in a special condensate chamber before passing through the pre-filter in the cartridge. This system prevents any bulk water migration into the desiccant media. This water is then separated during regeneration of the reservoir. Subsequently, the air passes through the desiccant which adsorbs the remaining water vapour. After the drying process the air passes through a particulate filter designed to collect any residual dirt or dust particles so that the air produced conforms to quality Class 2 according to DINISO8573.1. For more visit www.boge.net.au

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PRODUCT WATCH

Mobile drum dispensing station Weighing just 44.5kg but with a load-bearing capacity of UDL 270kg, the Polly Dolly’s ergonomic design ensures workers involved in mobile dispensing use their correct major muscle groups to support and propel the load from a correct distance, rather than straining smaller muscle groups by being hunched over too close to the load.

SLIP and fall accidents are one of the leading causes of industrial injury, along with body strain injuries resulting from manual handing of heavy workplace items. To help prevent injuries when handling the ubiquitous

205 litre (44 gallon) drums found throughout industry, Enware offers a tough, light and ergonomic mobile dispensing station engineered to reduce drum handling and improve safety. The Enpac Poly-Dolly not only

provides 24-hour protection against spills and leaks of industrial fuels, chemicals and hazardous fluids, but also features thoughtful design to protect workers moving drums around industrial plants.

Features also include: • Integrally moulded rolled grip handle for extra strength and easy lifting. • Extra large easy roll 25cm polyolefin wheels (and optional pneumatic wheels for rugged terrain). • A built in secondary containment unit to prevent accidental spills landing on the floor. Convenient drain plugs. • Drain hole into enclosed sump area elevated above dispensing well for major spills – 304 litre sump. Go to www. demm.co.nz/enquiry quote:

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D110711

Hydraulic Tool Sales, Service & Hire.

Hydraulic Torque Wrenches

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PRODUCT WATCH

Heavy lift system grows with user needs

using the best available technology.” Akey driver of the design is modularity, meaning that customers can select exactly the features they need for their process, both now and in the future. Thanks to standardized modules, products can be customized reliably and faster than ever before to suit the special needs of individual customer processes in widely differing fields of the process industry. There is no need to equip Smarton with everything a user might expect to use in the future. The product can easily be updated with additional features, such as automated positioning, defined working areas, maintenance monitoring, or remote diagnostics. This is enabled by the crane’s intelligent control system based on programmable The Smarton high performance modular crane system is designed to maximise safety while minimising energy consumption and downtime.

SMARTON, the new Konecranes heavy-duty process crane, adapts to user needs. It is designed as a customized, intelligent, and environmentally sustainable solution for demanding maintenance and heavy process use. This high performance modular crane system is designed to maximise safety while minimising energy consumption and downtime. Smarton cranes come in capacities initially up to 160 ton and progressively extending to 500 ton. The compact crane system can save building and building services costs by fitting into smaller structures. The design enables new industrial halls, for example, to be smaller than before, so the product pays back in the form of lower construction and heating expenses. The compact structure of Smarton also allows the user to put the load down much closer to the wall. “Smarton was designed from the outset to symbolize process industry customer expectations for an optimum overhead crane system,” says Konecranes sales and marketing manager, Warren Ashton. “We wanted to introduce a crane that satisfies customer needs and is implemented

July 2011

logic, which can be adjusted according to the control need. In addition to being more compact, the product is also designed to meet or exceed environmental standards. The feedback of braking energy, a standard feature, can save up to one-third in energy consumption. And Smarton is at least 98 percent recyclable. One of the main goals in the development of Smarton was to minimize the duration of maintenance shutdowns. The service platform folds over the trolley to protect the trolley components. The space-saving, foldable platform is a brand new concept, for which Konecranes has sought patent protection. All service points are located on the same side and are easily accessible. The crane monitors its own condition and recommends when and what kind of inspections or preventive maintenance to perform. Among other things, Smarton is designed to continuously monitor the condition of the hoisting motor brake. The service panel, in turn, shows the location of the fault. Konecranes has also paid special attention to the durability of wire ropes. The service life of hoisting wire ropes is a key element in maintenance expenses. “We have clearly extended the life of wire ropes by optimizing the pulley rope angles in the hook housing, making them as small as possible to reduce the wear and tear of wire ropes,” says Ashton. Remote maintenance is a standard feature. Three support centers located in different time zones around the world ensure that Konecranes can offer 24/7 support for equipment, irrespective of the location. Go to www.demm.co.nz/enquiry quote: D110712

•

Air nozzles improve work environment NORSKBlikkvalseverk, Scandinavia’s biggest producer of sheet metal for the packaging industry, recently installed Silvent air nozzles to improve the working environment at its rolling mill. The use of compressed air was one of the company’s greatest problems, due to the intolerably high noise levels it generated. After studying the various manufacturing processes, Silvent recommended solutions for every application of compressed air usage throughout the mill. These solutions sought to cut noise to an acceptable level, as well as lowering energy consumption and improving the quality of steel being produced. Different air nozzles were chosen depending on the application in question. The nozzles most frequently utilised were the 209, 705 and 920 models. The Silvent 209 air nozzle, made of zinc,

can be used for a wide variety of applications to cut noise levels and energy consumption. The Silvent 705 air nozzle is made entirely of stainless steel, with aerodynamic slots to allow for optimal utlilisation of compressed air whilst keeping the noise level to a minimum. The Silvent 920 air nozzle, made of zinc, is a flat nozzle that generates a broad and efficient air cone. Satisfaction with Silvent air nozzles previously installed led Norsk Blikkvalseverk to opt for full-scale implementation of Silvent’s proposed solutions. Calculations have shown that the reduction in compressed air consumption at the Kvarto Works alone to be 1.2 million Nm2 per year, translating to an annual cost savings of approximately NZ$20,000 – an ROI of just a few short months. Go to www.demm.co.nz/ enquiry quote: D110712a

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PRODUCT WATCH

SouthMACH showcases innovative technology

VISITORS will be captivated by the range of innovative and new technology on display at SouthMACH 2011 – New Zealand’s largest engineering, manufacturing technology and machinery trade show.

Taking place on August 17 and 18 at CBS Canterbury Arena in Christchurch, the show will bring together more than 80 machinery, engineering and manufacturing technology suppliers from all over New Zealand and Australia.

Visitors will be also able to gain valuable ideas and insights from the complimentary Focused on Industry seminars. Topics range from “How to protect inventions and trademarks” to “Maintaining factory floors and driveways” to “The factory of the future: direct digital manufacture.” Free entry includes two days of constructive seminars and workshops. Visitors can register to visit online free at www. southmach.co.nz One SouthMACHexhibitor, Anzor Fasteners on stand 42, specialises in stainless fasteners. They have recently implemented a quality testing programme using some highly sophisticated X-Ray spectrometer equipment. Design Energy on stand 30Anot only develops great products but goes one step further by assisting with the “productionisation” of the final product. Forklift hire company, Forklifts NZ on stand 87, is establishing

a stronger presence in the Christchurch and wider South Island markets. In April, the Southlandowned and operated company acquired Christchurch-based Loadlift Equipment and rebranded it under the Forklifts NZ umbrella. Manager Klaus Sulz says this is the company’s first serious foray into the Christchurch market, apart from a small company called Canterbury Forklifts that it already owns. Roadrunner Manufacturing on stand 44 will have a fully operational Maxiem Abrasive Waterjet Machine on display. The team of Camfil Farr NZ and Viking Ironcraft on stand 41 at SouthMACH will show you the best solutions for your dust collection needs. Visitors must register to attend the show. SouthMACHand associated onsite events are free to attend. For further information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www. southmach.co.nz

•

17 – 18 August 2011 CBS Canterbury Arena Wednesday 10am – 5pm Thursday 10am – 4pm

the machines are back! the engineering, manufacturing and machine technology show is back!

Register online to visit SouthMACH and go in the draw to win one of five Macpac Sundowner Jackets valued at over $350 each. Go to www.southmach.co.nz today to register for FREE. Draw closes 12th August at 5pm.

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Official publication

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fOOD PROCESSiNg

UHP technology secures avocado export deal

UHP processing technology uses pressures of up to 87,000psi to shock and kill bacteria in food.

NEW Zealand’s avocado industry recently secured a multi-million dollar export deal with Japan thanks to new food processing technology. The technology, introduced earlier this year, dramatically extends the shelf life of avocados without the use of any chemicals or other additives. Ultra High Pressure (UHP) processing technology, also known as cold pasteurization, uses pressures of up to 87,000psi to shock and kill bacteria in food products. Kiwi owned Fressure Foods, a grower-owned company, imported the technology last year, establishing its plant in Pukekohe

and creating 40 jobs. Fressure Foods CEO, Vern Dark, says with its ability to extend the shelf-life of avocados and deliver them in a convenient ready to use pack, the industry is capable of boosting the country’s annual exports by 20 million dollars. “Avocados usually last around 30 days but now we’re able to extend this to 60 days. We imagine this extended shelf life will open many new markets. With this technology we are able to add significant value to a commodity product which was too perishable for some of the countries we wanted to export to.”

One of the first products to receive the UHP treatment is the Fressure Foods Guacamole with significant orders being delivered to Japan and Singapore. Export negotiations are also well advanced in Australia and the products have recently been launched locally. Dark says ultra high pressure treatment has driven up total consumption of avocados in the US, something he is hoping will be repeated here. The UHP process does not affect the texture, flavour, consistency or nutrients in food and could be

utilised for a number of other New Zealand grown fruit and vegetables, along with meats. An environmentally friendly process, the UHP system does not cause emissions and uses less energy than thermal pasteurisation, says Dark. Fressure Foods’ is currently looking for additional funds from its investors to sustain the progress made to date and support its anticipated rapid export-led growth. Go to www.demm. co.nz/enquiry quote: D110714

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Hoods ideal for frozen food production COMBINING functionality and comfort, the new Polar Hood is a balaclava style hood that provides protection from inclement weather while still complying with strict workplace safety standards. Responding to the increasing need for workers to stay warm while also staying safe, the Polar Hood provides protection from cold climates while ensuring optimal earmuff attenuation. The Polar Hood features patented side panels to help eliminate the gap between headphone earcups and the ear – reducing hazardous noise exposure without distorting sound quality or earmuff attenuation. Made from warm and durable fleece and with a seal around the face to prevent further exposure to the elements, the Polar Hood ensures its wearer stays warm and comfortable at all times. The adjustable design also includes a front zipper for ventilation and a foldaway visor for additional protection, at the same time the bright green trim enhances visibility and safety for workers operating outdoors. The Polar Hood fits under most hardhats and is compatible with all Howard Leight earmuffs. It is ideal for airport ground crews, construction workers, oil/gas/ petrochemical workers, frozen food production and other workers exposed to cold weather conditions who require hearing protection. Go to www. demm.co.nz/enquiry quote: D110714a

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July 2011

Real-time bacterial enzyme detection

See us on d 11 Southm Stan Looking forach

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DUCT Duct & FLEX Flex EUROTEC Limited is now distributing a new line of bacteria detection kits in New Zealand. Designed and manufactured by DeltaTRAK, a leading US-based innovator of cold chain management solutions, the FlashCheck Real-Time Bacterial Enzyme Detection kits include products that can screen for the presence of harmful bacteria on surfaces of equipment and food. They provide the fastest detection of low levels of bacteria associated with contamination and food-borne illness. Using the kits will allow growers, producers and processors to identify the presence of bacteria in the product or equipment facility in as little as 20 minutes. “Field studies and microbial rapid screen validations at the University of California and Michigan State University confirmed that the FlashCheck test kits demonstrated over 98 percent accuracy when compared to traditional growth media procedures,” says Frederick Wu, president and CEOof DeltaTRAK.“In addition to being extremely accurate, the kits are inexpensive, easy to use and produce results in 20 minutes as compared with 48 hours for other tests. This means users can test more often and thereby reduce the chances of food contamination going undetected.” FlashCheck Real-Time Bacterial Enzyme Detection technology uses a unique enzyme detection system consisting of synthetic substrates, which in the presence of enzymes specific to certain microorganisms causes a chemical reaction. The kits are capable of screening for the presence of bacteria on surfaces, equipment, and food; or in water and beverages. Kits come in low cost, manual swab/strip formats or a handheld fluorometer format. Antigen/antibody technologies commonly used for bacterial detection, such as ELISA, culture and PCR, tend to be slow, cumbersome and expensive. ATP tests are ineffective for bacteria detection as they test only for the ATP molecule which is present in all organic matter, and can result in many false positive results. With enzyme detection, users will know if harmful bacteria are present. Additionally, users can significantly cut the time it takes to determine the presence or absence of bacteria, which will facilitate the checking of these critical control points effectively and rapidly. Go to www. demm.co.nz/enquiry quote: D110715

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www.nzduct.co.nz 15

fOOD PROCESSiNg

New dust filter concept means lower prices

Anything can be manufactured in wood, including this bridge seen at the recent Ligna exhibition.

JKF Industri, the Danish-based company at the forefront of the dust extraction industry in Europe, was just one of many exhibitors at the recent Ligna Exhibition in Hanover, Germany. Geoff Ebdon from Auckland-based New Zealand Duct & Flex visited the show to assist JKF with enquiries from New Zealand companies and to look at new products from existing suppliers that are suitable for the New Zealand market. “I investigated new suppliers for where there are gaps in our product range not covered by the existing main tier suppliers,”

confirmed Ebdon. For a new product discovery exercise, the five days at the Ligna Exhibition was a feast he says – 1765 exhibitors displayed their latest innovations covering every possible aspect of the woodworking and construction industry. Why travel so far to a show of this size? “If I was looking to invest in a major purchase for my wood processing business, I would definitely make an effort to attend,” says Ebdon.“Covering every aspect of wood working and construction, the show had exhibitors for tree cutting

and transportation equipment, right through to highly automated cabinetry and joinery machinery and everything in between. “The big benefit was that you could see every aspect of the industry covered, talk to 20 to 30 different suppliers for each and every sector, all in one place and with their machinery all operating over the five days. “We buy everything from our Danish supplier,” adds Ebdon. “Ducting, fans, rotary valves, pneumatic product and filters and bag houses. The quality of their entire range is excellent. “The only downside has been that the cost of shipping has meant some of the larger dust filters aimed at medium to large wood processing and engineering firms have been expensive to get to New Zealand due to their sheer size.” Now, however, the Danes have launched a new range of very high volume filters – the ‘SuperJets’. Due to their design, they are easy and quick to assemble and can handle high dust volumes. For most visitors to the JKF Industri stand, it was the construction strength and high dust volumes that were the attraction of the new design. Transport costs are not a major concern for

them. However, for Ebdon it was the way the filter parts were packed and assembled that was immediately interesting. “This new filter design and construction allows JKF to pack them in such a way into our containers that, for the first time, we can offer the latest design, larger European-quality filters at very competitive prices. With these new filters I think we can really offer an attractive package to larger New Zealand companies. If I hadn’t attended the show and seen the filters going up, I would never have picked up on what, to us in New Zealand, is an important attraction.” The distributors’ dinner hosted by JKF has an awards section where companies worldwide, that have shown outstanding support or achievements in what has been a tough two year period, receive recognition. New Zealand has a population of only four million; Ebdon knew he had no chance to compete with his opposite numbers from Germany, Russia or the UK. In fact, the only award he received was for boarding the most number of aeroplanes on his way to the show – six in total! Go to www.demm. co.nz/enquiry quote: D110716

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The new ‘SuperJet’ dust extraction filter – launched in Germany in June.

July 2011

fOOD PROCESSiNg

Intelligent batch processing

FactoryTalk Batch software improves recipe capabilities, compliance, run-time control and material management.

ROCKWELL Automation has expanded the application development capabilities of its FactoryTalk Batch software to help users design and run batch applications more rapidly. The software features new intelligent recipe capabilities, secure operator overrides, expanded data collection and reporting and improved material management capabilities. FactoryTalk Batch version 11 is now shipping as part of the scalable PlantPAx Process Automation System, and provides solutions ranging from small, basic sequencing to large, complex batch applications. The need for greater agility and responsiveness is driving manufacturers away from custom-engineered batch software applications to standardised, open technology. FactoryTalk Batch software, based on ISA-88 standards, is designed to meet that demand, while providing batch operators with more control during runtime. The new features include: • Intelligent Recipe Features – When defining a product, recipe authors can now reference system-wide data, such as previous ingredient feed-actuals or material properties, to simplify recipe development. The use of expressions based on this historical data rather than entering specific defined values allows the system to adjust run-time set points to accommodate variable batch activity. • Improved Run-time User Control – Operators with security

clearance now have the ability to move a batch forward in the process. In the past, procedural flexibility had to be designed into the system. With this latest version of the software, operators have more control to advance a batch based on real-time conditions, without timeintensive system engineering. • Expanded Data Collection and Reporting – This release continues to expand the system data logged into the electronic batch record. This includes information on shared equipment such as pumps and other processing equipment, to help manufacturers further meet track-and-trace compliance. Rockwell Automation is also adding context to data within the batch system. System designers can now associate a material set point with the actual amount delivered – without relying on naming conventions or other complex association methods. • Improved Material Management Capability – FactoryTalk Batch Material Manager brings just-in-time material management to batch execution systems, allowing more effective management of materials and recipes. The latest version FactoryTalk Batch helps increase flexibility by allowing late binding to material inventory. This is critical for batch applications where some materials are in transit or not available at the start. In the past, batch applications required custom engineering to accommodate these situations. Go to www.demm. co.nz/enquiry quote: D110717

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www.multiracknz.co.nz 17

fOOD PROCESSiNg

Gentle pump suits curd transfer CHEESE curd is a fairly delicate substance and, as such, no damage should be permitted as a result of pumping processes. Damaged cheese curd can lead to increased ‘fines’ that are lost to the whey stream, which in turn reduces cheese yield. Furthermore, damaged curd is typically more resistant to dressing, which means greater dressing quantities are required to improve the product’s appearance and consistency. By the very nature of their operation, certain pump types will unfortunately break curd into small particles that pass through whey screens on drain tables, where they collect. This is because the standard meshing rotors used by rotary-style pumps, for example, create a compression action that damages sensitive products like cheese curd. The result is that, after each cycle, these fines have to be added manually back to the drain tables for reprocessing.

Customers transferring cheese curd require a pump that gently produces a constantly displaced

Sine pumps gentle and reliable for dairy • Low shear pumping protects product integrity • No pulsation or meshing rotors • Fewer parts - lower maintenance and is fully CIPable • Improve cheese curd yield by lowering fines • Perfect for curds and whey, yogurt, cream and cottage cheese

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July 2011

volume. This will generate a higher cheese yield by lowering the fines content. At one particular cheese manufacturing plant samples were taken of the suspended solids found in the whey after it was separated from the transferred curd and whey mixture. After installation of a MasoSine pump, the average suspended solids decreased from 0.37 to 0.33, an approximate 11 percent decline. And since the MasoSine pump has been in place, the plant claims to have 19 percent fewer fines. The reduction of fines also has another benefit. Because fines can plug or ‘blind’ the drain table, fewer quantities of fines means less downtime is required to unplug the belt, leading to a subsequent increase in productivity. The unique MasoSine pump design is ideal for the transfer of cheese curd. The MasoSine pump’s large open cavities, a constant displaced volume, and gentle transfer of product from inlet to discharge transfers curd with little damage. Because this lowers the amount of fines created it produces higher curd yield and higher fat content. The latter is also an important factor in generating greater product yield. The MasoSine pump handles

viscous, shear sensitive products while providing powerful suction lift and pulse-free laminar flow. A sinusoidal rotor creates four symmetrical compartments in the pump housing. As the rotor turns, these compartments provide a positive displacement of product from suction to discharge, thus transporting product through the pump while maintaining product quality. A sliding scraper gate within the pump prevents the return of product past the discharge and back into the suction side of the pump. Curd and whey applications typically call for MasoSine pump models such as the SPS-6, MR-160 or EC60. These are all six-inch positive displacement pumps that can operate at speeds up to 320rpm in curd applications to replace an equivalent positive displacement rotary style, double shaft, double rotor unit. MasoSine pumps are usually paired with a variable frequency drive in order to optimise pump speed and flow rate. Applications usually involve emptying double-O vats and transferring to drain tables. Maintenance is also simple – with the pumps capable of being cleaned in place. Go to www. demm.co.nz/enquiry quote:

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D110718

Bagging plant upgrade for food producer

Committing to the future

Next Generation! With the professional Testo data loggers, a new age begins for you

Logger series testo 174

Logger series testo 175

Logger series testo 176

The new generation of Testo data loggerss Record the temperatures in refrigerated and deepfreeze rooms reliably, and if required additionally monitor the product temperature – e. g. with the testo 175 T1 – certied according to DIN EN 12830 Aurora Process Equipment provided this quality transfer, bagging and stitching solution for an Auckland food producer.

A MAJOR Auckland-based food producer recently required a bagging plant upgrade to reduce labour, handling, health and safety issues, and increase throughput, accuracy and operator health and safety. The company had been operating a manual bagging slide and scale, portable stitcher and manual pallet wrapper. Aurora Process Equipment became part of the food producer’s progress planning and, after analysing its needs, made recommendations to suit the process and to help achieve the customer’s goals. Aurora provided a range of process equipment including a floveyor (aero-mechanical conveyor) to transport product to the bagging bin; a 3.3 cubic metre food grade P.E. bagging bin; Taylor TE100 automatic bagging scale; a bag closing conveyor and stitcher; as well as a pallet leveller and wrapping station. By implementing this equipment into their process and keeping the same number of staff, the client increased production, reduced manual handling and strain injuries, and achieved much greater accuracy. “We would recommend this equipment, and be free to bring anyone through our plant,” was the client’s feedback. Go to www.demm.co.nz/ enquiry quote: D110719

•

Your benets from the new Testo data loggers: • High user-friendliness thanks to easy programming and readout via standard interfaces (Mini USB, SD card) • Security thanks to password protection and anti-theft lock • Large memory for up to 2 million measurement values (testo 176) • New software ComSoft Basic 5 as a free download

AUCKLAND : Tel : (09) 579 1990 WELLINGTON : Tel : (04) 499 3591 CHRISTCHURCH : Tel : (03) 366 0017 Email : sales@eurotec.co.nz WEBSITE : www.eurotec.co.nz

fOOD PROCESSiNg

In-line leak testing of MAP packaging MODIFIED atmosphere technology has taken root in the food industry and keeps gaining importance. For a long time the actual packaging process was the centre of attention of process enhancement – now conclusive leak testing has become increasingly important. Protective gas packaging appeals to producers battling for consumers, due to its promise of fresh, attractive and high-quality goods without additional preservatives at any time and any place. However, this modern packaging technique makes comparatively high demands on the packaging process. Most notably, the sealing process contains various sources of error which can lead to leaks – such as defective temperature or pressure distribution, improper sealing tool arrangement, impure or worn out tools, as well as seal contaminations. Defective material can also lead to undetected serial leaks. Even with special diligence during the process design, inaccurately packed goods cannot be totally avoided.

Expensive leaks The impact of leaking Modified Atmosphere Packaging (MAP) on product can be grave: from loss of nutrients to loss of flavour, taste, texture or colour to the point of deterioration due to pathogenic microorganisms. Depending on the product, even health risks cannot be eliminated and there may be legal consequences. Plus, expensive and image damaging product recalls can potentially jeopardize a company’s existence. Admittedly, leak testing in general is currently not regarded as a critical control point for the purpose of a HACCP concept. However, given the risk mentioned before it is not surprising that this topic has gained in importance for food producers – not least because major food retailers put increasing emphasis on the proven quality control of producers. Only complete leak testing of packages in the final inspection offers genuine safety. In practice, however, the intent of optimal quality in the past often collided with the aim of a preferably high production output. The reason? The available technical solutions for an in-line control simply couldn’t manage the high speed of the upstream packing machines. Therefore, many businesses currently often work with sample testing.

Thankfully, there already are systems that have solved this dilemma for food producers – for example, the in-line Leak-Master Mapmax system by Witt-Gasetechnik which focuses on the analysis of CO2 as a trace gas. The Leak-Master Mapmax features even the smallest detection of leaks. This is enabled by a measurement method developed by Witt which evaluates the signals of a CO2 sensor. With a speed of up to 15 cycles per minute products are conveyed into the test chamber directly after the packing process. This chamber is subjected to a certain level of vacuum briefly and this vacuum causes CO2 to escape from the leaky package, which is then detected by a highly sensitive sensor. The measuring range lies between zero and 5000ppm, with a resolution of one ppm. If a product is detected as leaky, the system can directly trigger a pusher to sort out a faulty package. Since testing of boxes and complete shipping cases is also possible, insufficient speed is usually not an obstacle anymore. Moreover, the use of CO2 makes this solution considerably less expensive for customers than, for instance, testing with helium. The system has already proven successful in numerous trans-European installations and is used for quality control of sausage and meat products, dairy products, bread or fish. For more information go to www.wittgas.com

Engineering Ltd

Integrators of specialised robot systems Phone: (64) 9 826 0580 Web: www.carbines.co.nz

"When the going gets tough - the tough get going"

July 2011

•

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PACkAgiNg & lAbElliNg

New packaging products increase shelf life

Next generation safety relays

A PrimePro carton liner.

EUROTEC Limited has announced the launch in New Zealand of a new line of ethylene adsorption packaging shelf life extension products designed and manufactured by DeltaTRAK, a US-based innovator of cold chain management solutions. PrimePro EAP (Ethylene Adsorption Packaging) products extend the shelf life of fruits and vegetables by removing ethylene gas that speeds ripening and decay from the packaging atmosphere. DeltaTRAK’s PrimePro EAP products will be offered in pallet cover, box liner and sheet form. “For people in the produce industry one of the most damaging effects of ethylene gas is the fact that it stimulates plant cells to increase their ethylene production, which accelerates the adverse affects associated with ripening, maturing, and decaying – thus shortening the window of time for shipping, storage, and sale,” says Frederick Wu, president and CEO of DeltaTRAK. “PrimePro EAP technology is extremely easy and quick to apply and does not require the extra time and expense of using other modified atmosphere packaging (MAP) gas systems.” The PrimePro EAP film contains a proprietary additive that removes ethylene from the air surrounding the fresh produce and will slow

July 2011

down the process of ripening and decay. The film is made of a porous, breathable plastic to allow proper exchange of gases through the packaging preventing the growth of anaerobic bacteria on fruits and vegetables. PrimePro EAP also has an anti-fog additive to reduce the accumulation of condensation inside the package. This feature is also essential for shelf life extension because excess moisture causes decay. PrimePro EAP used in conjunction with proper temperature management will ensure that produce is delivered in saleable condition with the best possible quality, and less chance of mould and bacterial growth. Go to www.demm.co.nz/enquiry quote: D110722

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WHEN it comes to safety relay offerings, there is a daunting choice of functionality, type and technologies. With this in mind, Rockwell Automation is introducing its next generation of safety relays, which address the majority of safety related applications. The company says this may sound like a paradox, but its offering comprises just six products. Existing Allen-Bradley Guardmaster safety relays will not become obsolete. Customers who wish to simplify their inventory and usage, will simply have the choice of a smaller family of next-generation safety relays. This much smaller family of relays can support a broad range of safety devices for a variety of applications. The universal input feature allows devices such as safety-interlock switches, emergency-stop switches, pressure-sensitive mats and OSSDdevices, such as safety light curtains, to use the same set of terminals. This removes the requirement for a specific safety relay for a specific type of input device. Simple logic tasks can also be achieved via the single wire safety connection between relays. This simple, one-wire link uses transistor technology and monitoring via dynamic signals. This removes the need for dual-channel connection and offers SIL 3, PLe safety rating. With this logic functionality, applications can be configured to offer flexible ‘AND/OR’ functional control. Other options can be configured for requirements such as regional and global e-stop functions. Go to www.demm.co.nz/enquiry quote:

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D110722a The PrimePro pallet covers.

PACkAgiNg & lAbElliNg

Flexibility is in the bag WHEN it comes to having the flexibility to produce a wide variety of bag styles on a single machine, the Bosch SVI range sets the benchmark. Distributed in New Zealand by NUPAC, the SVI series is capable of producing multiple standard bag styles, not just limited to pillow bags, side gusseted bags and stand up block bottom bags, but also bags with ‘corner seal’ and Doy style bags with optional zippers. “There is no doubt the Bosch SVI vertical series includes some of the most flexible bag makers available,” says Peter Pontikis, managing director, NUPAC Industries. “This flexibility provides the most costeffective and competitive solution for customers looking to increase their production efficiency as well as differentiate their products at pointof-sale with a diverse choice of bag shapes and styles.” The SVI series consists of two machines for packaging different bag sizes and lengths: the SVI 4020

packages bag sizes 120-400mm wide and 100-500mm long, while the SVI 2620 produces bag sizes 60-260mm wide and 100-400mm long. The combination of low machine height and numerous retrofitting options make Bosch’s SVI series ideal for packaging an extremely wide range of food and non-food products, including powders, bakery and confectionery items, tea, coffee and fresh pasta as well as pet food and non-food products such as detergents. “In addition to the number of different bag styles these machines can produce, it’s the speed at which operators can switch between bag styles that also makes them so popular,” explains Pontikis. “For production of pillow bags, side gusseted bags and stand up block bottom bags, the operator simply changes the forming set. “For corner edge sealing, the manufacturer can upgrade the machine with an additional modular unit without the need to change or

adapt the machine height or the dosing platform. The production of a Doy style bag can be easily performed by turning the machine’s cross seal jaws to a 90 degrees position. This reduces downtime during format change and increases the overall performance of the equipment.” The flexible SVI machines also offer heatsealing and poly

heatsealing options, with freely adjustable sealing temperatures according to product specification. “If you’re looking for a bagging machine that will provide you with the largest number of output options, then look no further that the Bosch SVI series,” says Pontikis. Go to www.demm.co.nz/enquiry quote:

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D110723

PACkAgiNg & lAbElliNg

MHL Show offers mini booths at mini prices THE exhibitor line-up at MHL 11 – New Zealand’s materials handling, warehousing and logistics trade show – is looking strong as stands continue to fill fast and visitor registrations increase. As the ‘three months to go’ milestone rolls by, the organisers have increased the number of smaller sized stands available to potential exhibitors. “There are still a few good sites available” says sales manager, Brian Simpson, “but if you are considering exhibiting, now is the time to act to avoid disappointment.” Over 70 materials handling, warehousing, logistics and technology suppliers representing international and local firms will be exhibiting, demonstrating and discussing the latest technology. Not only does MHL deliver a world class trade show, but this year, visitors will also have access to a number of exhibitor workshops and industry seminars. One repeat exhibitor, Dematic

Two Shows Two Days One Venue...

on stand 257, a global leader in intelligent logistics and materials handling solutions, will amaze crowds with its voice-directed computing technology and new supply chain software, allowing SMEs to integrate voice-directed computing into their warehouses utilising their current system. Secure ALoad on stand 237, a specialist in cargo handling and load restraint systems, will prove the advantages of investing a little to reduce theft and make the transport and handling of materials safer. Other exhibitors sure to impress with high quality seminars and workshops include Crown NZ on stand 249, Pocket Solutions on stands 241 and 243 (mobile computing and automated data capture solutions), and ride-on industrial cleaning company, KP Sweeping, on stand 221. MHL 11 will maintain an innovative and futuristic focus for which it has earned a reputation, with the Kerrect Interlogic

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July 2011

interactive theatre wowing audiences for another year. While the organisers are still reluctant to give too much away, the theme of the interactive theatre is likely to be ‘The Next Evolution in Logistics’. Repeat exhibitor, Power Save Light Company, is once again on board to assist with the lighting for the interactive theatre as well as showcasing all of its energy efficient, cost saving, industrial and commercial lights and fittings on stand 248. Other local materials handling, warehousing, logistics and freight transport firms that have signed up to exhibit in the last week include GS1 on stand 229 – the New Zealand arm behind the only global system for bar coding, and for standardised

identification of products, assets, services, places and organisations. Independent Verification Services on stand 213 are experts in NZ’s biosecurity system, regulations and business requirements and is a new training provider for the National Certificate of Freight Forwarding. Running alongside MHL 2011 is The National Safety Show 2011, New Zealand’s largest dedicated workplace health and safety event. MHL and The National Safety Show will be held in pavilions one and two at the ASB Showgrounds in Greenlane Auckland on 21 and 22 September. For further information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www.mhlshow. co.nz

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Heat-shrinkable continuous ID tubing ��

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TE Connectivity now has a new low fire hazard, heat-shrinkable, continuous identification tubing for a multitude of applications. HXCT continuous tubing is a flattened, heat-shrinkable tubing, providing superb print quality for wire and cable harness identification. The tubing offers several cost and labour benefits during a print run: as it comes on continuous 50m or 100m spools, it minimises the number of spool changes. In addition, sleeves can be printed at a typical print speed of 75mm per second, which increases production speeds. so one

part can be used instead of multiple assembled sleeves. Also, there is a flexibility to either cut or perforate the sleeve, with the latter saving manual cutting. The tubing can also be used for applications where limited fire hazard characteristics are necessary. The zero halogen material coupled with low smoke and low toxic fume emissions makes this product best used in enclosed spaces such as mass transit, marine and industrial installations. Go to www.demm. co.nz/enquiry quote: D110725

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Pasteurization systems provide green technology AS AN alternative to noxious gases, radiation, or carbon producing thermal techniques, Radio Frequency Company’s New Macrowave UltraSeries pasteurization systems apply a high frequency electric field to food products proven to effectively control pathogens. The material to be treated is conveyed through a high frequency electrode array where the alternating electrical energy causes the material to heat rapidly and uniformly throughout the product thickness. Due to this rapid, volumetric heating, the material is not exposed to elevated temperatures for long durations such that nutritional values and functionality are preserved. Radio Frequency (RF) heating is a highly efficient, ‘direct’ form of heating such that no energy is wasted heating large volumes of air or preheating the system itself. The technology is ‘instant-on, instant-off’ using energy only during the treatment process. Radio Frequency Company offers a full line of systems for the bulk or bagged pasteurization and/or insect deinfestation of nut meats, various types of flour, grains, pasta, tobacco, fishmeal, xanthan gum, and other food ingredients – as well as finished products. For more information go to www.radiofrequency.com

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Pipes measure up for rebuild The February earthquake in Christchurch rendered the FrankPKS team’s premises unusable, but the men knew their city would need their product for rehabilitation. So they packed their massive machines and moved. Sixty days later sewage, water, and irrigation pipes were rolling off a new factory floor. Jenny Baker reports. In early February, Christchurch company FrankPKS achieved a milestone in its history. It manufactured a two-metre-diameter extruded high-density polyethylene (HDPE) plastic pipe, the largest in New Zealand. Barely a week later, on February 22, an earthquake devastated the city, irreparably damaging FrankPKS’s two factory sites in Bromley, as well as damaging some plant. New Zealand rallied fast to assist the stricken city, and the FrankPKS team, too, lost no time to assess its situation and implement remedies to restore the factory’s production.

July 2011

GM Bryan Wilson with the first two-metre HDPE pipe produced in New Zealand.

“We’ve been part of Canterbury a long time, through both the community we live in and the products we make,” says general manager Bryan Wilson. “We knew once the immediate shock was over we’d have to start rebuilding our lives and, at the same time, play our part to rebuild our city. I’m lucky to be part of a great team. When the pressure was on, the team members performed with immense skills in record time – hands to the helm and steering. A lot of people helping each other.” The team spirit travels a long way. FrankPKS was established in 2005 as an associate of Frank GmbH in Germany. The company produces high-density polyethylene extruded wastewater, stormwater and irrigation pipes for supply to the infrastructure market around New Zealand. The production process is flexible, and the dimensions and stiffness of the pipe is designed according to the customer’s requirements.

Size matters Until recently, a 1.8-metre diameter pipe was the biggest the factory could produce. Bigger pipes were imported from Europe. In August last year, the company decided to invest in specialist new tooling machinery to make twometre diameter pipes on site too.

Manufacturing a 1.8-metre diameter pipe.

fEATURE

Welding benching into a manhole for Tauranga’s Southern Pipeline Project.

Wilson says the possible development of large-scale irrigation schemes across the Canterbury Plains and the rejuvenation of existing open race irrigation systems throughout the province mean Canterbury has a particular need for pipes of this size. “The pipes are in many instances replacing older concrete pipes, for large infrastructure like sewerage and stormwater systems. We believed that given the applications that largebore HDPE pipe can be used for, it was an investment well worth making,” he says. FrankPKS has contracts to manufacture pipes for projects in Dunedin, Nelson, and Tauranga. Wilson says after the September 4 jolt in Christchurch the team realised there would be a real need for its products to be used in the repair of the city’s sewer system. “After the February and June earthquakes, there are likely to be even more. “The increased diameter and capacity of the new production line is likely to serve Christchurch well as the rebuild of the city’s sewer system gets underway. We now have the opportunity to rebuild in a way that futureproofs our city, and avoids mistakes of the past. I believe our product is ideally suited for our conditions,” he says. In addition, Wilson says the HDPE pipes are more flexible and have twice the service life of concrete pipes. The end product is a fraction of the weight of traditional concrete piping, making transportation and installation costeffective. HDPE profile pipes also provide high

strength and SN ratings. “It is ironic that given the need in Christchurch and Canterbury for large diameter plastic pipe, the first pipe to be produced would service a new trunk sewer development for the city of Tauranga,” he says. He estimates the February quake delayed production for the Tauranga job by about three weeks.

Pipe production Wilson explains that extruded pipes, in particular larger ones, require a precise manufacturing procedure under strict operational constraints. First, a software controlled gravimetric dosing system mixes the raw material PE pellets. The pellets then go into a 10-tonne tangential extrusion unit, where they are fused through heat and pressure, resulting in a homogeneous mass. Next, a die head connected to the extruder emits the mass as a band. The die head is part of a moving production station that passes along a six-metre-long rotating steel mandrill on a rail system. The band forms overlapping continuous loops around the mandrill, which is preheated by gas heaters. The mandrel sits on a platform of driven rollers. For the production of a profiled pipe, the head emits a two-layered mass. A co-extruder produces the first layer in a bright colour that facilitates inspection. The main extruder produces the second layer. This gives the pipe maximum stiffness with the most frugal

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fEATURE damage the older plant sustained to various drives and gearboxes. The next day, Bryan Wilson and manufacturing manager Nick Brown decided on a sensible division of tasks. Wilson would focus on staff and dealing with customers, while Brown would focus on the move itself. Wilson lost no time getting hold of customers, informing them of delays in delivery, explaining the team’s plan of action, and negotiating new schedules. While some of the staff had to take time off to attend to personal matters, the team members who could turn up did the lion’s share of the work involved in the move and preparing the new premises to receive the plant. This involved levelling floors, laying down a series of rails, and hooking up the processors, plastic vats and cooling towers. Manufacturing a two-metre-diameter HDPE pipe, the largest of its kind to be made in New Zealand.

possible use of materials. Frank GmbH designed and built the tangential extruder production unit and mandrils, which range in size from 500 millimetres up to the new 2,000-metre unit. The equipment was installed by FrankPKS staff following training in Germany. All the equipment needs to stand on a perfectly level platform for the process to work – this is one of the reasons the February earthquake brought operations to an abrupt stop. Wilson says fortunately none of the new plant was damaged in the earthquake, and neither was the extruder. The jolt however knocked down some of the walls and, critically, caused liquefaction of the floors. “Technically the buildings were still standing up, but rendered unusable. This left us with a problem – there was no way we could operate and if we don’t operate, we go out of business. So it was shoulders to the wheel, and immediately,” Wilson recalls.

Post-quake action Within the first few hours of the February

The first consignment of pipe ready to ship after the February 22 earthquake.

quake, all 19 staff members had determined they and their families were safe. They started clearing debris from the extruder, and put in the temporary power to test whether it was in working order. Within the next seven days, the team, assisted by Mark Richardson Engineers and Action Electrical from Christchurch, ensured it was functional and had repaired

Contractors installing an HDPE pre-fabricated manhole for the Gore District Council.

July 2011

Mark Richardson Engineers assisted, doing, in Wilson’s words “…an excellent job”, while Smith Cranes moved the plant. The latter was difficult work, as the cranes had to be positioned carefully over the damaged area to lift the plant, and then had to position them precisely on the rails again on the other side. “We had white knuckles and short tempers, but Smith Cranes did it just right,” he says. Wilson says the business has actually been able to improve its production facilities by streamlining its manufacture process at the new site. Previously, it had to move product between the Senior Place and Whickam Street sites. By the end of April the two sites had been consolidated and pipe was rolling off the factory floor again. The company is now filling its orders without problems, including the pipes to Tauranga. Says Wilson: “Our customers all round the country have been very good to us, very understanding.” Current contracts will keep FrankPKS busy all through winter, and beyond that the business is eyeing an opportunity to supply pipe for the repair of the Christchurch City Council sewerage system. No production staff were laid off as a result of the earthquake and, in fact, since the business will increase production this year, more staff will need to be hired. Jenny Baker is an Auckland-based freelance writer.

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ADVERTORIAL

ACC experience rating rewards safer workplaces By ACC General Manager Insurance & Prevention Services, Dr Keith McLea With the introduction of experience rating on 1 April this year, ACC can now provide businesses and self-employed people with fairer ACC Work Account levies. Experience rating means a business’s ACC claims history is now factored in when ACC calculates its levy payment. It gives discounts on levies for businesses with better claims histories, similar to no-claims discounts offered by your insurance company, and puts loadings on those with poor safety records. Image: Dr Keith McLea – ACC’s General Manager Insurance & Prevention Services

Experience rating looks at your

loading of up to 50% on the current

to their levies, while those with a

claims history, so what you do right

portion of your Work Account levy.

total duration of more than 70 days

now matters. If you can improve

ACC will look at the number of

or any fatal claims will receive a

workplace safety and reduce your claims, it will have a direct impact on the levies you pay later. That’s good for businesses, it’s good for ACC, and most importantly of all, it’s good for employees.

10% loading.

work-related injuries with medical

When you receive your experience-

costs of $500 or more during the

rated invoice, there will be additional

three-year experience period (for the

information explaining how we’ve

2011/12 levy year this is from 1 April

applied it to your business and what

2007 to 31 March 2010), the length

In addition to introducing experience

claims were included. It will also

of time employees receive weekly

rating, ACC has increased the

show any discount or loading to the

compensation, and any fatal claims.

current portion of your ACC Work

That information will be compared

Account levy.

with information on other

Some businesses are not eligible

businesses in similar industries,

for experience rating and will have

with similar injury risk profiles. If

their levies calculated as usual.

your business’s claims performance

These are businesses and self-

is better, your levy may be lower.

employed people that have not

However, if your performance is not

been operating for at least three

as good, your levy may be higher.

years, and those whose earnings

For smaller businesses and self-

are below the minimum for each

employed people with annual

year of the experience period.

number of levy risk groups and made changes to some classifications. These changes will enable us to group businesses with similar levels of risk more fairly and accurately. For some businesses, this may result in an increase or decrease in their base levy rate against which experience rating can be applied. How experience rating works

ACC 2261

claims made by employees for

The amount of levy discount or

levies of less than $10,000, you will

loading depends on the size of

get a no-claims discount of 10%

your business, how many claims

provided no weekly compensation

employees have made and the

claims or fatal claims occurred in

industry you are in.

the experience period. Those who

If yours is a larger business paying

have had weekly compensation

annual ACC levies of $10,000 or

claims with a total duration between

more, you could receive a discount or

one to 70 days will see no change

To find out more about experience rating, injury prevention support and our return-to-work programmes go to www.acc.co.nz/er

MAINTENANCE MATTERS Superior New Zealand-made screws IT has been almost 32 years since Rotorua-based Screw Productions first began manufacturing fastenings for a wide range of local industries. A lot of screws, rivets and associated fasteners have rolled off the company’s production line since – and for both local and overseas markets. The manufacturing environment has changed a great deal since those early days and today the company finds itself as one of the last bastions of local fastener production. 100609_tcrange_leaflet_v4_MB.qxd:A4

100609_tcrange_leaflet_v4_MB.qxd:A4

25/6/09

12:31 PM

Fortunately, after the turmoil of the late 80s and 90s, Screw Productions has emerged as a strong leader in the fastener field – small and specialised compared to overseas manufacturers perhaps, but nevertheless able to provide customised fasteners to suit particular client applications. In the face of the wave of Asian product flooding the market, Screw Productions pride themselves on being able to provide a superior level of product quality and, just

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Leaf: TCRange 06/09 Australian Sales Branches Telephone Email Melbourne (03) 9262 3355 melsales@renold.com.au Tasmania (03) 9262 3355 melsales@renold.com.au Sydney (02) 9618 7984 nswsales@renold.com.au Wollongong (02) 4256 4110 nswsales@renold.com.au Newcastle (02) 4969 5944 nswsales@renold.com.au Brisbane (07) 3275 2155 brisales@renold.com.au Townsville (07)5018, 4779 5922 tvlsales@renold.com.au AUCKLAND 594 Rosebank Road, Avondale, Ph: 09 828 Fax 09 828 5019 Email: aksales@renold.co.nz Adelaide (08) 8346 9077 adlsales@renold.com.au CHRISTCHURCH Ph: 9479 03 338 2169, Fax: 03 338 8663, www.renold.co.nz Perth 31 Birmingham Drive, Middleton, (08) 1388 pthsales@renold.com.au

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July 2011

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as importantly, a solutions-focused approach to service. Dealing with Asian suppliers is often not as nearly straightforward. ‘Special product’ is a major part of business for Screw Productions. “There are so many special needs for manufacturers of built-up products and we have the expertise and technology to help with any special fastening needs,” says MD Paul Adlam. “It’s not just in the manufacture of suitable fastenings either – we also get involved at the design stage.” Awide range of industries look to Screw Productions for small runs of special fastening products that will fit and perhaps enhance their products. These industries include automotive, aluminium joinery, kitchen joinery, car restoration, curtain and blind companies, roofing and spouting, electrical products, switchgear, dairy farm equipment, appliance manufacturers, to name just a few. Adlam and his team welcome feedback from industry – even on fastener products by other

manufacturers. “As a manufacturer we like to know, and record, what problems are about so we can take steps to ensure we don’t produce similar product,” he says. “All our product is put through stringent testing and measuring procedures to ensure our product will not cause user frustrations. “Even though your problem screws may not be made by our company, we would be interested in learning of your problem and seeing if we can establish the cause and subsequent solution.” “Experience shows that a large proportion of complaints of faulty screws have nothing to do with the screw quality,” says Adlam. “Many screw failures are due to the wrong fasteners being used in the application, or the use of improper installation techniques. “If you have a problem, go to our website (screwproductions.co.nz) to contact us and you’ll also find useful stock and technical information.” Go to www.demm.co.nz/enquiry quote: D110730

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New capabilities at CMI

CMI Fasteners has recently embarked on a strategy to further boost its technical strength. This follows an investigation of new opportunities coming via the international fastener market. “After upgrading our ability to make and alter tooling in-house approximately 12 months ago we have researched new plant,” explains general manager Andrew Baker.“Our latest addition has been a ‘pinch point’ machine which allows us to make drill point screws to order. “Currently we are working to install and commission a mechanical plating plant, which provides an alternative to electroplating and hot dip galvanising. This will service the fastener market generally plus allow us to launch a new range of zinc-plated fasteners with corrosion resistance much higher and more technically developed than anything else in the local market. “This plating can also be applied to small parts other than fasteners.” Baker says clients choose CMI products mainly for the technical support and to ensure the fastener is correct for the application. “At CMI you are always talking to people very close to the manufacture of the fasteners, people with broad technical knowledge,” says Baker.“Our level of experience in the manufacture of fasteners is second to none. We repeatedly see customers using imported goods who experience a failure or change in their fastener and struggle to rectify the issue. Often the response is to dump the fasteners and get a new batch until a workable product is located. In a critical

situation having cheap fasteners lets you down is the last thing you want.” CMI’s major strengths are that it can consistently manufacture and supply-to-order fasteners that are fit for purpose.“High repeatability is important especially where the fasteners go into an automated application,” says Baker.“We stay up to speed with fastener developments worldwide. This means companies working in new product development can utilise our technical skills to ensure they get the most up to date input. We have started a cycle of product development ourselves which ensures we are updating our own capabilities to stay up with the contemporary fastener market. “Kiwi based companies are often great innovators and being limited by fastener technology is simply not acceptable. We have case studies where customers have used imported product for years, attempted product development but have not been able to get anywhere because the company making the fasteners is too remote or there are other barriers to the open communication and sharing of IP that is required to succeed at an international level.” Baker acknowledges that niche production runs will always be a large proportion of CMI’s work.“However, we desire to become so technically strong by working with our partners that our type of service becomes indispensible. In some cases we are looking to develop IP that really does belong to us and we have a number of informal arrangements already in place protecting some key customers. “The ability to find and develop IP

MAINTENANCE MATTERS

is just as important to a manufacturer like CMI as it is to a technology or IT company,” explains Baker.“We already have some of the most experienced machine setters in the world in this discipline. And as we expand our technical knowledge we increase our value to the market.” Baker says CMI has around ten projects in its product development pipeline at any one time: most of which are confidential.“The next most important projects include extending our technical coatings to build on the mechanical plating. This will add dip/spin technology and the ability to make coloured fasteners. We have a particular interest right now in titanium coatings of a range of substrates similar to coatings on machine tooling. “Also, advanced methods of metallurgical analysis are of interest, and very important when troubleshooting. “Modern fastener equipment is easily available internationally so new products requiring new plant is not as

capital intensive as other industries,” says Baker.“Therefore if there are companies who desire a fastener not currently made in New Zealand and they’re interested in a contractual relationship to produce them, then they should talk to us.” In recent times CMI has been working on developing fasteners for changes in the steel construction industry. “We’ve had to track these changes with one of our key customers, commissioning new plant and keeping up with their product development timelines as we go,” says Baker. Consistency in batch performance is one of CMI’s key strengths he says. He knows of at least one company that has been caught out by inconsistencies through the use of imported product. Getting to the source of an issue can be problematic when the supply chain is long. “Whereas, with CMI, you can talk to the source of the fastener instantly.” Go to www.demm.co.nz/enquiry quote: D110731

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CMI Fasteners Ltd Quality made certain CMI FASTENERS QUALITY MADE CERTAIN

CMI is committed to pursuing customer satisfaction in order to be the preferred New Zealand manufacturer and supplier of small fasteners by providing quality products and excellent service.

For more information on your requirements please contact us: 246B James Fletcher Drive, Otahuhu, Auckland, 1024 Phone: +64-9-270-0522 Fax:+64-9-270-0533 Email: sales@cmifasteners.co.nz

MAINTENANCE MATTERS

CAD and CAM: maximising the synergy COMPUTER Aided Design (CAD) and Computer Aided Manufacturing (CAM), somewhat surprisingly, still struggle to find their place in New Zealand’s engineering community, and their combined role is not as well understood as it should be. This is the view of Prosoft’s managing director Roy Parlane. Engineers generally understand drawing, design and modelling – the elements of CAD– he says. “But CAM is a different matter, with the collective power of both often missed or, at best, compromised. “Recognition needs to be given to the role and interface ability of both CADand CAM,” he adds. “In a pure design case, less importance may be credited to CAM; however it should not be entirely overlooked. Agood understanding of the role of

providing clean drawing or model files that have no construction lines left in the file and/or where layers are clearly defined or removed, says Parlane. “The key is to leave a clean solid file which can then be easily imported, allowing manufacturing strategies to be quickly applied. “One alternative is to have

CAM following the design process has the ability to enhance business opportunities – for example, providing models in the format that the CAM user can easily accept and/ or modify will significantly help reduce the time to process the file for machine part manufacture. CAM is often best served by CAD

a package that can seamlessly interface with that of the CAD product. Agood understanding of the application limits is required when evaluating this option.” When purchasing CAD/CAM software, due diligence in these matters is imperative if companies want to avoid under-performing

outcomes. Parlane says often the problem is that the purchase exercise is given dominance over the implementation process. “The implementation process for CAD/CAM has been traditionally undervalued and, in the case of CAM, it can be extremely disadvantageous to good outcomes for the company involved. “It should be noted that the more significant impacts of success and profitability rest heavily on the CAM function, not CAD. In other words, it’s very easy and less expensive to create a new model or drawing than to remanufacture a part. “In many cases at engineering shop level, engineers and middle management approach the software purchase individually. This results in little or no consideration of how the two (CAD and CAM) might best be interfaced to capture the maximum synergies. Amore planned approach is paramount.” Parlane says CAD/CAMsoftware should not be seen as an ‘add on’ to the business – but the very foundation. As such, it’s important to keep up to date with any new software developments.“Until this is truly recognised the company will always have difficulty in moving forward.”

Do it once, do it right Parlane’s advice to engineering companies is to carry out proper research through accredited sources to truly assess the suitability and sustainability of any potential CAD/ CAMsoftware. “Do it once and do it right. I have seen on far too many occasions companies purchasing new replacement software and/or running multiple packages based on personal preference rather than the synergy consideration of company and staff. “Understand the value of a proper

July 2011

maintenance program. Learn from the poor purchase decision made in the first instance.” Get it wrong, he says, and you’ll almost inevitably incur a negative impact on your bottom line.“One that might not be so clearly obvious in the immediate term.” Parlane says we can look to Australia for inspiration. “There I have noticed on many occasions that the evaluation process and purchase recommendation are made by the professional engineers within an organisation. “In New Zealand financial professionals allocate budget and make final decisions often without the engineer’s consideration being taken into full account. Pressure is often exerted upon the engineer to accept the lower priced option, making for a compromise in performance. “I believe there is an engagement gap between the roles of financial managers and engineers, with overriding consideration being placed on the initial investment cost rather than performance and longer term sustainability.” One issue creating real concern for Parlane right now is “the fact that industry and educators are not working cohesively in the way they go about training young student engineers in CAD/CAM. “There’s little recognition of today’s learning programs – programs developed and maintained to world standards and being denied to our new student trainee engineers due to the lack of understanding of the speed of technology by those in control of education.” Prosoft is currently seeking a strategic partner to become a ‘certified provider’for the delivery of MastercamU(Mastercam University) online CAD/CAMtraining courses to the student, engineering and manufacturing sectors. Parlane says there is a real need to provide a sustainable uniform nationwide standard of CAD/CAM training which not only meets the needs of New Zealand industry, but is also recognized globally. “One that is proven, used internationally globally and linked to technology partners who drive its continued advancement.” Go to www.demm.co.nz/enquiry quote:

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D110732

MAINTENANCE MATTERS

Gears for every industrial application

GEARS quite literally turn the wheels of industry, and when it comes to gear manufacture and repairs, Christchurch-based family business Duralloy Gears has an outstanding reputation for meeting and exceeding client expectations. Duralloy Gears sales and production manager Hadleigh Jones says the global recession and the Canterbury quakes have had little impact on the company. Its

12 specialist staff are fully engaged and committed to building and repairing gears for a diverse range of applications. “No job is too big or too small for Duralloy – we make gears from 2.5 metres in diameter to tiny precision gears that are used in medical equipment for eye surgery,” he says. “Our gears are in aircraft – such as the landing gear for the Lockheed C130 Hercules – as well

as printers, ski lifts, fishing winches, sewing machines, locomotives, wind turbines, cars and motorcycles – to name just a few. “We can produce anything from a single gear to large production runs,” adds Jones. “We combine manufacturing efficiency and gear cutting precision to ensure a consistently high quality job, gear after gear. Each project is planned to produce a gear which meets our strict specifications and is monitored constantly according to exact testing and quality control standards.” Beware of cheap gears, warns Jones, made with budget materials and low spec equipment. “They may cost you much more in the long run with replacements and downtime.” Specialist services at Duralloy Gears include precision grinding. “We have a rare internal cylinder grinding machine which allows us to grind units with large bores while holding the unit stationary – ideal for applications such as the grinding of large hydraulic components.” Gear and spline grinding is also performed using machinery unique in New Zealand – and the company is well equipped for all the disciplines of turning and machining. Gear repairs and gearbox servicing are also fields that Duralloy excels in, and has done

so for more than 60 years. It is the approved service agent for Lohmann+Stolterfoht and Kissling gearboxes. “We still use specially imported welding rods and equipment for our repair work,” says Jones, “as well as crack testing and inspection. We use detailed gear measurement and inspection machines to check that the repaired gear is within tight specifications for use.” Jones says the company has invested heavily in new technology, improved processes and training to improve the overall quality of its gearbox servicing and maintenance. When it comes to the reconditioning of gears, it offers a service that is not only environmentally friendly (by not requiring new raw material) but also cost efficient for the client. “We re-gearcut the large gear with carbide coated hobbs or gear-grind the teeth to obtain a new tooth surface and make a new drive pinion sized to suit,” says Jones. “This provides all the main benefits of a new gear set at a fraction of the cost.” Duralloy Gears provides full consultation services, including on-site – and emergency support and breakdown teams are available when required to minimise costly down time. Go to www.demm. co.nz/enquiry quote: D110733

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POWERFUL SOLUTIONS. GLOBAL FORCE.

Safe and swift heavy lifts Enerpac’s easily manoeuvrable and self-contained POW’R-RISER® lifting jack provides safe and efficient heavy duty lifting in even the tightest locations and over rough terrain. This outstanding innovation from the trusted name in high-force tools combines a high capacity (54-181 ton) cylinder and an electric or air-powered hydraulic pump unit integrated into a mobile cart.

Enerpac POW’R-RISER®

Enerpac POW’R-RISER® has the speed, power and versatility for a wide variety of on-site site applications, including: • Servicing tyres, tracks and other maintenance functions on heavy equipment • Lifting and positioning of large constructed elements • Safe heavy lifting in remote locations.

AUS 1800 225 084

NZ 0800 363 772

info@enerpac.com.au www.enerpac.com.au

neville@enerpac.co.nz www.enerpac.co.nz

MAINTENANCE MATTERS

Vibration tester for on-site diagnosis THE Fluke 810 Vibration Tester is an advanced troubleshooting instrument that enables maintenance teams to rapidly collect data and diagnose and solve mechanical problems. The handheld Fluke 810 is designed and programmed to diagnose the most common mechanical problems of unbalance, looseness, misalignment and bearing failures in a wide variety of mechanical equipment – including motors, fans, blowers, belts and chain drives, gearboxes, couplings, pumps, compressors, closed coupled machines and spindles. When it detects a fault, the Fluke 810 identifies the problem and rates its severity on a four-level scale to help the maintenance professional prioritise maintenance tasks, and recommends repairs. Context-sensitive on-board help menus provide new users with real-time guidance and tips. The Fluke 810 Vibration Tester uses a simple step-by-step process to report on machine faults the first time measurements are taken, without prior measurement history.

The combination of plain-text diagnoses, severity ratings and repair recommendations helps users make better maintenance decisions and address critical problems first.

Planning & Scheduling for Planners 4 Day CourSe

Course Highlights

Leads to unit standard 26566 – Demonstrate Knowledge of Planning & Scheduling in BCM. Part of level 5 National Certificate in Mechanical Engineering. Training for existing planners and schedulers can increase tradesmen time on tools by 50% or more. Teach planners the tools they need to take planning to the next level.

Course content includes:

Freeing up of technician’s time with more effective planning and scheduling

Typical vibration analysers and software are intended for monitoring machine condition over the longer term, but they require special training and investment. The Fluke 810 is designed specifically for maintenance professionals who need to troubleshoot mechanical problems and quickly understand the root cause of equipment condition. Mechanical diagnosis with the Fluke 810 begins when the user places the Fluke triaxial TEDS accelerometer on the machine under test. The accelerometer has a magnetic mount and can also be installed by attaching a mounting pad using adhesive. A quick-disconnect cable connects the accelerometer to the Fluke 810 tester. As the machine under test operates, the accelerometer detects its vibration along three planes of movement and

transmits that information to the Fluke 810. Using a set of advanced algorithms, the 810 Vibration Tester then provides a plain-text diagnosis of the machine with a recommended solution. Evaluating mechanical equipment typically requires comparing its condition over time to a previously established baseline condition. Vibration analysers used in condition-based monitoring or predictive maintenance programs rely upon these baseline conditions to evaluate machine condition and estimate remaining operating life. In contrast, the Fluke 810 analyses current machinery condition and identifies faults by comparing vibration data to an extensive set of rules developed over years of field experience. It determines fault severity using a unique technology to simulate a fault-free condition and establish a baseline for instant comparison to gathered data. This means that every measurement taken is compared to a “like new” machine. The Fluke 810 Vibration Tester includes Viewer PC software to expand its data storage and tracking capability. With Viewer the user can: • Create machine setups at the computer keyboard and transfer the data to the tester. • Generate diagnostic reports in PDF format. • View vibration spectra in greater detail. • Import and store JPEGimages and Fluke .IS2 thermal images for a more complete view of a machine’s condition. Go to www.demm. co.nz/enquiry quote: D110734

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Improving the scoping of work orders

Developing plans to identify critical path, slack in the current system and resource identification Major maintenance event (annual shut) planning and management

Understand good work management process and subprocesses

Dates/Locations 14 – 17 June, Rotorua

23 – 26 August, Auckland

Investment $1,680 + gst

29 November – 2 December, Auckland

For more info: www.skills4work.org.nz or contact Phil Hurford p.hurford@skills4work.org.nz 027 488 6446

July 2011

From our website this month: iMonitor provides solutions that enable the management of assets no matter where they are in the world – via satellite, cellular and wireless mesh networks.

For the full story go to

www.demm.co.nz

MAINTENANCE MATTERS

Operational and maintenance challenges with transmission chain Aprime example of the benefit of Solution Chains is the Daiken MDF plant in Rangiora. On its express conveyor it was having constant chain breakage problems. Having tried most chains on the market, Ian Doggett found that the Renold Synergy chains outlasted all others, and the chain problems were eliminated. The estimated annual cost saving is $81,000 for an investment of less than $10,000. This has freed up over 60 hours of maintenance time to do something more useful. This type of application, and solution, is surprisingly common. Where maintenance managers are putting up with a high cost maintenance area, the solution can be as simple as using the correct specification chain and sprocket. The savings are often substantial. In another example, the Laminex site in Kumeu, was achieving approximately three months chain life in a critical area of the plant. The incumbent supplier offered a special chain requiring special sprockets, with little or no improvement in life. Renold offered a Solution Chain with standard sprockets, which was still performing well after two years operation. The cost saving was ongoing at $30,000 after two years for an investment of $5,000. As in many areas today, the market is flooded with low cost products. Many of these are being sold as quality industrial chains rather than low cost chains. Renold is unique in providing a distinct three-tier product range: Tier 1. Renold Synergy. Up to six times the life of other quality chains. Aunique Solution product with no direct competition. Tier 2. Renold A&S. Areliable high specification industrial chain. Tier 3. Renold SD. An economy chain made by Renold that will outperform all other economy chains. Other Solution Chains include lubrication free Syno, wet environment Hydroservice, and abrasive environment Sovereign. That Renold has a chain for all segments of the market takes the risk out of knowing the brand. We work closely with our customers to understand their needs to offer the best solution for their business and work through a cost savings

calculator to help determine the most economic solution. Our customers profit and long term survival will be determined by operating costs. At Renold, we have been working hard to emphasise the three tiers of chain specification and performance so our customers can have the assurance that they are receiving best value for money. The added value comes from the brand, optimising plant performance, reducing operating costs and maximising profits. Our future

is entirely linked to our ability to enhance our customers profitability. For the future, Renold has developed Smartlink technology, which measures the actual load in a chain dynamically in operation. This can help identify the optimum chain for an application for maximum efficiency and reliability. Article supplied by Allan Grigor, New Zealand manager for Renold. Go to www.demm.co.nz/enquiry quote: D110735

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Hose reels for

HWG1215

OVER the past two years, with an ever-increasing demand on maintenance budgets, we have noticed an increased focus on ensuring value for money. Most organisations understand the value of preventative maintenance, but many also struggle with the up-front costs. So while some customers have been in survival mode, fitting economy chains only as and when the existing chain fails, Renold’s sales of Solution Chains have also been increasing due to the significant cost savings that can be gained from a longer lasting product. Asimple maintenance improvement can be changing worn sprockets. This may appear an unnecessary cost when you are changing the chain. However, a worn sprocket can reduce chain life by 70 percent and more, causing you to replace more chain, more often, as well as creating costly downtime. The cost of the sprocket can be recovered in a matter of minutes downtime. Additionally, we encourage the use of hardened tooth sprockets which will last three to four times that of mild steel sprockets – giving a corresponding improvement in chain life. Other customers have insisted in staying with our high performing Solution Chains. The argument has been that when maintenance staff have been cut, one of the last things they have time for is changing chain. Achain that lasts six times longer than others soon comes into its own at this point. We have found that our greatest challenge is to understand our customer’s business and plant, to be able to offer the correct specification chain to suit their requirements. This was amplified two years ago when Renold launched its low cost SD range of transmission chains. There was an immediate clamour for these chains. The SDchain was immediately successful – a low cost chain manufactured by the world’s leading chain manufacturer was always going to be of interest. However, the most noticeable effect was the number of times that customers started talking about a budget chain, then concluding that they needed a higher specification Renold A&S Industrial Chain, or even the unique Renold Synergy Solution Chain.

hot water wash down

ReCoila’s GEN III HW Series spring rewind reels are an ideal solution for hot water washdown in food processing areas. Various hose congurations are available with or without a heavy duty insulated washdown gun. Need a reel for a different application? We’ve got thousands to choose from - or we can manufacture to your specic requirements. Call us for more information or visit us online at www.recoila.co.nz

Phone +64 9 441 0177 Email sales@recoila.co.nz www.recoila.co.nz

MAINTENANCE MATTERS

Time to get back to basics

NOmatter what our role within our organisation is, we are all here for the same reason – to produce a reliable and quality product for our customers. Whether we work in

maintenance, operations or serve lunch in the canteen that’s the reason why we are all here. We can argue that we already provide a reliable and quality

MORE POWER FOR YOUR MONEY GATES POLY CHAIN GT DRIVES

Maintenance engineers around the world are changing to Gates Poly Chain GT belts. In comparison with other belts, Poly Chain GET drives weigh up to 35% less, use sprockets that are up to 67% narrower and have up to 4 times more power. Gates Poly Chain GT belts last longer, require no lubrication and are practically maintenance-free for reduced overall costs.

RR Fisher & Co Ltd PO Box 23293 Auckland

Auckland Ph: 09 278 4059 Fax: 09 279 8286 Christchurch Ph: 03 377 0025 Fax: 03 377 0086

July 2011

product and even argue that we are the market leaders, but we will only stay that way if we remain focused and keep on top of our game. For maintenance that means always striving to improve asset reliability because if we aren’t continuously making improvements then we can be sure that we won’t stay at the top of the heap for long in this globally competitive world. The over-riding concept of good maintenance is strikingly simple – get the basics right before moving on to more complex tools and processes. As engineers we love to focus on complex tools – whether that’s a physical tool like a new thermo-graphic camera or a process based tool like reliability centred maintenance. For most of us it’s far more satisfying to use something new than it is to ensure we are doing the basics right. So where should we start? The easiest productivity gains can be made in work management. Planning and scheduling is often the achilles heel of the maintenance department but when the figures show that unplanned maintenance is four to 12 times more expensive than planned maintenance it’s easy to see the radical effect improvements to work management can have. We need to look at our planners and schedulers and ask ourselves whether they are getting the support they deserve. Was the CMMS they’re using designed for maintenance or for accounting? Do they get the support of management? Are they well trained? Are operations involved in maintenance planning? Work management is a cornerstone of good maintenance and any investment we make in it will pay huge dividends.

Areas to focus on Improvements to work management will give productivity gains but when looking for equipment reliability improvements then the easiest gains can be found by focusing on three areas: detailed cleaning, correct lubrication and tightness of fasteners. In one study it was found that 55 percent of failures could be attributed in one way or another to incorrect tightening

of fasteners. During a recent maintenance training course I conducted only 30 percent of the technicians had easy access to a torque wrench. We all know how to correctly tighten fasteners and we all know the importance of the correct locking of fasteners but it is still an area that we should all consciously work to improve. By carrying out detailed cleaning we are able to spot faults before they cause failure. Dirt and foreign matter penetrates rotating parts, pneumatic and hydraulic systems, electrical control systems and sensors. This causes loss of precision, malfunction and failure as a result of wear, blockage, frictional resistance, etc. It is so easy to prevent this type of failure by a simple routine of cleaning and examining equipment but this must be more than a cursory wipe over with a rag. We should clean regularly, clean deeply by opening covers and guards, clean attachments as well as the main unit and don’t give up when a part gets dirty again. Note how long it takes and come up with a solution to protect it from contamination.

Lubrication Another area where real reliability gains can easily be made is lubrication. Lubrication is a huge and complex subject but we aren’t talking here about the relative merits of different lubrication systems or the molecular structure of oil. At an elementary level we simply want to ensure that lubrication is taking place when it should, that the correct type and amount of lubricant is used and that lubricants and lubrication equipment are correctly stored and identified. The smallest particle that can be seen by the human eye is around 40 microns but the oil film on a mechanical seal or bearing is far thinner than that. So, just because the lubricant looks free from dust and particles doesn’t mean there aren’t microscopic particles in it that could harm seals and bearings. The only way to ensure lubricants are not contaminated is to take care when using and storing them. We have to ask ourselves whether our approach to lubrication is as precise

and controlled as it should be. The only way for our organisation to succeed is to produce a reliable and quality product for our customer. The role of maintenance in this process is to continually work towards greater equipment reliability. While it’s tempting to look for a “quick fix” in the form of the latest tool or process it just isn’t that easy. Good reliability stems from good maintenance and good maintenance has always been about getting the basics right. Putting extra effort into better work management, detailed cleaning, correct lubrication and correct tightening of fasteners isn’t as interesting as some things we could be doing, but the results will

Committing to the future

NEW! always speak for themselves. Phil Hurford is the maintenance excellence programme manager for Skills4Work. Phone 027 488 6446 or email p.hurford@skills4work.org.nz

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Demonstrating safety and bolting efficiency

SOME of the world’s most compactly powerful non-impact bolting technology was introduced to staff of one of the resource industry’s most safety conscious employers recently when Rio Tinto Alcan (RTA) hosted a Manual Handling Ergonomics Expo at Queensland Alumina Limited (QAL) in Gladstone. Enerpac and hydraulic and lubrication partner Cooper Fluid Systems demonstrated a host of their latest technologies at QAL’s Ergo Expo, including Enerpac’s latest torque wrenches, pumps and high performance hydraulic bolt tensioners to facilitate faster, safer and more precise maintenance and fabrication operations. “This was an outstanding opportunity to demonstrate the best use of advanced safety and efficiency technologies directly to the people who use them and whose safety is

being safeguarded by their employer, RTA,” said Enerpac national bolting manager Pat Molloy. QAL’s Ergo Expo briefing says about 30 percent of RTA’s injuries arise from manual handling or workplace ergonomic issues. As part of a comprehensive initiative to address this issue, RTABauxite and Alumina sites have commenced the deployment of a Manual Handling and Ergonomic (MHE) program. The aim of the program is to eliminate or design out manual tasks and ergonomic problems rather than relying on administrative solutions to manage the risk. This program is based on participative ergonomics where employee involvement at each stage of the process is critical for success. Go to www.demm.co.nz/enquiry quote: D110737

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Testo 875 & 881 Professional Thermography

Professional Measurement Technology Testo, world leaders in the manufacture of measurement technology, provide a total range of measuring instrument solutions for fast and tough everyday use across a broad spectrum of industrial processes and industries. Applications include :

Testo 635 Humidity with wireless probe for Industrial Applications

Testo 830 Infrared Thermometer Measurement for industry

Testo 925 Thermometer with Standard, Infrared or Wireless Probe

Testo 175/177 Data-loggers

AUCKLAND : Tel : (09) 579 1990 WELLINGTON : Tel : (04) 499 3591 CHRISTCHURCH : Tel : (03) 366 0017 Email : sales@eurotec.co.nz WEBSITE : www.eurotec.co.nz

MAINTENANCE MATTERS

Sneak peek at conference papers By Craig Carlyle. The attendance fee of $680 +GST per person removes traditional cost hurdles for engineers. This year sees the introduction of the ‘Bring a Buddy’ rate of $400+GST per person for second and subsequent attendees from your site. Abetter bang for your buck will not be found anywhere else for such an inspiring and informative event. Registration forms and background/paper details can be found on the Society website at www.mesnz.org.nz/nmec/ For further details on the 2011 MESNZ Conference, contact Leanne Powley on (09) 296 1333, email info@adminoncall.co.nz or go to www.mesnz.org.nz.

Craig Carlyle is secretary of the Maintenance Engineering Society of New Zealand. Email craig@transformn.net.nz

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It’s not all serious stuff at the Conference, as these photos from the 2010 event prove.

WITHthe November 2011 National Maintenance Engineering Conference now approaching fast, pressure is mounting on the organisers to reveal the speaking program. Whether to justify attendance or a specific search for solutions, the speaking program is always eagerly anticipated by prospective attendees. This year has seen no reduction in the pressure to deliver and event facilitator (and MESNZ chairman) Barry Robinson has finally shown his hand with the first release of the 2011 program. Featuring an eclectic mix of international, expert and peer speakers, this year’s program is well worth the wait, satisfying the ethos of reality-based maintenance management topics and the Society aim of raising the bar of maintenance engineering in New Zealand. The two day conference will feature papers on ultrasonics, lean manufacturing, earthquake case studies, employment law, engineering education, competitive manufacturing, HASNO and preventative maintenance. The papers are designed to deliver a balanced mix of peer experience and expert learning to inspire attendees and arm them with the maintenance engineering tools to take back to their own workplace. The 2011 National Maintenance Engineering Conference is being held at The Distinction

July 2011

Hotel in Rotorua on November 9 and 10. Backed again by industry sponsor Hydac, the event presents a popular format of thought provoking papers, while providing ample breakout opportunities for engineers and suppliers to explore solutions to their particular issues. The annual conference is the jewel in the crown of the Maintenance Engineering Society of New Zealand (MESNZ), a technical group of IPENZ. Exhibitors too, will be pleased with the opportunity to get in touch with engineers over the two day event and the pre-conference trade expo.

Join the maintenance management success story! BWM Maintenance Management Software designed for engineers by engineers... Health, Safety and Plant Reliability Management Experts

Enquire today! Maintenance Transformations Ltd p. (09) 292 2919 | f. (09) 292 2913 m. (027) 414 4260 | www.transform.net.nz

mACHiNERy SAfETy

Inadequate guarding leads to hefty fines IN THE six months to May 2011, 12 New Zealand employers have been prosecuted and fined more than $365,000 after some of their employees suffered a range of horrifying injuries because machinery wasn’t properly guarded. Hundreds of machine guardingrelated accidents occur in workplaces each year and the Department of Labour follows up these incidents. As well as the 12 prosecutions, the Department has issued 21 prohibition notices, 101 improvement notices, 18 written warnings and reached 253 negotiated agreements. “In the last six months we’ve seen cases of unacceptable practices by employers, requiring their employees to work on machines that are not protected,” says the Department’s chief adviser health and safety, Dr Geraint Emrys. “This has left workers with amputated fingers or limbs and in one case a man was killed when he was dragged into a large heavyduty pulp press in Kawerau.

“No employee should be injured while doing their work. Machine guarding is a very basic way of making sure this doesn’t happen,” Dr Emrys says. To respond to the high number of cases the Department has begun a three-year project on the safe use of machinery, with a focus on adequate guarding in the first year. “We want the severity and

number of these accidents reduced. Raising the awareness and understanding of employers and those in control of workplaces about how to use machines safely will help. “Since the project started in August last year, health and safety inspectors have visited 876 businesses across New Zealand to talk to employers about machine guarding.

“Effective machine guarding could literally mean the difference between life and death. It is very important to make sure that employers properly identify all hazards and put in place appropriate controls to manage them. Guarding is one means of controlling the hazards associated with machinery that needs to be considered. “Employees using machines should be properly trained and if necessary, supervised. Lock out procedures should also be in place. Comprehensive written operating procedures should be made available to staff,” Dr Emrys says. Machinery accidents occur across many industries but the vast majority of incidents investigated by the Department are in the manufacturing, construction, food retailing, agriculture and forestry sectors. More information on the Department’s recent prosecutions is available at: www.dol.govt.nz/ News/media/index.asp

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Push buttons with enhanced functionality

ALLEN-Bradley 800B 16mm Push Buttons offer modularity and high quality resulting in less downtime. Users needing compact Push Buttons with excellent reliability for light

industrial and instrumentation applications can take advantage of the new 16mm line. The Push Buttons help reduce maintenance and associated downtime costs with LED pilot lights that indicate if a motor is in operation and trigger-action emergency-stop (E-stop) devices that cease motion. The E-stop Push Button features a triggeraction anti-tease to help ensure the E-stop command will disengage equipment, helping to improve worker safety. The new 16mm line provides reliability by meeting global standards, including UL, CSA, CE and CCC. The entire family is constructed of durable corrosion-resistant

plastic materials that are highly effective at sealing (IP65/66) and help to extend the overall product life.

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mACHiNERy SAfETy

Cost-effective, machine guarding

Guardmaster SensaGuard switches feature RFID coding capabilities and Distribution Block connectivity.

THE Allen-Bradley Guardmaster SensaGuard range provides a cost-effective, machine guarding solution – secure safety switching, diagnostics and

monitoring in one compact package. Combining the cutting-edge technology of RFIDcoding with a M23 Safety Distribution block, SensaGuard simplifies the integration of multiple sensors. The latest in RFIDcoding provides an additional level of security, allowing a SensaGuard switch and actuator to be paired with a specific code. This enhances safety by reducing the possibility of other actuators being used to bypass the switch. The switch is paired with an actuator on initial power-up and can be locked to this unit immediately. If some flexibility is required, the switch can be re-paired to another actuator up to eight times. After the eighth time, it is locked to the last-paired actuator. At any time during the pairing process, the switch can be locked to a specific actuator permanently. When multiple sensors are installed, the use of the Allen-Bradley M23 Safety Distribution block will simplify integration of the SensaGuard family of products. Available with either 4 or 8 ports, the M23 Safety Distribution block facilitates the direct local connection of M12,

8-pin SensaGuard safety products. The Safety Distribution block provides the ability to connect up to 8 SensaGuards to meet Cat4/SIL3/PLe, with an individual auxiliary contact from each device going back to the control panel. This provides specific diagnostic information for each door or device to the control system. Ideal for guarding equipment with part- or full-body access, SensaGuard switches are particularly suitable for applications where multiple access doors must be monitored up to safety Category 4/Safety Integrity Level 3 (SIL3)/ Performance Level e (PLe). The SensaGuard RFIDcoding and connectivity with the M23 Safety Distribution block offer a costeffective solution that is ideally suited to a wide range of industrial safety applications. Following certain installation requirements, the M23 Safety Distribution block also allows connectivity of other devices via dry contacts to products such as e-stop or OSSDtransistor outputs for light curtain applications. Go to www.demm.co.nz/enquiry quote: D110740

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Controllers programmed for safety With the MSI 200 safety controller, systems with up to 140 safety modules or with 44 drive components are no problem.

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July 2011

THE new MSI 100 programmable safety controllers from Leuze electronic come with 20 safe inputs and control machines with a wide range of different safety components, including: E-STOP buttons, two-hand controls, safety switches, locking devices and light barriers. In addition, the compact safety relay, just 67.5mm wide, can monitor up to four drive components independent of one another. For large machines and systems, the MSI 100’s ‘big brother’, the modularly expandable MSI 200, is the right solution. With this device, systems with up to 140 safety modules or with 44 drive components

are no problem. Additional MSIFB fieldbus modules enable the transfer of diagnostic data to the respective PLC via the fieldbus. The function of the relays can be quickly and effectively programmed using MSIsafesoft software. PLCopen-certified function blocks, which can be integrated in the safety circuit using ‘drag and drop’ functionality, facilitate menu-driven and trouble-free configuration. To assist the user right from the start there is an integrated simulation mode and automatic logic test. Go to www.demm.co.nz/enquiry quote:

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D110740a

iNDUSTRy WATCH

The NZ face of WAM

THE WAMGroup is a market leading manufacturer and supplier of equipment for bulk materials handling, dust filtration, solids-liquid separation, mixing and vibration technology – and is strongly focused on the requirements of the market and the individual needs of its customers. In line with this philosophy the WAM Group now has a representative based in St Johns, Auckland servicing

the entire New Zealand market. Jim Fairlie has been a member of the WAM team for three years and has more than 30 years experience in the engineering, pneumatics, metals, powder and granular materials handling industries. The diverse range of equipment WAM offers includes screw conveyers, valves, dust collectors, silo safety components, mixers, pnuematic components, wastewater treatment equipment and industrial vibrators. This comprehensive range means that the company can operate in a number of sectors. “Our major business is in the cement and concrete industry, however our products are suitable for the food, chemical, processing and water treatment industries,” says Fairlie. “We can provide one off components or assist in the design and supply of systems to meet your individual needs.” High quality and an excellent price- performance ratio make WAM Group equipment the ideal choice for project engineers, equipment builders and end users. Jim Fairlie is happy to take your calls to discuss your individual equipment needs and provide industry specific solutions.

Engineering company gets new identity AFTER a year of working together, Dow Design has revealed the new visual identity and company name for the merged businesses which formerly made up the Realcold Milmech group. The engineering company is now trading as ‘Milmeq’ (pronounced mil-mek). Atransition from Milmech, it acknowledges the group’s heritage and expertise; the ‘Q’, a subtle scientific reference to a company focus on thermodynamics and heat energy transfer. The company began working with Dow Design through participation in the Design Integration Programme offered by Better By Design, a specialist group within New Zealand Trade and Enterprise (NZTE) that connects ambitious, established companies with leading design practitioners to help their businesses grow. “After years of mergers and new business divisions opening up, the Realcold Milmech group had lost brand consistency,” says Andy Jaquet, strategic development director at Dow Design.“Aconfused brand identity was restricting company development. We needed to distill down its various business operations and understand the company as a whole so that we could tell its brand story in a clear and compelling way and release the handbrake for change.”

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Sharpen up on employment agreements THE Department of Labour is reminding all employers that from 1 July 2011, employers must keep copies of employment agreements or terms and conditions of employment for all employees signed by both parties. “Employment agreements have been required by law since the introduction of the Employment Relations Act 2000. There is evidence that many workplaces still don’t have employment agreements in place, and this 1 July deadline will put responsibility on all employers to ensure agreements are in place, or they may face penalties,” says the Department of Labour’s chief advisor employment relations, Craig Smith. “It’s the employer’s responsibility to maintain and keep an up to date copy of each employee’s employment agreement that reflects the current terms and conditions of the employment relationship. Employers must also provide a copy of the agreement if an employee requests it,” he says.

“Recent changes to the Employment Relations Act give labour inspectors the ability to seek a penalty against an employer who is in breach of employment agreement requirements. There are penalties of up to $10,000 for individuals and $20,000 for companies for failure to comply with the legislation. “If a 90-day trial period is agreed between the employer and the employee it must be in the written employment agreement before the employment begins, otherwise the trial period doesn’t comply with the law.” There are some provisions that must be included in employment agreements by law, and there are also a number of minimum conditions that must be met regardless of whether they are included in agreements. The Department of Labour has developed an Employment Agreement Builder, to help create employment agreements, at www.dol.govt.nz/ agreementbuilder.

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“There are many important issues affecting New Zealand’s engineering and manufacturing industries which deserve to be brought into the public arena for discussion and debate.”

Send your views and opinions to

editor@demm.co.nz 41

iNDUSTRy WATCH

Screening for synthetic cannabinoid Synthetic cannabinoids JWH018 and JWH-073 are the two most common synthetic chemicals responsible for the euphoric and psychoactive effects that imitate marijuana. However, research shows that these chemicals can in some cases produce effects stronger than standard THC/Marijuana with adverse effects of agitation, rapid heart rate, confusion, short term memory loss, dizziness and nausea. Synthetic cannabinoids are legally sold in New Zealand under brand

New Schneider Electric LifeSpace GM NEIL Swanney has been appointed by Schneider Electric as the new general manager for the LifeSpace business unit (Clipsal and PDL brands). Swanney brings to the role more than 30 years experience in the electrical industry, both in New Zealand and overseas. Swanney commenced his career as an industrial electrician and progressed to hold various sales and senior management roles, including general manager for Omron and most recently Teubels Ltd.

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names such as Kronic and Spice. The name Kronic (slang for cannabis) can be purchased by an individual 18 years or older at the local dairy for around $15 per cigarette. Users looking for a “legal high” turn to these herbal smoking or incense products due to the fact that they do not show up on a standard urine drug test. And unfortunately, New Zealand laboratories are unable to offer screen tests for JWH-018 and JWH-073. However, as of May 19, The NZ Drug Detection Agency (NZDDA) has the capability to workplace laboratory screen and confirmation test for synthetic cannabinoids JWH-018 and JWH-073 through a US laboratory. This new service has an estimated turnaround time of 48 to 72 hours from receipt of the specimen at the laboratory. Afull brief on the cost of the on-site screen test is available upon request from The NZDrug Detection Agency. “Education and awareness around synthetic cannabinoids in the workplace is paramount,” says NZDDA managing director Kirk Hardy.“It is highly important that employees are educated on the dangers that

these so called herbal drugs pose in the workplace and compromising everybody’s’ safety.” To keep abreast with current issues, NZDDAhas revised and updated its education and training program to include the use of synthetic cannabinoids. Due to the high level of danger these drugs create they are now included in the list of drugs that NZDDAtests for in a series of random screen testing programs. Hardy encourages employers to review and, if necessary, amend their Drug and Alcohol policy to deal with testing for synthetic cannabinoids.

•

NZ’S LARGEST ABC AUDITED CIRCULATION TO THE ENGINEERING & MANUFACTURING SECTORS

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IW-45K

IW-50A

• 45T punch pressure • 5HP 415V motor • Five stations, including notcher • Punch capacity ø22 x 15mm • Flat bar shearing 300 x 10mm • Angle shearing 75 x 75 x 6mm $

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Food processing technology update

8,200 (P170)

8,300 (P170A)

8,995 (P171)

IW-60S

IW-80S

IW-100S

• 60T punch pressure • 7.5HP 415V motor • Five stations, including notcher • Punch capacity ø28 x 15mm • Flat bar shearing 350 x 15mm • Angle shearing 100 x 100 x 13mm

• 60T punch pressure • 7.5HP 415V motor • Five work stations, including notcher • Punch capacity ø22 x 20mm • Flat bar shearing 350 x 15mm • Angle shearing 130 x 130 x 13mm

• 80T punch pressure • 10HP 415V motor • Five work stations, including notcher • Punch capacity ø26 x 22mm • Flat bar shearing 460 x 15mm • Angle shearing 152 x 152 x 13mm

• 100T punch pressure • 10HP 415V motor • Five work stations, including notcher • Punch capacity ø28 x 26mm • Flat bar shearing 610 x 16mm • Angle shearing 152 x 152 x 15mm

12,000 (P173)

17,500 (P174)

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√ Swage & Jennys √ Pressbrakes √ Mills √ Pipe Notchers √ Lockseamers √ Drills √ Punch & Shears √ Bar Benders √ Lathes √ Welders √ Guillotines √ Ring Rolls

• Automatic safety fusible link on lid • 240V input

140 Litre $

180 270 WET & DRY VACUUM CLEANER

HYDRAULIC PLATE CLAMP

(A368)

(A374)

• 240V motor • Stainless steel tank • Includes: 1 brush, 1 crevice tool 1 dry floor nozzle, 1 wet floor nozzle

26,000 (P176H)

1000W 30L

2000W 80L

$ 310 (V503) 470 (V510) SHEET METAL CURVING ROLLS $

MANUAL PANBRAKES

PB-820 PANBRAKE

• Extended ﬁngers for bending up to 220mm boxes • Heavy duty steel fabricated frame • Includes rear manual back gauge & safety support stop for clamp beam

• 2500 x 2mm capacity • Removable ﬁngers • Heavy duty steel fabricated construction

HEAVY DUTY SECTION ROLLS • Two bottom rollers are powered • 1.5kW / 2HP 415V (S686) • 3kW / 5HP 415V (S694) • Adjustable side support guide rolls • Standard ﬂat & angle rolls are included

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PB-422A 1250 x 2mm

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PB-820A 2440 x 2mm

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60 x 60 x 6mm angle cap. RR-75 (S694) $

(S564)

❏ Bearing maintenance issues exposed • Industrial 4 shelf rack with strong wire mess top • Dimensions (LxWxH) 1955 x 610 x 1830 • Silver corrosive resistant powder coated ﬁnish • 364kg per shelf capacity • Adjustable grid pattern wire shelving • Vertical posts have double sided punched 364kg holes allowing to link units together

• 907 x 608mm platform base • Soft foam handle folds ﬂat • 2 ﬁxed & 2 swivel wheels • 127mm solid wheels (T670) • 203mm pneumatic wheels (T672)

• 952 x 608mm platform (T674) • 1257 x 761mm platform (T676) • 152mm solid wheels (T674) • 203mm pneumatic wheels (T676) • 2 ﬁxed & 2 swivel wheels

❏ MESNZ’s New Year NEW resolutionsNEW

AL-320G GEARED HEAD BENCH LATHE

Made in Turkey

• 320 x 600mm capacity • 38mm spindle bore • 160mm C.H. • 600mm B.C. • 12 speeds (60-1600rpm) • 1hp 240V motor

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• SAE 150 quality certified steel rolls with high tensile strength • Single handle adjustment of bottom rolls • Cast Iron end frames • Conical bending device

240 (L142)

300kg $

95 (T670)

300kg

130 (T672)

300kg

230 (T674)

500kg

275 (T676)

www.demm.co.nz Unit D/38 Highbrook Dr,

East Tamaki T: (09) 2717 234

BG-12 HEAVY DUTY PEDESTAL GRINDER

• 255mm wheels • 1.3HP 415V motor • Full cast iron body • Includes dust chutes & stand

$ $ 80 (G180) 100 (G181) AL-340H GEARED HEAD CENTRE LATHE • 2-Axis digital readout system • 39mm spindle bore • 500mm between centres • 2hp motor • 8 spindle speeds 70-2000rpm • D1-4 camlock spindle • Includes: Quick change tool post, lead screw cover, chuck guard, coolant & light

5,400 (L179H) ELECTRABRAKE MAGNETIC PANBRAKES

√ Cold Saws √ Grinders √ Linishers √ Tool Boxes

• 305mm wheels • 3HP 415V motor • Adjustable wheel guards • Full cast iron body • Includes dust extraction outlets, safety eye shields & stand

$ 720 (G167) PN-76 PIPE NOTCHER

Forklifts with high IQ

$ 1,040 (G164) WELDING HELMETS

Auto Darken

• Ideal for steel, stainless, pipe & tube at 90º & angle joins • 20-76mm outside diameter capacity • Compound action swivel vice achieving angles between 30 - 90º • 3kW Motor 415V • Rollers are sold separately 20-76mm • Complete with stand

• Adjustable shade: 9-13 • Tec I darkens in 1/10,000 sec • Tec I & Tec II no batteries required • Tec II & Tec III darkens in 1/25,000 sec • Tec III has 4 arc sensors with 2 batteries

Tec I

2,700 (L850) SB-375 SAND BLAST CABINET

Tec II

Tec III

110 (W008) $160 (W010) $260 (W012) SB-420 SAND BLAST CABINET

• EB1250 • 1250mm bending length • 240V

• LED control panel • Includes: light, dust extraction, stand, hopper, industrial duty blast gun, tempered glass screen & gloves

• Steel Cabinet • Includes: Gloves, air regulator, work light, replacement shield, blast gun & ceramic tips

1050 x 1mm cap.

3,950 (L682)

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(S780)

COLD SAW

(S782)

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1200 x 600 x 340-570(D)mm

940 x 600 x 580mm

(S5301)

• 1250 x 3mm capacity • 3kW / 415V motor • 635mm wind out back gauge with mechanical counter • Electro mechanical operation for high stroke rate • Single or multiple cutting • Foot pedal control • Rear guarding included

• 135 x 85mm capacity • 1.5kW / 2hp 415V motor • Extremely accurate mitre cutting ±45º • Heavy gearbox drive • Coolant system • 2 speed (21-42rpm) • 24 months warranty • Includes stand

(S300)

(S302)

METRIC / • ON/OFF in any position IMPERIAL • Remembers the last setting SWITCH • Metric/Imperial switch • Mini USB connection to the display unit

❏ The long term benefits of fluid analysis AUSTRALIAN MADE

7,500 (S127)

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620mm

720 (T739)

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❏ Pumps & Valves update ❏ Hazardous Areas technology

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❏ Dust control & filtration success stories

BONUS 3MT LIVE CENTRE

Prices & specifications are subject to change without notification & are valid until 31-03-11. All prices Exclude GST.

1270 x 1.6mm cap.

2,150 4,050 1,040 6,950 1,520 ❏S350D Machinery installation & alignment for better performance HEAVY DUTY MG-432 GUILLOTINE TOOL BOX SET DIGITAL SCALE

2,400 (L141)

AL-336 GEARED HEAD LATHE • 300 x 900mm capacity • 38mm spindle bore • 150mm centre height • 900mm between centres • 18 speeds (65-1810rpm) • 2hp 240V motor

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350 (S010)

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April 2011 $6 INCL GST

March 2011 $6 INCL GST

February 2011 $6 INCL GST

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80 (D665)

900mm

100 (D667)

Prices & specifications are subject to change without notification & are valid until 30-04-11. All prices Exclude GST.

www.machineryhouse.co.nz

4_DEMM_010411

THE popularity for synthetic cannabinoid use in the workplace is increasing at a rapid rate, and is a growing concern. In the US the Drug Enforcement Agency (DEA) recently placed five synthetic marijuana products into Schedule 1 of the Controlled Substances Act, right alongside PCP, Ecstasy and real marijuana. The DEA’s addition of the synthetic cannabinoids into the Controlled Substances Act means that it is now illegal for all Americans to possess and use them.

❏ Why nuts and bolts come loose

www.demm.co.nz

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July 2011

iNDUSTRy WATCH

Winning health and safety awareness project

ANinnovative installation designed to promote health and safety awareness amongst staff working on Auckland’s Victoria Park tunnel construction programme has won a major international environmental design award. “The installation has had a huge impact on everyone working on the project,” Fletcher Engineering environment, health and safety divisional manager Stuart Chapman

says.“It is integral to our health and safety promotion on site, which has seen lost time injury frequency decline from 1.15 per 100,000 man hours to 0.48 since the campaign started.” The judges of the prestigious Society for Environmental Graphic Design awards said the installation was “a grand evolution of the heartless warning sign: sophisticated, clever, easy, and touching.” The installation is prominently

positioned around site workers’ facilities that construction staff pass at the beginning of work each day. It includes a series of graphics with real life stories of how workers’ lives have been affected by accidents, x-rays of injuries, a video interview with a seriously injured worker, and a display which helps staff see safety in the context of the impact on workers’ families. The final element is a mirrored

surface which allows workers to ‘put themselves in the picture’ and check that they are equipped with vital personal protection equipment as they enter the site. Created by design and brand agency Studio Alexander, the installation has already scooped New Zealand’s supreme Best award for graphics, and featured in the Victoria Park Alliance’s award winning entry to the New Zealand Workplace Health and Safety Awards.

•

Metal Exchange launches new store

The new Glenfield branch.

EXCHANGINGscrap metal for cash has just become a whole lot easier for Auckland tradespeople with the launch of Metal Exchange’s North Shore branch. The new site in Glenfield provides a quick, clean and easy drive-through service. Metal Exchange director Eldon Reeve says the focus is very much on convenience.

“We know how important convenience is for tradies – when you’ve got a busy day, the last thing you want is to have to drive halfway across town to trade in your scrap. Having two handy locations is going to make life a lot easier. Simply drive in, drop off your metal and we’ll give you cold hard cash in exchange.” To celebrate the opening of the new

branch, Metal Exchange is offering customers an extra $10 cash for every $100 worth of metal exchanged at either of their two sites until 31 July. Metal Exchange’s two Auckland branches are located at 245 Archers Rd, Glenfield and the corner of Beach Rd and James Fletcher Drive, Otahuhu.

•

Dear reader! Is your business associated with any of the following industries? AuguSt ISSue:

● Water treatment & Wastewater Systems ● Lubrication ● Corrosion Control ● Hydraulics & Pneumatics

SePtember ISSue:

● Oil & gas Industry ● Industrial Cleaning ● Pumps & Valves ● Welding

Key suppliers to these industries will be profiling their products and providing productive solutions in the upcoming issues of DEMM Engineering & Manufacturing magazine, please enjoy the magazine and stay informed. All we ask is that you tell the supplier where you saw them, here in DEMM magazine. Best regards The DEMM Engineering & Manufacturing magazine team. PS: If you are a supplier to the engineering and manufacturing industries and would like to know more about highlighting your business, your industry or product news in this magazine please contact Frank Atkinson on frank@adrenalin.co.nz or 09 477 0362, mob 021 464 156

iNDUSTRy WATCH in association with

TelstraClear Pacific 2011 NZ Oil & Gas Exhibition & Conference

10-11 August, 2011 TSB Stadium, New Plymouth Staged by Swan Exhibitions. Contact Mike Twiss, mike@energy-pubs.com.au or visit www. nzoilandgasexpo.com.au

Brightwater facility benefits Westport

NELSON-based engineering company Brightwater, is finalising the construction plans for a new, state of the art purpose-built Foodpro workshop facility in Westport to be completed by the end of this year. 10-13 July, 2011 It is expected that the new workshop will employ upwards of 30 Sydney Convention & Exhibition Centre trades staff and will provide a much needed modern engineering Showcasing the very latest in food processing machinery, technology and packaging innovation. For more go to www.foodproexh.com facility in Westport. “For many years Brightwater has provided a remote service for SouthMACH 2011 Westport from facilities in Nelson and Greymouth,” says Brightwater 17-18 August, 2011 CBS Canterbury Arena, Christchurch Services GMMitchell Easton.“However this has often been a The South Island’s only dedicated engineering, machinery and technology trade show. For further compromise to both Brightwater and our customers in many information visit www.southmach.co.nz ways. The time has come for Brightwater to address that by further MHL 11 commitment in the region. 21-22 September, 2011 “As with all Brightwater operations throughout Australasia, we ASB Showgrounds, Greenlane, Auckland New Zealand’s materials handling, warehousing and logistics trade show. For further will continue to invest in our Westport staff with the same level of information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www. commitment we demonstrate to our external customers. This will mhlshow.co.nz see opportunities for young Westport teenagers to become a part National Safety Show 2011 of our successful apprenticeship scheme or our engineering cadet 21-22 September, 2011 program. Career paths into both Business and Project Management ASB Showgrounds, Greenlane, Auckland New Zealand’s largest dedicated workplace health and safety event. For information, exhibiting will also become available through the local facility. The opportunity enquiries, visitor registration and a list of current exhibitors, go to www.safetyshow.co.nz to build these professional skills coupled with local industry process NZ Clean Energy Expo knowledge is invaluable.” 14-16 October, 2011 In addition to the substantial workshop facility the recent ESCO NZ Clean Energy Centre, State Highway One, Taupo distributorship acquired by Brightwater will be supported out of A showcase of clean energy innovation – including geothermal and bio-energy initiatives. For more information call Rob McEwen, CEO, NZ Clean Energy Centre on 021 728 875 or visit both the new Westport facility and the Gray Brothers Engineering www.nzcleanenergycentre.co.nz workshop in Greymouth.

•

Water New Zealand Annual Conference & Expo

9-11 November, 2011 Rotorua Energy Events Centre ‘Advancing Water Reform’. For more information visit www.waternz.org.nz

www.pacific.org.nz

Read an article in this magazine and want to know more? It's simple, fill out the form and fax it in to 09 478 4779 or mail it to: DEMM EnginEEring & Manufacturing reader enquiry, Freepost 4359, PO Box 65 092 Mairangi Bay, Auckland City 0754, Auckland, or for quicker results go to

www.demm.co.nz/enquiry or email frank@adrenalin.co.nz reader reply form Reader enquiry number:________________________________________________________ Name:_____________________________________________________________________ Your business name:__________________________________________________________ Position:___________________________________________________________________ Phone numbers:______________________________________________________________ Email:_____________________________________________________________________ Postal ______________________________________________________________________ _______________________________________________________________________

July 2011

Investing in energy efficiency SMALL to medium companies can get financial help to boost competitiveness and reduce costs through energy savings, The Government has launched Energising Business, a new programme run by the Energy Efficiency and Conservation Authority (EECA). The programme will assist around 180 companies to increase profitability and competitive advantage by helping them invest in energy efficiency. The Government is investing $1.46 million in the programme, which is expected to deliver nearly $2 million in energy savings to participating businesses each year. Under the programme, companies spending less than $300,000 a year will get 33 percent of the cost of identifying and implementing energy-saving initiatives, up to a maximum of $30,000 per project. Organisations with energy management expertise have been contracted to deliver the programme, targeting different technologies and business types across the country. The first Energising Business programme to launch is the Employers’ and Manufacturers’ Association (Northern) EcoSmart Business programme run in partnership with Auckland City Council. As well as general energy efficiency support for small to medium companies, Energising Business will target EECA’s priority business sectors: food production and tourism. Further programmes targeting key sectors and regions will be rolled out in coming weeks. Companies interested in participating, or finding out more, should visit www.eecabusiness.govt.nz/ energisingbusiness

•

2011

Both areas have the potential to sized discoveries which could dr THERE is no doubt that New Zealand’s energy industry is at a cross roads. New Zealand’s energy fu change The country’s Government has introduced new legislation that is set to have a dramatic effect on New Zealand’s energy future with a preference for new renewable energy generation.

Growing attention ENGiNEERs, MaNaGERs, New Zealand remains anMaiNTENaNcE attractive destination forinternational international on government the new Great is South Basin b explorers and developers and the country’s moving TRadEsMEN, LiNE MaNaGERs, assET MaNaGERs ternational leaders Exxon Mobi strongly to ensure that the nation’s prospectivity to be In the meantime, the hunt for newcontinues oil and gas taken up large positions an to bolsterhave the country’s dwindling recognised around the globe. supplies stocks is continuing unabated.

Twenty eleven - to begin high cost exploration p Lifting Game of Maintenance And industry is also playingthe its part in taking the country’s oil and gas sector forward. Engineers in New Zealand While most attention will be on A major focus of exploration interest will be on the deepwater areas off the coast of Taranaki and the Great South Basin.

work continues to develop the T

Leading local and Presentations internationalfrom players have putistoinhost ground for Both peers areas have the potential “elephant” and experts onplace Lifting which still the powerbase sized discoveries which could dramatically breaking exploration may lead to agasrange of new Game inthat Maintenance Management; Preventative & Gas Exhibition - Booth No. P07 YOURplans change New Zealand’s oil energy and future. sector. discoveries and developments. Maintenance, Staff Management, Health and Safety GrowingApprentices, international attention is beingas focussed Management, Training, as well Technical on the new Great South Basin blocks where inSwan Exhibitions, innovations, one of thepractical region’s most experienced resource applications case studies. ternational leadersNew Exxonand Mobil, OMV and new Mitsui developmen finds and taken up large positions and arethan preparingtwo industry exhibitionTrade organisers, ishave celebrating more Basin continue to and keep the loca Expo representing: suppliers, careers to beginengineering high cost exploration programmes. decades of stagingemployment, highly successful Oil & bling Gas Exhibitions and hydraulics, pneumatics, electrical, bearings, software, along ready to take advant Conferences in New Zealand. preventative maintenance, condition monitoring, motors. new developments in the deepw While most attention will be on the electric “big” plays, work continues to develop the Taranaki Basin which is still the powerbase for New Zealand’s Safety? stress are needed, it matters that the tools to deliver are bothTalking unquestionably reliable and oil and gas sector.

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ENGINEERING & WORKSHOP EQUIPMENT √ Mills √ Drills √ Lathes √ Guillotines

√ Pressbrakes √ Lockseamers √ Punch & Shears √ Ring Rolls

√ Vices √ Band Saws √ Wood Working √ Parts Washers

√ Swage & Jennys √ Pipe Notchers √ Bar Benders √ Welders

HM-50 MILLING MACHINE • 1.5kW 240V motor • 1000 x 240mm worktable • 30INT spindle • 6” machine vice • Metric collet & chuck set (4-16mm) • Travel: (X) 600mm (Y) 220mm (Z) 340mm

√ Engine Stands √ Motorcycle Lifter √ Sand Blast Cabinets √ Workshop Equipment

HOR. / VERT. MILLING MACHINES • 2hp 240V (M161), 415V (M163) motor • 30INT spindle • Includes: coolant system, halogen lamp, 150mm machine vice, drill chuck & arbor, 2 & 3MT adaptors, 8-piece Metric collet chuck set (4-16mm)

√ Threading Machines √ Tooling √ Accessories √ Panbrakes

SPD-20B PEDESTAL DRILL • 1hp 240V motor • 16-speed • 2MT • 16mm drill capacity • Safety micro switch on belt cover • Includes 16mm drill chuck & arbor

(M163 model shown)

HM-52

4,100 (M160)

4,900 (M161)

HM-32 MILLING & DRILLING MACHINE • 1.5kW / 2hp 240V motor • 12 speeds (100-2150rpm) • 3MT spindle with 75mm diameter quill • 820mm x 240mm table with ‘T’-slots • Includes: drill chuck, 3MT arbor, tungsten-tipped cutter, 3” tilting vice & toolbox • Includes: Drill chuck, arbor & face cutter • Travels: (X) 540mm (Y) 190mm OPTIONAL STAND $ (Z) 410mm (M135)

HM-52G

4,900 (M163)

BM-40V MILLING MACHINE • 3hp 415V motor • 3-Axis Digital Readout • 30INT spindle • Variable 70-3500rpm • X axis power feed • 1370 x 254mm worktable • Includes halogen light, coolant system, clamp kit • Travels: (X) 860mm (Y) 360mm (Z) 430mm

390 (D140)

√ Folders √ Measuring √ Rolls √ Presses

√ Cold Saws √ Grinders √ Linishers √ Tool Boxes

GHD-22 GEARED HEAD DRILL • 3MT spindle, 1hp 415V motor • 31.5mm drilling capacity • 8 spindle speeds (105-2900rpm) • 500 x 350mm T-slotted worktable rotates 360º • Emergency stop with overload protection • Drilling depth stop setting with scale • Rack & pinion table height adjustment with locking lever • Drill ejector lever

2,300 (D170) EB-280DS DUAL MITRE SWIVEL HEAD BAND SAW $

CS-315D COLD SAW • 1.5kW / 2hp 415V motor • 110 x 70mm rectangle capacity • 100mm round capacity • Ø315mm blade • Dual material clamp system • Rugged cast iron construction • Built in blade coolant pump • Lock at any angle between -45° or +45° • Includes: stand, coolant pump & HSS blade

• 245 x 180mm rectangle capacity • 1.5hp, 415V • Swivel head double mitre cut to 45º right & left, 60º right • 2-speed motor • Quick-action lock / release vice

250

10,900 (M607D)

2,700 (S828)

3,490 (B063)

AL-50GB BENCH LATHE

AL-1000C CENTRE LATHE

AL-340H GEARED HEAD CENTRE LATHE

BS-13DS DUAL MITRE SWIVEL HEAD BAND SAW

• 550W 240V • 500mm between centres • 115mm centre height

• 356 x 1000mm capacity • 40mm spindle bore • 1000mm between centres • 178mm center height • 1.5kW / 2hp, 240V • 9 spindle speeds (80-2000rpm) • Includes: 3 & 4 jaw chucks, faceplate, ﬁxed & travelling steadies, foot brake, splash tray & stand

• 2-Axis digital readout system • 39mm spindle bore • 500mm between centres • 2hp 240V motor • D1-4 camlock spindle • 8 spindle speeds 70-2000rpm • Includes: Quick change tool post, lead screw cover, chuck guard, coolant, light & foot brake

TAIWANESE QUALITY

1,490 (L158)

• 458 x 235mm rectangular capacity • Adjustable hydraulic vice pressure regulator • 19-102 M/min variable blade speed • Auto blade breakage sensor • 1.5kW / 2hp, 415V motor • Mitre cuts to +45º, -60º • Laser guide

LIMITED STOCK

7,995 (L240)

9,700 (B030)

5,400 (L179H)

IW-45MQ PUNCH & SHEAR

PM-35T PUNCHING MACHINE

HG-440B HYDRAULIC GUILLOTINE

PB-416H PANBRAKE

• 45T punch pressure • 5hp, 415V motor • Four stations • Punch capacity ø22 x 15mm • Flat bar shearing 350 x 8mm • Angle shearing 80 x 80 x 8mm

• 35T punch pressure • 5hp, 415V motor • Punch capacity ø18 x 14mm • Throat depth 310mm • Table size 700 x 500mm

• 1300mm x 4mm cutting capacity • 5.5kW / 7.5hp 415V motor • Hydraulic operated machine • Motorised back gauge with DRO counter • Blades made from 9CrSi material suitable for cutting stainless steel

• 1250 x 1.6mm capacity • Robust steel-fabricated construction • Has a range of ﬁnger widths to enable the bending of pans or boxes to a depth of 70mm

TAIWANESE QUALITY

7,950 (P170)

8,550 (P192A)

11,200 (S924)

Unit D/38 Highbrook Dr, East Tamaki T: (09) 2717 234

2,250 (S253)

Prices & specifications are subject to change without notification & are valid until 31-07-11. All prices Exclude GST.

www.machineryhouse.co.nz

7_DEMM_010711 5_DEMM_010511

1,790 (M121)