Demm Engineering & Manufacturing March 2012 by Adrenalin Publishing Ltd

NZ’S LARGEST ABC AUDITED CIRCULATION TO THE ENGINEERING & MANUFACTURING SECTORS March 2012 $6 INCL GST

• CONTENTS

Editor's

note

Fakes cost more It was a spectacle that drew massive media attention: In January 2007, at the FAG premises in Schweinfurt, Germany, about 40 tons of rolling bearings were scrapped with angle grinders and blowtorches. The bearings with the brand imprints INA, FAG and SKF had a nominal value of some 8 million Euros. But they were fakes, discovered at an independent German bearing dealer. Only recently I meet up with Larry Wiechern, The Maintenance and Reliability Centre Manager at Manukau Institute of Technology, and he told me he was disappointed at the fact that “when I talk to people, they have never heard of this incident. It should be made known more widely to alert people to the dangers of counterfeit bearings and the extent of the problem.” It's a problem that sometimes is quite hard to identify: In one case Larry and his team had to conduct a microscopic examination to be able to decide whether a large spherical roller bearing was a fake or the real deal (see the interview starting at page 38). The International Chamber of Commerce (ICC) estimates that by 2015, the total impact of the trade in counterfeits and pirated goods – including the value of domestically sold fakes, those traded on the internet and the added costs to society through lost taxes and jobs – will exceed $US1 trillion. Fakes cost more: they might endanger lives, they can cause industrial accidents, machine breakdowns and unplanned shutdowns, and they are able to ruin the image of a brand. To protect yourself you ought to heed Larry’s piece of advice: “Always buy from preferred suppliers!” Or, as the ICC has put it, “Fakes cost more – I buy real”.

Stefan Richter

2 12

Product Watch

A roundup of technologies and services designed to increase the productivity, efficiency and safety of the engineering and manufacturing sector.

Food Process Industry

The latest developments in the world of food processing, including a report on the benefits of Vaughan chopper pumps to this industry.

20 Safety in the Workplace

Read about CPNZ, the new pan-industry contractor health and safety prequalification service.

24 Air Compressors

Synthetic compressor oils can save money in the operation of a brewery. Discover how and also get an update on new products.

Dust Control & Filtration

Maintenance Matters

Electrical Technology

Coming Events

A range of stories relevant to this sector, including an answer to the question, “Do I need a new dust collector?”

Larry Wiechern has some food for thought on the importance of maintenance and demands that manufacturers in NZ lift their game.

Learn how UPS systems can keep your business running and how to choose the right technology for your application.

Stefan@adrenalin.co.nz SubScriptionS: An 11-issue annual subscription in New Zealand is $59.00 (incl GST). Please call us for overseas rates. copYriGHt:

DEMM Engineering & Manufacturing Magazine has a copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed nor facts stated in advertisements are necessarily agreed to by the editor or publisher. Whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information.

AdvertiSinG Frank Atkinson, Email: frank@adrenalin.co.nz publiSHer: Cathy Parker, Email: cathy@adrenalin.co.nz editor: Stefan Richter, Email: editor@demm.co.nz deSiGner: Rob N Hood, Email: Rob@adrenalin.co.nz circulAtion MAnAGer: Kim McIntosh, Email: kim@adrenalin.co.nz

SubScriptionS: Hilary Keen, Email: subs@adrenalin.co.nz proof reAdinG: George Ward

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• PRODUCT WATCH

One billion protected hands Glove manufacturer Ansell has announced an historic milestone – the sale of its 500 millionth pair of HyFlex gloves. “Since its creation, the HyFlex brand has become the number one selling industrial glove around the world, with over half a million workers wearing it daily in a wide variety of industries,” said Mitchell Mackey, Ansell Asia Pacific Marketing Manager. “When first introducing HyFlex in 1996, Ansell for the first time demonstrated how optimal protection does not mean one needs to give in on comfort. Ever since its launch, the original HyFlex concept has set a benchmark for industry players active in this category. In 15 years, HyFlex has gained critical recognition and market share

for its winning combination of ergonomic design, comfort and superior mechanical protection.” Today, the HyFlex range extends to 28 individual styles, ensuring that there is a glove that fits every worker’s job performance requirements and comfort expectations. Magnus Nicolin, CEO of Ansell Ltd, said, “This milestone pays tribute to the HyFlex original brand concept which is all about delivering protection and comfort without compromise. With innovation being the hallmark of the HyFlex glove range success today, Ansell is committed to continue to innovate and develop new ways of ensuring that our HyFlex series remains in pole position, and is the number one choice for workers across the globe.”

Ansell says its HyFlex brand is the most comprehensive light-duty synthetic portfolio in the industry. Its patented Zonz Knit Technology reduces hand

Edit o choi r's ce

fatigue by providing stress release in the knuckle areas. Go to www.demm.co.nz/enquiry quote:

•

D120302

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March 2012

• PRODUCT WATCH

Die-cast enclosures in three interesting new shapes to IP54, protecting against the ingress of dust and water, and the painted finish is only applied to the external surfaces, maintaining RFI integrity. All

units can be supplied factorymodified with machining and silk screening to the user’s specification; AutoCAD and PDF dimensioned drawings

can be downloaded from www.hammondmfg.com/ dwg_OctTrap.htm. Go to www.demm.co.nz/enquiry quote:

•

D120303

MetalFix

Responding to customer requests from several different sectors for die-cast enclosures to provide a strong and robust environmentally sealed housing with good EMC screening in a non-rectangular shape, Hammond Electronics has extended its popular 1590 family with the introduction of the 1590TRP and STP models. The first applications for the new shapes have been for audio equipment, industrial remote controllers, desktop switch arrays and hand-held test equipment controllers. The octagonal 1590TRP is 133mm across the flats and 39mm high; it will house a circular PCB up to 126mm in diameter. The two 1590STP trapezoidal units are also 39mm high; the smaller portrait format unit is 112mm long, narrowing from 79mm to 62mm, the larger landscape format one is 95mm deep and narrows from 151mm to 122mm. All three types are available in natural finish and in a smooth gloss polyester powder paint, which does not chip after machining and provides a good surface for labels and silk screening. The strong and vibrant painted colours are black; cobalt blue, RAL 5013; green, RAL 6024; light grey, RAL 7035; orange, RAL 2009 and red, RAL 3011. A lap joint seals the units

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• PRODUCT WATCH

Fully recyclable screening media Metso have developed the first fully recyclable modular screening media – Metso Trellex LS-Eco. In response to customer requests for sustainable and environmentally-friendly screening media solutions, and in line with the company’s sustainability program, they have taken the Metso Trellex LS rubber modular screening media systems and successfully replaced the traditional steel reinforcement with an environmentallyfriendly composite material. This makes it possible to effectively recycle customers’ screening media. In addition to providing environmentallyfriendly screening media panels, Metso will implement a unique program to provide

its customers with a suitable range of recycling services. The Metso Trellex LS-Eco offers a wide range of health, safety and environmental benefits. Each screening media panel is up to 40 percent lighter than standard steel reinforced Trellex LS panels. This makes handling easier and the working environment safer. Lighter panels also help to reduce the overall stress on the entire screening installation. Compared to steel-reinforced panels, the compositereinforced panels of the Metso Trellex LS-Eco are more flexible and will reduce the effects of pegging and blinding during screening operations. The Metso Trellex LS-Eco promises reduced

downtime and increased productivity. The Trellex 300LS and Trellex 305LS rubber and polyurethane panels are already acclaimed worldwide as being among the most versatile modular screening media solutions. They can be attached to most screening media systems and handle all types of screening applications – fine and coarse, wet and dry. In the future, when Metso customers need new screening media panels for their existing system, they can choose Metso

Trellex LS-Eco and be assured that their panels will be safely and effectively recycled. Go to www.demm.co.nz/enquiry quote: D120304

•

Hand wheel with integrated electronic display In 1963, Siko invented a mechanical position indicator integrated in a hand wheel – a product the field of mechanical engineering could hardly do without today. As inexpensive and easy-to-use gauges, Siko hand wheels with integrated position displays reliably perform a variety of tasks ranging from roll positioning, aligning limit stops and tools, to manual metering settings. The new DKE01 adjustment knob with LCD display combines the experience of nearly 50 years of positioning technology with the state-of-the art functionality of an electronic display. Because the display values are user-definable, it is possible to handle the most diverse of challenges using a single basic device. The managing of multiple types of devices, and therefore also keeping the parts required for them on-hand has become a thing of the past. Extra features such as allowance for offset values and a reset button for calibration expand the range of uses. Thanks to a particularly energy-efficient measuring technique, the electronic DKE01 adjustment knob has a battery life of eight years. The power is supplied using a conventional coin battery, which can be easily replaced by the device user at the end of its service life. Go to www.demm.co.nz/enquiry quote: D120304a

•

March 2012

• PRODUCT WATCH

Suction fingers and angle arms for light-weight construction Fipa is expanding its product portfolio of universal gripper components to include structurally optimised lightweight, modular, adjustable angle arms and suction fingers. “The new

suction fingers and angle arms are just another example of what Fipa sees as universal applications. The new gripper components fit seamlessly with all the other elements of our product range,” explains Rainer Mehrer, Fipa CEO. The new adjustable suction fingers weigh around 50 percent less than their predecessors. The angle arms weigh up to 22 percent less than previous models. These latest developments are just another example of Fipa’s dedication to lightweight construction, which allows shorter cycle times and reduces energy consumption. Both the new suction fingers and the new angle arms offer high flexibility in terms of their application due to their continuous angle adjustment. The modular, adjustable suction fingers that integrate vacuum cups into gripper

systems are available in 12 models with various clamp diameters, shaft lengths and connection threads. Another advantage is their secure installation and removal without using any snap ring. The elimination of snap rings from the design avoids the need for long searches for matching snap rings and the safety hazards arising from the use of snap rings that do not match exactly. The modular, adjustable angle arms utilise an innovative clamp on the angle arm joint, which prevents any accidental angle changes due to excessive stress on the clamping head. The process safety of the system is greatly increased as a result. Another advantage of the new design is that the clamp shaft of the grippers can be attached directly to the shaft of the now rigid angle arm – provided that the angle adjustment capability is not needed. This flexible adjustment is made possible by the identical diameters of the clamps. The adjustable angle arms are also available in 12 models, which differ in their shaft diameter, shaft length and clamp diameter. Go to www.demm.co.nz/enquiry quote: D120305

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• PRODUCT WATCH

New design for aluminium cap redrawing machine

MACA Engineering, of San Quirino in Italy, a designer and manufacturer of machinery for the assembly and cutting of aluminium and plastics caps, has released a new version of their RRM10 redrawing machine, where the two redrawing stations are now built on the same frame which reduces the footprint compared to the previous model

by 2.5 metres in length. The RRM10 is a continuous rotary motion redrawing machine with ten punches suitable for lengthening and trimming long and extra-long caps starting from either first draw (caps with heights up to 49mm) or second draw shell for caps that

exceed 49mm. The redrawing is made by ten dies that have a pneumatic drawing system that can be adjusted on each individual punch. A cam with a constant descent profile ensures consistent control of the redraw

(lengthening) process. The caps are discharged oriented, with separate ejection of the trim. Matrixes are made from sintered tool steels and are coated to ensure long life. The new design has integrated the control panel of the machine under the loading channel which features a serpentine infeed that reduces the length of the equipment, but maintains the necessary quantity of caps required to feed the machine. It has an output speed of 36,000 caps per hour. MACA Engineering is represented in Oceania by HBM Plastics Technologies. Go to www.demm.co.nz/enquiry quote:

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D120306

Hi-tech safety glove launched Industrial safety equipment specialist BOC has launched a state-of-the-art new work glove, the UMATTA Silverback Lite. Constructed to the highest levels of compliance and conforming to EN388.4121, the gloves are designed to enhance safety, comfort and practicality in a wide range of industrial applications. Senior Product Manager, Safety at BOC, Joe Martinez, said the Silverback Lite was an exceptionally lightweight, comfortable and dextrous glove. “It has been designed to repel liquids for excellent wet or dry grip and has extra ventilation with good tactile sensitivity.” The glove base consists of a knitted 13-gauge seamless grey nylon-lycra blend shell with a palm coating of foam-dipped black nitrile for enhanced grip. Other advanced features include abrasion resistance technology and elasticised knitted cuffs to fit snugly around the wrist and prevent particles from entering the glove. UMATTA Silverback Lite has applications in the automotive industry, white goods assembly, materials handling, plumbing, packaging, warehousing, manufacturing, landscaping, gardening and general purpose. Go to www.demm.co.nz/enquiry quote: D120306a

•

March 2012

• PRODUCT WATCH

Extended power range for PowerFlex 755 AC drives Building on the foundation of the Allen-Bradley PowerFlex 755 high-power models, Rockwell Automation has extended the power range of its PowerFlex 755 AC drives to 900kW and added 690 volt ratings. The new drives, well-suited for a variety of heavy industrial applications, provide users with increased application flexibility, advanced diagnostics and a common DC bus option. “We’ve expanded the horsepower range and added new features to bring the benefits of the PowerFlex 755 family – advanced diagnostics, a convenient roll-out design and control options – to a broader range of motor control applications,” said Andrew

Hoch, Solution Architect Power Control, Rockwell Automation. “This helps heavy industrial users reduce costs through enhanced flexibility, reduced downtime and low meantime to repair.” The common DC bus option allows users to connect the PowerFlex 755 AC drive to a common DC bus configuration, which takes advantage of different drive cycles to share energy. In this configuration, a DC bus acts as a common energy source that feeds energy from a generating load to a motoring load. Managing energy from a shared source increases overall system performance and reduces losses – ultimately improving the application’s energy efficiency.

BUILD IT Exactingly right – Every time –

Like all PowerFlex 755 drives, this latest frame size includes an embedded Ethernet port and five option slots, so users can tailor it to their application. Option modules include I/O, feedback, safety, additional communications and an auxiliary power supply. A convenient roll-out design allows easy access to the drive for fast installation and maintenance. The drive’s converter and control pod can remain in the unit while the inverter is rolled out, so control wiring can remain connected. In addition to the extended power range, a firmware upgrade for all PowerFlex 755 drives will contain the following new features and benefits:

Interior Permanent Magnet Motor Control – Delivers increased application flexibility and high energy efficiency. “Stop Dwell” feature – Helps prevent a motor from coasting to a stop. Ideal for converting applications, it allows users to preconfigure the motor to perform a controlled stop to protect valuable motor investments. Go to www. demm.co.nz/enquiry quote:

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D120307

• Motors • Brake motors • Servo motors • Geared motors Gear units • Control Technology

Quality European Manufacturing • Motors • Gear Components • Control Technology

Final test.

High voltage motor test.

Painted to customer application requirement.

Individual components selected to specification for the gear unit.

Finished products ready for delivery.

Fast, customised assembly at purpose designed workstations.

New Zealand Assembled

When you deal with SEW-Eurodrive, you are dealing with the `manufacturer’. • Fast, customised assembly for every Our huge range of quality European manufactured componentry is held in drive requirement stock at our Auckland & Christchurch plants, ready for fast turnaround customised assembly. In tight economic conditions, getting it `right’ every time, is even more crucial. Contact us for advice, planning and drive calculations.

AUCKLAND 82 Greenmount Drive, East Tamaki. Ph: (09) 274 5627. Fax: (09) 274 0165 PALMERSTON NORTH Ph: (06) 355 2165 CHRISTCHURCH 10 Settlers Crescent, Ferrymead. Ph: (03) 384 6251. Fax: (03) 384 6455 Email: sales@sew-eurodrive.co.nz • Web: www.nz.sew-eurodrive.com

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E&M212

Components for the motor are quickly order picked to each customer application requirement.

INDUSTRIAL DRIVE TECHNOLOGY

• PRODUCT WATCH

User-friendly new servo controller range

The Escon 36/2 DC is the first product in the new servo controller range by maxon motor and exemplifies how user-friendly drive technology can be. The extremely compact, powerful 4-quadrant PWM servo controller offers efficient control of brushed permanentmagnet activated DC motors up to approximately 72W. The servo controller has excellent control properties and a very fast digital current controller with an enormous bandwidth for optimal motor current/torque control. The drift-free yet extremely dynamic speed behavior enables a speed range of 1 to 150,000rpm. The controller provides a wide range of functions, with fully configurable digital and analogue inputs and outputs. It is well matched to maxon’s range of motors and thus allows dynamic drive solutions that meet the highest demands. Furthermore it can be run in various operating modes: speed controller (closed loop), speed controller (open loop) and current controller. The ultra-compact servo controller is controlled by means of an analogue set value. This value can be specified by means of analogue voltage, an external

or internal potentiometer, a defined value or by means of a PWM signal with variable duty cycle. Other interesting functions are for instance the ability to enable or disable the power stage depending on the direction of rotation, or to use speed ramps for acceleration and deceleration. The speed can be regulated by means of a digital incremental encoder (2-channel, with/without line driver), DC tacho or without encoder (IxR compensation). The servo controller has been designed specifically with easy startup and user-friendliness in mind – no in-depth knowledge of drive technology is required. When the servo controller is connected to a PC via a USB port, it can easily and efficiently be configured with the ‘Escon Studio’ graphical user interface. During startup and configuration of the inputs and outputs, monitoring, data recording and diagnostics, the user has access to a large variety of functions and is assisted by user-friendly software wizards, as well as a welldesigned automatic procedure for fine-tuning the controller. On the hardware side, the Escon 36/2 DC comes fully equipped

March 2012

with everything that is needed. For example, no additional external filters or motor chokes are required and pre-assembled cables for the start-up are available as accessories. The Escon 36/2 DC has protective circuits against overcurrent, excess temperature, under- and over-voltage, against voltage transients and against short-circuits in the motor cable. Furthermore it is equipped with protected digital inputs and outputs and an adjustable current limitation for protecting the motor and the load. The motor current and the actual

speed of the motor shaft can be monitored by means of the analogue output voltage. The large range for the input voltage and the operating temperature allows flexible use in almost all drive applications, in automation technology, in small machine manufacturing and equipment engineering, and in mechatronics. With its exceptional efficiency of 95 percent, the controller is a good choice for mobile, highly efficient yet consumptionoptimised applications. Go to www.demm.co.nz/enquiry quote:

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D120308

Handling drive-related tasks without external controller For functionally complex and dynamic drive applications, Nord Drivesystems has introduced a new model from its SK 500E line of control cabinet inverters. The new intelligent SK 540E inverter supports the convenient and free programming of drive-related functions according to IEC 61131. It has all the established features of the series but supports a wider range of drives than any of its sister models; in particular, it can control synchronous motors. It integrates a new universal encoder interface for energy recovery. SK 540E performs even sophisticated tasks without an external PLC, thus saving considerable costs. Pump drives, for instance, can be upgraded with monitoring functions and characteristic curve functions, enabling them to directly react to fluctuating flow rates. Thanks to its high-performance microprocessor, the new inverter model is also suitable for high-speed cutting processes in turning and milling. Just as the established models from the series, SK 540E provides the safety function Safe Torque Off as well as sensorless current vector control and an integrated brake chopper for regenerative operation, and it identifies the parameters of the connected motor automatically. Go to www.demm.co.nz/enquiry quote: D120308a

•

Tenix. Working with you to build a sustainable future. Solid experience in delivering projects

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• PRODUCT WATCH

New polymer with increased load-bearing capability Oz Seals’ new super polymer material, OzMonyt, exhibits great flexural strength and modulus of elasticity, and, according to the manufacturer, boasts with greater load-bearing capabilities than thermoplastic materials currently in the market. Wil Prinz, Manager of Oz Seals Pty Ltd, says what makes the new material unique is the reinforcing filler used. Conventional polymer materials are unfilled. OzMonyt uses specially developed glass fibres, which remain dispersed in the material. Load-bearing capability compared to conventional polymers is about three times more. The polymer contains three lubricants, including molybdenum, making the material ideal for applications of high friction. The new

Oz Monyt material shows little impact after being hit with a sledge hammer.

polymer continues to exhibit high lubricity throughout its long service life. Not only will OzMonyt bushes last longer, but the life of the mating pins and shafts are also extended. Wil Prinz explained that OzMonyt has been developed for use in low-friction, longlife bearing applications. The material provides load bearing

capabilities greater than white metal and self-lubricating characteristics far better than those of ordinary materials. OzMonyt is on its own in applications where high loads must be carried with small clearances and in dirty environments, where there is little lubrication. The material also works well in moist

and corrosive environments. The polymer exhibits high dimensional stability and only has minimal swelling (0.8 percent) in water. This is in contrast to materials like nylon 6 and nylon 66 which tend to absorb up to nine percent water of their total weight – with the consequent expansion and softening of the material. OzMonyt is easily machined to extremely fine tolerances for use in metalworking equipment. The material also exhibits very low creep rates under design loadings of 30Mpa and has a much higher load capacity than nylon, as this is not affected by water absorption. The thermal expansion is less than three times that of bronze. By comparison, conventional nylon can expand 5-10 times. Go to www.demm. co.nz/enquiry quote: D120310

•

Reliable and economic screw package Industrial Air Systems’ Rotor Compact 7.5-15kW (36-72cfm) series screw compressors offer a high-quality, reliable

and economic compressed air supply, all in one neat integrated package. The Rotor Compact screws feature the highly efficient direct drive transmission system as normally only employed by much larger industrial screw compressors, which means utilising an oversized air end, spinning at half the revolutions of the traditional belt driven screw model. Without the contaminating wearing transmission belts, the RC screw runs much cleaner, and is fast

March 2012

and simple to service, which saves thousands of dollars in operating costs over the compressor lifetime. Rotating at only 2900rpm (instead of 5-7000rpm,) the Air Command RC is very quiet running, and requires no noise insulation as found on any other belt driven model. Unlike most rotary screw compressors, the RC model is designed to stop/start or run continuously – up to 100 percent duty cycle, which means it can be installed into most compressed air environments, and only operates on demand, leading to power savings and reduced machine wear. The RC screw

compressor is mostly installed as a fully integrated model (screw, receiver, refrigerant dryer) in 7.5, 10 and 15kW sizes, making it ideal for the one to seven man compressed air operation in the automotive, engineering and manufacturing industries. With the benefit of being 100 percent European designed and manufactured, the direct driven Air Command RC screw compressors offer a very good investment for the small industry wishing to improve their efficiencies with a trouble-free clean compressed air supply. Go to www.demm.co.nz/enquiry quote: D120310a

•

• PRODUCT WATCH

Opening the door to energyefficient freezing Maintaining temperatures of -25°C or lower in freezers is hard work. Operating through the summer months with higher temperatures and humidity, maintaining these temperatures gets even more difficult and very expensive. As well as the extra energy costs there are risks of product being damaged and rejected through temperatures not being maintained correctly. Traditionally a lot of attention has been given to the refrigeration, and rightly so, but what is often overlooked is the cause of the problem: All the warm air enters the freezer via the doors, a fact which is often overlooked. The refrigeration units are working overtime sucking up large amounts of electricity, the evaporator is getting iced up, ice forms on the floor, walls and ceiling etc, all because warm moist air is entering into the freezer through inefficient, slow or uninsulated doors. This is

often attempted to be rectified by PVC strip curtains, motorising freezer panel doors or even rapid roll doors with limited and varying success. Ulti Group specialise in this area and have developed a fast acting bi-parting insulated freezer door that solves these problems and is being rapidly embraced by leading players in the refrigerated food industry. The Ulti-Flex door features 150mm thick insulated door leaves that creates an airtight seal when shut but yet is flexible enough to flex if hit by a forklift. Speed of the total opening cycle is very important to reduce ingress of warm air and the Ulti-Flex satisfies this requirement with its speeds of over 2m/s and adjustable hold open times. Andrew Lane of Tegel Foods in Henderson had an Ulti-Flex door installed recently by Ulti Group into his freezer and is delighted

with the result. “Temperatures in the freezer dropped by 4°C after the door installation, and the door controls the temperature so well that temperature in the neighbouring room has risen, showing starkly how efficient the Ulti-Flex door is,” says Andrew, who is well supported in this with others reporting a similar temperature change after door installation. These companies include Tip Top Foods, Foodstuffs, Affco, Halls Transport, Watties and McCains, to name a few. Go to www.demm.co.nz/enquiry quote:

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D120311

The Ulti-Flex High Speed Bi-parting Freezer door Eliminates Ice Problems! No ice build up around doorway Lowered maintenance costs Improved Safety

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• FOOD prOcess inDustry

Integrated supply chain expertise wins lion’s share for Linfox Linfox is Lion’s in-house logistics provider, servicing a large proportion of its transport and operations needs, including ambient and temperaturecontrolled warehousing on the east coast of Australia and line haul transport nationally on all major legs. Lion engaged Linfox to manage the majority of its Australian distribution requirements.

Lion’s new national distribution centres were established by Linfox.

PROUDLY AUSTRALIAN

MADE

& OWNED

March 2012

Lion (formerly Lion Nathan National Foods) is a leading beverage and food company with a portfolio that includes many of Australia and New Zealand’s favourite brands. The Dairy & Drinks division (formerly National Foods) produces household name brands of milk and dairy beverages, juice, dairy, cheese and soy products. The Dairy & Drinks footprint includes production facilities and sales offices in all Australian states, as well as New Zealand, Singapore, Malaysia and Indonesia. In addition to consolidating line haul and transport operations for Lion, a key feature of the massive 3PL contract was the establishment of two new national distribution centres (NDCs) in Sydney and Melbourne. The Sydney NDC was up and running in January 2009, with the new Melbourne NDC at Laverton now fully operational as of June 2011. With a storage capacity

of more than 26,000 pallets, the new 28,600m², temperaturecontrolled Laverton NDC is a high velocity operation, distributing over 100,000 cases per day. Linfox’s NDC Operations Manager Travis Small said “Many of the SKUs (stock keeping units) we distribute for Lion have a limited shelf life. Stock turns over very quickly. Storing and distributing such SKUs efficiently requires a smart DC layout and storage systems, and that’s exactly what Dematic delivered. “The use of drive-in or double deep storage racks would have improved the site’s total storage capacity. But, given the high turnover of the products we are distributing, Linfox opted for single deep selective racking to provide safer, faster, unrestricted access to every product line,” he said. “It also gives us total storage flexibility, with just about every product capable of being slotted in every location.”

• food process industry Meeting demanding project milestones “Dematic didn’t just meet our demanding project deadlines; they exceeded expectations at every phase of the project,” added Linfox’s Travis Small. “We basically took possession of a massive empty shed in October 2010 and had to bring the first phase of the NDC with over 20,000 pallet locations online before Christmas. Fitting out a DC with over 20,000 pallet locations in such a short timeframe is no small task, and installation of the storage system was very much on our critical path. Dematic’s ability to complete the installation of more than 26,000 pallet storage locations ahead of time across all four implementation phases contributed greatly to our meeting critical project delivery milestones.” Dematic’s Project Engineer Joe Carmody said implementing the short two-month installation

schedule required all of Dematic’s extensive project management experience. “It was essential we had all of the storage equipment in place prior to each phase going live, which meant working around the clock, seven days a week when necessary,” he said. “The installation of such a large storage system in less than two months was only made possible through Dematic’s ISO9001 Certified Quality Systemaccredited project management and implementation methodology,” said Mr Carmody. Initiatives included: • Setting up a steering committee comprising senior Linfox and Dematic managers to facilitate open communications at a high level, and ensure any non-project related matters that may impact the project were assessed. • Project planning and scheduling, including a detailed program of works covering all major implementation tasks

from site establishment and installation to commissioning and acceptance. • Development and implementation of a structured risk management process. • Regular site meetings, detailed weekly progress and monthly reporting.

Flexible DC design and layout The Laverton NDC is currently configured with two separate chambers – one

Engineering Ltd

is providing storage for over 21,000 pallets, and the other for more than 5000. Splitting the NDC into separate chambers gives Linfox the flexibility to run different zones at different temperatures if required. The NDC and storage system layout make it easy for walls to be added to create further separate chambers if required. About half of the NDC’s orders are despatched as full pallets. Split case orders are picked from

Carbines Engineering supplying Motoman & OTC Daihen robots to New Zealand Industry for over 25 years, gives “Adept” as an example of the Motoman quality product. Picture shows 4x of the Multiple 6 axis 6kg Motoman Robots mounted and interfaced into Adept's “Toyo” Plastic injection MouldingMachines.

Since the first UP6 installation in October 2006 a further 12 Robots have been added to their family of tireless Machine tenders.

• food process industry

all rack uprights, together with end-of-aisle protection. All aislefacing uprights have also been fitted with Colby Protect-a-Base. The new baseplate protector is mounted to the base of front uprights providing protection at ground level against minor collisions with forklifts and pallets. It features an angled front face, which curves and wraps around the whole upright to eliminate any catch points when pallets are being placed or removed. Colby Protect-a-Rack upright protectors interlock with the Protect-a-Base, forming a highly robust member. Protect-a-Rack

Joe Carmody (left), Dematic’s Project Engineer, and Travis Small, Linfox’s Operations Manager

Colby Cartonflo carton live storage and packed into shippers and palletised for local direct-tostore delivery through Linfox’s route trade distribution network. All order picking is RF-directed, with both Linfox and Lion running SAP IT. Through its Vision Zero program, Linfox is totally committed to ensuring occupational health and safety (OH&S). To that end, the NDC’s storage systems incorporate a number of safety initiatives including Dematic’s ColbyRACK Protect-a-Rack. Dematic designed the 26,000 pallet capacity storage system to

suit Lion’s requirements, which includes not storing products on the ground for hygiene reasons. A first storage beam level 300mm above ground keeps all pallets clear of contamination or pests, and provides sufficient access for regular cleaning. Pallets are typically stored six high with a top beam level of around 8m.

Optimising storage system safety To help prevent rack damage during pallet put-away and retrieval, the storage system incorporates modified Colby Protect-a-Racks to suit the 300mm high first beam level on

upright protectors not only deflect impacts away from the upright, they also absorb them and transfer inertia to the strongest part of the rack – the bracing nodes. They also include a rear flange protector to ensure the entire upright is shielded from direct impact damage from the rear. “Safety is obviously our number one concern. Preventing storage systems from getting damaged in the first place not only provides a much safer workplace, it will also reduce operating costs over the life of the DC,” said Linfox’s Operations Manager Travis Small.

Hygienic pressure switch Wika has expanded its family of electronic pressure switches with a new product for sanitary applications. The new PSA-31 is fitted with hygienic process connections and is therefore recommended, among other things, for applications in filling and packaging machinery for the food and pharmaceutical industries. The instrument is extremely robust and the wetted parts are particularly easy to clean. The hygienic design of the pressure switch conforms to the 3-A standard 74-03. With its case that can be turned through 300 degrees, this electronic pressure switch can be easily adjusted to any individual installation situation. The large, angled display, which is also rotatable, is easy to read from any position. For this concept, which is characteristic of the entire family of electronic switches, Wika has already been awarded the IF product design award for 2009. This was awarded on the market launch of the PSD-30. Go to www.demm.co.nz/enquiry quote: D120314

•

GEA Freezing GEA Freezing 356 Church St, Penrose, Auckland, New Zealand

Offers a wide range of energy efficient freezing and cooling systems. The design of our Spirals, Tunnels and Carton Freezers has

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evolved from more than 30 years’ experience in the food processing

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ensure the freezers or chillers fully meet your processing needs.

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March 2012

TC0179_DEMM

GEA Refrigeration Technologies

• food process industry

Branding – Why bother? The necessity and value of branding for engineering and manufacturing businesses is often difficult for many owners to rationalise. Your business probably isn’t selling to a consumer (you sell business to business), your customers know who you are anyway (or at least that’s what you think), you don’t need to advertise or, most commonly I hear, you don’t believe in it. However, great branding is more than just a pretty logo (which probably cost you more than what you wanted to spend in the first place!). Great branding is how your business presents itself to your customers, your target market and your strategic partners when you’re not there doing the selling.

Greg Knight shows off the new branding for Florentines.

It’s the ‘face’ you put on your business. And just like you would put on a decent suit to meet someone important, how your business looks from the outside does form a first impression which impacts on how people judge everything about who you are and what

you do, as a business. Does your business look tired or messy from the outside? What sort of impression is that giving to your potential customers? Let alone your potential growth with your existing customers. What sort of business do you really look like? What sort of

assumptions do you think other people are making about your business from the way you look? It’s worth taking a minute to think about! So starting from your logo (which maybe could do with a bit of a freshen up), working through to your brochures, website, presentation materials – basically everything that visually represents your business – make sure that it all ties together nicely. Just like a great outfit! Look for consistent use of colours, images, font styles, copy styles and, of course, your logo. And if you get stuck, well there are plenty of great designers out there who can help you. Because if your business looks like it delivers leading-edge, top-quality, innovative (... fill in the blanks here...) products

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• food process industry

and services, your target market will believe it too. Ensuring you deliver on that promise is then up to you.

Case Study: Florentines invests in branding to secure market position Florentines is a Taurangabased food manufacturing business which specialises in supplying premium frozen cakes and desserts to food service distributors, restaurant chains and cafes throughout Australasia. Having recently invested in a complete review of the brand strategy and a subsequent rebrand for Florentines, managing director Greg Knight is already noticing some positive results for his business. “We are seeing increased brand loyalty with our customers,” explains Knight. “Rebranding has given us the opportunity to make sure everyone understands our benefits. It has given us a more professional position in the

market, and it shows that we are proud of who we are and what we do.” Standing out from the competition is particularly important for Florentines, in an industry where unique product advantages and benefits aren’t immediately visible. When everyone else in the industry sells the same delicious-looking Mud Cake, brand awareness becomes the primary differentiator. “We don’t want to be just another ‘metoo’ supplier,” explains Knight. “Our customers now choose the Florentines brand products over our competitors because they understand it represents a certain quality, consistency and flavour that the other products don’t have and it was important to make sure that our brand reflected these key differences.” Article by Chantelle Laurent, Marketing Strategist, Formula One Results

CMY

WAM (MHE) NZ Call: 09 6222803 Email: sales@wammhe.co.nz

March 2012

Packaging adds value When Tetra Pak was founded almost 60 years ago, founder Dr Ruben Rausing said, “A package should save more than it costs.” This thinking continues to guide the company and its work today. Tetra Pak launched aseptic packaging in 1961, and has been refining and improving the technology ever since. Aseptic packaging delivers safe, nutritious and flavoursome food to millions of people around the world, without the need for preservatives Noel Ayre, Managing Director or refrigeration. Managing Director of Tetra of Tetra Pak Oceania Pak Oceania, Noel Ayre, said, “Aseptic technology makes food safe and available everywhere. This includes the processing and packaging of the food or beverage, as well as the environment in which these operations take place.” The benefits are in production and distribution, particularly over cold-chain-bound products and over alternative ambient products such as powders and canned goods. Mr Ayre said, “Tetra Pak pioneered the technology in the 1960s, and two years later was producing 2.7 billion packages annually. In 2010, two-thirds of the 158 billion packages we produced used aseptic technologies. And today, in New Zealand and Australia, this technology is delivering liquid milk to consumers in Asia, who can’t get enough of this quality product.” Additionally, in these increasingly environmentally aware times, aseptic technology development is at the forefront of the drive towards reducing water consumption and product loss to zero. Mr Ayre said, “Protecting the environment is a key driver for Tetra Pak, and is a must to remain competitive. This includes using renewable resources, recycling, reducing our environmental footprint, and responsible environmental leadership.” In Australia, the first cartons to be certified by the Forest Stewardship Council went on sale in Victoria in 2011. Tetra Pak proudly supports and promotes FSC and is rolling out FSCcertified packaging material worldwide. The certification means the wood content of the paperboard is from responsibly managed forests and other controlled sources. In New Zealand, Fonterra Co-operative Group has launched a Milk for Schools program which will deliver daily servings of milk to primary school children in FSC-certified cartons. Fonterra is piloting the initiative in the Northland region. Finally, a word about automation. Food and beverage producers work to exacting requirements: delivering quality products to customers while improving production efficiency and profitability. Mr Ayre said: “Tetra Pak is using innovation to bring new technologies that meet the challenges of a rapidly changing dairy industry – an industry which is focussed on improving efficiencies and reducing costs. In a short period of time, automation has moved from the simple linking of individual pieces of equipment to fully automated lines, with the major benefit of increasing equipment reliability and reducing operational costs. In the future, automation systems will offer benefits that go far beyond production efficiency. This includes full line responsibility and traceability, which demonstrates credibility and engenders confidence with producers, customers, suppliers and consumers.”

• food process industry

Problem solver for food industry Food processing companies are increasingly discovering the benefits of utilising Vaughan chopper pumps in environments in which conventional pumps have historically failed.

The benefits of Vaughan chopper pumps There are many benefits to using a Vaughan chopper pump. Positive chopping allows large, troublesome materials to pass through the pump, eliminating downstream plugging of valves, heat exchangers, nozzles or other pumps. A single Vaughan chopper pump can replace two pieces of equipment; i.e. a comminutor (or pre-grinder) and a ‘non-clog’ pump, resulting in much lower

The Vaughan S series submersible chopper pump is available with a range of motor options, including explosionproof, close-loop cooled, or continuous in-air for low level operation.

maintenance costs. Vaughan chopper pumps can handle solids that no other pump can handle. Chopping material at the pump produces a more homogeneous slurry and reduces pipeline friction. The heavy-duty mechanical seal design and bearing system incorporated in each Vaughan pump reduces downtime by withstanding the heavy workload and associated forces of chopping and pumping solids reliably. Vaughan chopper pump impellers, cutter bars, upper cutters and cutter nuts are made of cast alloy steel which is then heat treated to a minimum of Rockwell 60C hardness to provide extended service life in most applications. Vaughan company’s 50 years of extensive experience in designing and manufacturing chopper pumps for severe duty applications instills trust and product confidence. In addition, every Vaughan chopper pump supplied is backed by a performance guarantee as assurance of clog-free, solidshandling performance. Instead of attempting to pass whole solids through the pump,

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ATTN12TOT72DEMM

As environmental awareness and resulting laws have come into effect, and as managers seek to increase production efficiency, improved methods for moving debris-laden waste slurries have been needed. Historically this has been accomplished through the use of the ‘non-clog’ pump, where a recessed or open impeller passes large solids through the pump. However, experience has proven that the name ‘non-clog’ does not mean the pump won’t clog. In many cases, especially where the solids size may be larger than the passages through a non-clog pump or where long stringy materials are present, a more aggressive approach, such as a chopper pump, is needed. Compared with a conventional non-clog pump, a chopper pump is essentially a non-clog pump plus a chopper system – that is, two machines in one.

12TOT72_half page NZ Contractor_88x257 v3.indd 1

14/02/2012 3:18:37 p.m.

• food process industry

a Vaughan chopper pump cuts material into smaller, more manageable pieces as it enters the pump. Using a patented chopping action, the sharp leading edge of each impeller blade cuts material against two stationary shear bars cast into the suction plate, which extends across the entire intake opening. Depending on the number of impeller vanes, shaft rotational speed, and discharge flow, large solids are chopped into varying sizes from 3 to 30 millimeters before passing through the pump. This capability, along with its heavy-duty design and non-clog performance guarantee, set the Vaughan chopper pump apart from other types of non-clog, grinder, macerator or cutter pumps available on the market today. There are some typical applications in the food processing industry where the use of a Vaughan chopper pump is going to provide

excellent results.

Meat processing Vaughan chopper pumps are successfully being used in a wide variety of difficult applications in the meat processing and seafood industries in New Zealand and Australia. In the meat industry a chopper pump will solve difficult solids handling problems with ease. Typical applications include chopping and pumping wastewater containing paunch material, fleshings and hide, wool, blood, bone, ears and face pieces, offal and casing threads, fat and other waste materials from the processing floor.

Seafood industry Vaughan chopper pumps are used to chop and pump fish wastes, entrails, scales, heads, tails and carcasses, mussels and crab shells. This type of material would easily clog other types of pumps especially when other types of waste material such a

plastic bags and strapping and rag enter the waste sump. A Vaughan chopper pump can chop and pump large solids such as entire fish carcasses which typically cause binding or damage to non-clog pumps.

Poultry industry The extensive poultry industry is finding that Vaughan chopper pumps are essential for minimising and eliminating maintenance time on processing systems which get clogged with feathers, blood, and other waste by-products. Typically, the pump would be installed in the main factory waste sump where it will chop and pump wastewater containing chicken or turkey feathers, blood, gut, legs, feet, etc. In most cases, a chopper pump would normally transfer the solids-laden wastewater to a rotary screen where the solids are removed.

Vegetable processing Vaughan chopper pumps are used extensively in vegetable processing plants to transfer processing wastes. Applications include pumping wastewater containing carrots, potatoes, lettuces, apples, corn cobs and husks, pumpkin shells, beans and beet, to name and few. Normally, vertical wet well or submersible type chopper pumps are used for this type of application, with a range of material options to suit depending on the fluid pH. All of the applications discussed here centre on the pump’s ability to handle solids from a pumping standpoint. It is important to note that Vaughan chopper pumps can also eliminate seal and bearing failures observed in other pumps. Because the chopper design requires heavy shafting, an added benefit is longer life resulting from stronger parts and less vibration. Quite often seal failures in conventional pumps are associated with solids wrapping or binding at the impeller or seal. This can

March 2012

The combination of the Vaughan chopping impeller pump-out vanes and upper cutter prevents stray solids from wrapping or binding in the mechanical seal area, providing reliable service over the long term.

cause severe vibration that is transmitted through the shaft and seal to the lower bearing. This results not only in seal and bearing failure, but also can introduce moisture into a submersible motor. The heavier shafting and short overhang of the Vaughan chopper pump bearing and seal design addresses this problem and reduces maintenance costs as a result. Companies in the food processing industry and engineering firms alike are increasingly discovering the economics of applying Vaughan chopper pumps in applications in which conventional pumps have historically failed. These failures are generally due to plugging or seal and bearing failure, and all contain hidden costs that must be addressed. More often than not, equipment that has purchased solely on price has a higher failure potential than properly specified and purchased equipment. The solution starts with the user’s request to obtain equipment that will operate maintenance free, and it ends with the foresight of those with purchasing authority to think toward the future. Article submitted by Pump Systems Ltd Go to www.demm. co.nz/enquiry quote: D120318

•

Sick and tired of pump clogging problems?

For guaranteed non-clog performance, invest in a Vaughan® Chopper Pump Sick and tired of your standard “non-clog” impeller pump frequently clogging due to heavy loadings of difficult solids? If so, come and talk to us about the non-clog guarantee and how installing a Vaughan® Chopper Pump can help. With thousands of proven applications worldwide, Vaughan® Chopper Pumps will solve the toughest clogging problems. We guarantee it.

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• SAFETy IN THE WORkPLACE

Chic, comfortable and secure Eye injuries are a major issue in the trade industry’s overall injury rate, and most workplace eye injuries occur through inadequate or inappropriate eye protection. The new, improved range of fashion eyewear from Honeywell Safety Products was designed to reliably protect workers in a range of situations. Each pair of safety glasses in the fashion range offer exceptional fit, maximum comfort and modern looks, as well as being available in a range of price points to suit an array of budgets. At the lower end of the price range, Chill safety eyewear will protect workers without comprising on quality or breaking the bank. Weighing less than one ounce (25.2 grams), these comfortable and affordable glasses feature a flexible temple to provide just the right amount of tension, ensuring the eyewear is kept comfortably in place at all times. They are approved to medium impact under ASNZS 1337.1:2010 and available in clear, grey and silver mirror lens tints with either hard coat or anti-fog coatings. Offering advanced protection, the Fulcrum safety eyewear range is extensively tested to ensure they meet all requirements for medium impact under AS/NZS 1337.1:2010 standards, without negating on comfort or design. Featuring a lightweight frame, smooth bayonet temples and a molded nosepiece, the Fulcrum offers wearers a comfortable fit and sleek style at all times. These glasses are available with a hard coat lens coating for longer lens life with clear, grey, blue mirror and light silver mirror lens tints, and with an anti-fog lens for hot and humid work environments in a clear lens. Featuring clean lines and a modern design, the Vexis offers workers outof-the-ordinary styling, whilst being approved to medium impact under ASNZS 1337.1:2010. The lightweight, all-polycarbonate frame is extended to provide added side coverage, while the 9-base, cylindrical lens shape creates a unique design with outstanding optical performance. The anti-fog lenses are available in clear and grey tints, with hard coat available in clear, grey and amber and all lenses provide 99.9 percent UV

March 2012

The Ambient OTG glasses offer customised fit.

Chill safety eyewear is comfortable and affordable.

The stylish Vexis glasses are being approved to medium impact under ASNZS 1337.1:2010.

protection and are comfortable enough to wear all day. Simple in appearance but highly sophisticated in design, the Millennia Sport offers sporty, sleek and stylish looks with excellent optical properties and a universal fit. These glasses feature a Flexicord retainer strap and a lightweight value-based frame which offers high side and brow protection, as well as a medium impact rating under ASNZS 1337.1:2010 and a dual 9-base wraparound uni-lens. Ideal for general use and protection against impact as well as mechanical work, the Millennia Sport is also now available in anti-fog with clear and grey lenses – perfect for workers in hot and humid work environments. The Ambient OTG glasses offer wearers of prescription eyewear full

protection while at work. Featuring ratcheting temples with three position lens inclination adjustments, the Ambient OTG offers a customised fit and can be worn over a wide range of prescription eyewear styles. Specifically designed with the temples curved outward to minimise temple interference, each individual pair can be bent and adjusted to accommodate the wearers’ face, head size and prescription frames. The soft, flexible and cushioned nasal fingers of the Ambient OTG conform to a variety of facial profiles and minimise slippage, while the lightweight, wraparound uni-lens design offers exceptional peripheral vision. The Ambient OTG is available in clear and grey lens options with an anti-fog coating and a clear lens with a hard coating. Go to www.demm.co.nz/enquiry quote: D120320

•

• SAFETy IN THE WORk PLACE

Disposable coveralls enhance mobility

pure and simple

PORTASTREAM II PUREFLOW 1000

A comprehensive range of disposable coveralls has been launched by 3M, providing protection for a variety of applications including food processing, light-duty industrial cleaning, asbestos removal, painting and coating, pesticide spraying and chemical spills, as well as decontamination and tank cleaning. The new protective coveralls contain no components made from natural rubber latex or silicone and are designed with extra material in the arms and legs for enhanced mobility. Two-way zippers provide added on/off convenience. Storm flaps offer additional protection and seamless shoulders and sleeve tops translate to fewer entry points for contaminants and increased comfort. 3M protective coveralls are available in a variety of sizes and are backed by 3M’s global technical capabilities and support. The range also includes accessories such as mob caps and disposable overshoe and overboot covers. Go to www.demm.co.nz/enquiry quote: D120321

Self-contained emergency eyewash stations

Honeywell plumbing-free emergency eyewash stations offer unequalled flexibility, performance, reliability, and value. All units comply to ANSI Z358.1 2009 & AS 4775 2007 standards. They supply a constant fluid rate and stream height for 15 minutes, delivering a purified and physiologically balanced solution to the pH and salinity of human tears. Trust us to find ways of making safety simpler.

•

• SAFETy IN THE WORk PLACE

Contractor prequalification service CPNZ Ltd and its foundation clients have released the CPNZ (Contractor Prequalification New Zealand) pan industry contractor health and safety prequalification service. This fully outsourced, pan-industry service is aimed at improving the speed, efficiency and cost of health and safety prequalification whilst helping to improve the safety of all types of contractors. “CPNZ is a New Zealand first and builds on international best practice, but tailored to the local market needs,” says Tom Reeves, Director of CPNZ Ltd. “We see it as a win/win/win. It’s good for the client who can concentrate on the job in hand, it means contractors have to prequalify only once to meet the requirements of multiple clients rather than multiple times for individual clients, and it drives

continuous improvement in safety – which ultimately is what everyone wants to see. “Through our parent company Impac Services Ltd we got involved in looking deeply into how a number of fatal accidents had occurred and quickly identified weaknesses in the whole procurement process. As a result of working with some of our clients to address these issues, we recognised that whilst improvements needed to be made at an individual company level, the biggest efficiency and cost saving could come from having one common prequalification process that is accepted by multiple clients. This means only contractors who can demonstrate robust health and safety practices and/or a commitment to continuously improve their processes are likely

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March 2012

to be engaged by clients. And if the assessment is outsourced to a specialist company then you get greater professionalism and consistency and the client no longer has to devote their scarce resources to developing and managing the process in-house. “Many businesses now acknowledge that contractors are one of their biggest risks,” says Tom Reeves. “It used to be thought that if you engage a contractor to do a difficult or dangerous job then they took on the safety responsibilities and you could sit back and relax. The truth is far from this and increasingly the Department of Labour have been focussing on the client/principal’s role in selecting the right contractor, agreeing the work method and monitoring their performance. Unfortunately for some this simply involved shuffling bundles of ACC certificates, safety policies and accident data backwards and forwards with little obvious value add. Clients thought they had met their obligations and contractors thought this is all that was required.” In simple terms, CPNZ offers a service to firms (clients) who engage contractors. Instead of each client undertaking their own form of prequalification, as required by the Department of Labour guidelines, CPNZ enables all clients using the service to access up-to-date and reliable information on the safety capability of their prospective contractors. From the contractor’s perspective they only complete the CPNZ prequalification process once every two years and the information is then shared with a wide range of clients (which clients have access to this information is determined by the contractor). For contractors

working for multiple clients the savings in time and trouble can be significant. More importantly, feedback from the assessment will identify specific areas where there are opportunities for improvement in health and safety management. The Foundation Clients who have already committed to the CPNZ process, and who are guiding its development, include Air NZ, Auckland International Airport, Carter Holt Harvey, Fonterra, GEA, Goodman Fielder, Gough Group, Meridian, Mainzeal and Ebert’s. Another 30 large corporates and government departments have already expressed strong interest in joining the scheme. They will require their contracted service providers to carry out a CPNZ prequalification to remain on their vendor lists. Initial communications from clients to the first 750 contractor organisations informing them of this requirement have recently been sent out. CPNZ is in the process of following up with registration information and instructions on completing the prequalification, as well as assessing completed prequalifications. “Feedback since we launched in November 2011 has been really positive. It’s not often you get a safety initiative that has such obvious benefits,” says Tom Reeves.

• air compressors

Saving costs with synthetic compressor oils

A lot of energy is needed before a decent pint can be enjoyed.

Choosing speciality lubricants for compressors and gearboxes offers high potential for reducing operating costs and improving CO2 footprint in the food processing industry. The following article illustrates how synthetic compressor oils can save money in the operation of a brewery.

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The production, storage and filling of beer in large quantities requires extremely high amounts of energy, resulting in high operating costs for breweries. Enormous potential for energy savings lies in the operation of refrigeration compressors, air compressors and gearboxes, as their energy footprint can be improved considerably by using state-ofthe-art speciality lubricants. “Reducing energy consumption is an important concern of equipment manufacturers and operators, as energy costs make up a significant part of their total operating costs,” says Manjesh Babu, Market Manager Food Processing Industry at

Klüber Lubrication München KG. “However, energy not only incurs costs for the user; energy generation is also one of the main sources of climate-damaging CO2 emissions. Reducing the energy consumption of a brewery is therefore also a marked contribution to environmental protection.”

High potential for energy savings The brewery example from table 1 (Potential savings in a brewery) with three production lines shows the high potential for energy savings in the operation of compressors and gearboxes. Typically, refrigeration compressor power in operation is 200kW, air

• air compressors

compressor power is 300kW and gear power 450kW. After the changeover to state-ofthe-art speciality lubricants, efficiency increases between 0.5 and 15 percent can be proven, depending on the type of equipment. The energy savings can add up to 224,400kWh, which is equivalent to more than 20,000 per year, taking 9.4 cents per kWh as a basis. Changeover to appropriate speciality lubricants is easy and pays off after a short while. The energy consumption of compressors constitutes a sizeable proportion of operating costs. By reducing friction and offering better gap sealing, a synthetic compressor oil based on a suitable formulation can contribute both to a higher volumetric efficiency and a reduction of energy consumption. Less than one percent of the operating costs of a compressor are attributable

to the compressor oil purchase. While synthetic compressor oils are more expensive to buy than conventional oils, they turn out to be more cost-efficient when considering overall compressor operation costs. Further factors having a strong impact on the operational reliability of compressors are the lifetime of the compressor oil, its tendency to form residues, relubrication intervals and the oil vapour in the air. Compared with conventional mineral oils, high-quality synthetic compressor oils offered by Klüber Lubrication are characterised by a high resistance to oxidation. Klüber Summit FG series compressor oils are based on synthetic hydrocarbon oils. They are highly resistant to oxidation, leading to a clear reduction of residues. Besides longer oil change intervals, this allows longer filter and oil separator

lifetimes, enabling in turn a reduction of maintenance and operating costs. The operation of refrigeration compressors also benefits from the use of high-performance products. Klüber Summit R series synthetic refrigeration compressor oils, for example, enable refrigerators to operate with high efficiency due to reduced residues and oil carryover. With these oils, refrigerators can be used for a wide range of applications with evaporator temperatures down to -50°C. Both Klüber Summit FG oils and Klüber Summit R oils are registered as NSF H1 and certified according to ISO 21469, making them the obvious choices for use in the food and pharmaceutical industries.

Speciality lubricants for refrigeration compressors and gears offer a high potential for savings.

Gear oils for the food industry Synthetic gear oils made by Klüber Lubrication also contribute to high process reliability and reduced energy consumption and are likewise registered as NSF H1 and certified according to ISO 21469 and hence permitted for use in the food and pharmaceutical industries. As their synthetic base oils are extremely resistant to ageing and oxidation, these lubricants

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• air compressors

offer a much longer service life and can increase gear efficiency considerably. Their good viscosity-temperature behaviour means that in many applications a single viscosity grade can be used for both high and low temperature applications. Klüberoil 4 UH1…N oils are gear oils for normal temperature use and normal loads that even enable lifetime lubrication in certain applications. For high temperatures

and high loads, the use of Klübersynth UH1 6 oils is preferred as the optimised friction behaviour of the polyglycol base oil reduces power loss and clearly improves gear efficiency. Klüber Lubrication also offers a fluid grease, Klübersynth UH1 14-1600, enabling a good supply of lubricant to the friction point due to the soft consistency. The special thickener provides good adhesion and corrosion protection, thus

enabling longer component life.

For a lower CO2 footprint

The positive effects are not limited to savings in operating costs alone. If energy consumption is reduced, the carbon footprint of a brewery improves. Approximately 447kg of carbon dioxide is emitted in Europe on average per megawatt hour, depending on the regional energy mix

Potential savings in a brewery Component

Power output

Refrigeration compressors 200kW Air compressors 300kW Gears 450kW

Operating time

Energy consumption

Potential savings

Energy savings

Savings in Euros

Improvement of CO2 footprint*

8,760h 6,000h 6,000h

1,752MWh 1,800MWh 2,700MWh

approx. 5% approx. 4% approx. 2.4% Total

87.6MWh 72.0MWh 64.8MWh 224.4MWh

8,520 6,800 6,100 21,150

39.2t 32.2t 29.1t 100.5t

All values apply to one year at an average energy cost of 0.094 Euros/kWh * 447 kg/MWh on average, depending on regional mix of energy resources; source: Carma 2008

CO2 emission per MWh of energy generated per region: Continent CO2 in tons MWh of energy kg of CO2/ MWh of energy Asia North America Europe Germany Africa Oceania South America

5,750,000,128 3,089,999,872 1,880,000,000 429,000,000 335,000,000 235,000,000 139,000,000

8,030,000,128 5,139,999,744 4,220,000,000 636,000,000 518,000,000 273,000,000 874,000,000

716 602 447 676 647 859 159

of fossil fuels, nuclear energy and renewable energies. If the brewery described above saves 224,400kWh, its carbon footprint improves by more than 100 tons of carbon dioxide per year. Article submitted by Klüber Lubrication München KG Go to www.demm.co.nz/ enquiry quote: D120326

•

All data provided refer to the results attained with the mix of energy resources used in each of the stated regions (fossil fuels, nuclear power, hydrodynamic and other renewable sources of energy). Source: CARMA (www.carma.org), 2008

Aluminium piping saves time and money Industrial Air Systems’ sales team reports that their new aluminium compressed air pipe system saves both time and money on installation and everyday operation. This is because it combines the hugely beneficial properties of polished aluminium conduit with simple-to-use and inexpensive nylon push-in fittings, giving the best of both worlds – efficiency and economy. In fact, in most instances the new IAS piping can be easily and rapidly installed without the need of professional labour, and as the piping is extremely lightweight it can be easily hung by one installer. The new aluminium pipe system is also very rigid, requiring less

than half the supports needed by most alloy or galvanised pipe installations. There is no risk of sagging (and resulting water accumulation) as in poly piping and no rusting as in galvanised piping. This reduces the risk of potential plant damage and costly production downtime caused by harmful water contamination. The thin-walled aluminium piping makes for very high air flow rates when compared to other piping and will transfer up to twice the airflow for the same outside wall diameter. This higher air transfer means lower air compressor operating pressures and significant power savings while reducing

March 2012

the workload and wear on the compressor and plant operated. The aluminium air piping utilises lightweight and strong nylon push-lock style fittings, which can be disassembled and reused at any point down the track. This means the system can be very simply extended, added to, or altered as is so often the need with growing compressed air requirements. Industrial Air NZ’s director says, “This new aluminium air reticulation system is taking over from the outdated galvanised and poly piping systems in Europe, the USA and Australia. This stands to reason as it is superior in every

way; for instance it’s faster and simpler to install, it’s more rigid, it doesn’t rust, it doesn’t leak, it can be easily altered or changed down the track with no wastage, and most of all it allows for the transfer of more compressed air – taking the load off your compressor.” The new aluminium air piping is available in 20mm up to 63mm sizes and is suited to reticulate air volumes from 20 to 1000cfm. Go to www.demm. co.nz/enquiry quote: D120326a

•

• air compressors

New rotary screw compressors

Kaeser’s new fluid-cooled CSD and CSDX rotary screw compressors combine high performance and energy efficiency with versatile and compact design. With motor powers from 45kW to 90kW, the five models of both ranges cover free air deliveries from 8.3 to 16.1 m³/min (at 8 bar) and are designed for pressures up to 15 bar. The

new rotary screw compressor ranges provide significant energy savings in four ways: 1: CSD and CSDX units feature a large, lowspeed Sigma Profile airend equipped with flow-optimised rotors for superior efficiency. In combination with additional optimisation measures such as the minimisation of internal pressure losses, Kaeser’s energy-efficient design has enabled specific power to be reduced by between three and five percent compared with previous models. 2: Kaeser rotary screw airends are powered by IE3 drive motors for maximum performance and reliability. These motors will become obligatory in the EU from 01.01.2015, but users can already enjoy the benefits that these premium efficiency motors have to offer by choosing Kaeser compressors. 3: Kaeser’s highly efficient 1:1 drive design eliminates the transmission losses associated with gear or V-belt driven systems, as the motor directly drives the airend. 4: The newly developed PC-based ‘Sigma Control 2’ compressor controller enables compressor

performance to be precisely matched to actual air demand, thereby allowing additional energy savings. Kaeser’s new Sigma Control 2 controller also offers added advantages. This advanced system provides greater flexibility through its numerous interfaces and innovative plug-in communication modules. Therefore, connection to energy-saving master control systems, computer networks and/or remote diagnostics and monitoring systems, such as Kaeser’s Teleservice facility, couldn’t be easier. The large display located on the control panel also simplifies on-site communication with the system, whilst an SD card slot speeds up data reading and updating processes. Furthermore, the addition of an RFID reader ensures service continuity, increases security and significantly raises service quality. The ‘Sigma Control 2’ is also responsible for monitoring of compressors, refrigeration dryers and frequency converters as available. Go to www.demm.co.nz/enquiry quote:

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D120327

QUALITY ASSURED Open Polytechnic’s new Certificate in Quality Assurance (Level 5), in association with the New Zealand Organisation for Quality (NZOQ), is New Zealand’s only qualification focusing specifically on quality assurance. If you are responsible for delivering business improvement in your workplace, or are interested in a career in quality assurance, the Certificate will provide you with quality assurance guiding principles and expert knowledge you need to advance your career. Studying with Open Polytechnic means you can choose when and where you study. With our flexible options you can even choose to speed up your study and achieve your study goals faster. Enrolments are open, so what are you waiting for?

Visit openpolytechnic.ac.nz/qualityassurance or call us on freephone 0508 650 200 For more information on NZOQ visit nzoq.org.nz

• dust control and filtration

Need a dust collector? Do I need a new dust collector? The triggers that make people ask this question can be quite varied. Dust from many processes can be an irritant, a nuisance or just too valuable to lose from a process. Often, the catch 22 situation is “we appear to need a dust collector, but how does it fit in with our accepted accounting practice of return on investment?” Other issues like meeting resource consent provisions, space limitations, infrequent use or just not really understanding how a dust collection system works can be real barriers to investing in a quality solution to the issues of dust in the workplace. Donaldson Filters have seen many people struggle with these questions before installing

a dust collection system. All too often, the comments after a new installation has been commissioned are resoundingly positive. The focus should always be on removing the dust issue and not losing sight of that goal. To be assured of the best system for any given dust issue, it is important to deal with a company that has a wide range of dust collector options to choose from. Technology continues to strive for smaller, more efficient packages and Donaldson have led the way with their new PowerCore range of dust collectors. Where once the ‘traditional’ baghouse dust collector was the system of choice, collectors have now been developed to target specific tasks such as mist and fume collection,

Dust extraction and material handling Vortex Engineering ltd provide quality Systems and Solutions for all types of Dust Extraction. ¾Baghouse filters ¾Electrostatic precipitators ¾Storage Silos and bins ¾Extraction fans, ¾Rotary valves, ¾Heat plants (coal or wood fired) Call us to discuss your dust problems.... Auckland: Ph 09 525 3251 Christchurch Ph 03 366 8255 Email: sales@vortexeng.co.nz Web:www.vortexeng.co.nz

March 2012

New Donaldson PowerCore dust collector on laser fume

powder handling, thermally generated dust, heavy dust loading applications and sticky, problem nuisance dusts. There is no single type of dust collector that will handle every type of dust in the most efficient manner; each type has its advantages and its limitations. Donaldson Filters has traditional baghouses, compact cartridge collectors, flat ‘Dalamatic’ fabric collectors, pleated shaker cleaning units, Downdraft work benches, portable and fixed dust, mist and fume collection systems, Pulse Pleat type collectors and, of course the new PowerCore range, including the TG series for thermally generated dust at their disposal. This range has come about through in-house development and field experience since Frank Donaldson began making filters in the USA in 1915. Selecting the correct type of collector and the right size is the domain of the sales and engineering staff at Donaldson. Driven by air volume and dust characteristics and load, the right unit is selected. Filter media type is also an important part of the process. With Donaldson being a filter company first and foremost, many types of media are available to suit specific applications.

There are many other factors that must be taken into consideration to ensure that the system is safe and workable. Donaldson has the experience and resources to identify potential issues and to deal with them before the system is installed. This makes for a quick, seamless installation job, affecting the manufacturing process of the client for the shortest possible time and with the least possible impact. Dust collection requires a strong empathy with clients and within Donaldson, staff tend to have very long periods of service with the company. Even a dust collection engineer with ten or 15 years experience will often admit that they are “just beginning to learn”! Donaldson Filters pride themselves on offering effective, workable solutions to dust problems. Including them at the very early stages of a project, from a wood waste system in a school through to a silo venting application in a food manufacturing facility, from a steel plate plasma cutting to mine site dust control, can provide direction and answers to a process that can seem problematic at face value. Go to www.demm.co.nz/enquiry quote: D120328

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• Dust control anD filtration

Absolutely Energy efficient anything you air cleaners need for Dust and Fume Extraction

Energy efficiency is today’s buzzword, in all countries across all industry sectors. The Australian Government’s Clean Energy Future sets to cut pollution by at least five percent compared with 2000 levels by 2020, which will require cutting net expected pollution by at least 23 percent in 2020. The Australian Government has also committed to a long-term target to cut pollution by 80 percent below 2000 levels by 2050. Similarly, by adopting the Kyoto Protocol, the European Union has undertaken to reduce CO2 emissions by at least 20 percent by 2020. To achieve this climate goal, the EU adopted the the ErP Directive (Energyrelated Products Directive). This new directive helps with studying the savings potential of numerous energy-related products and stipulating minimum requirements. These new regulations mean that up to 50 percent of existing electrical fans will need to be upgraded. Limits for fans were defined in June 2010 and are valid now. Fans are used in many areas of manufacturing and in many in-design products, so

the EU changes could be long-lasting in cutting CO2 emissions – not only in Europe but also in other countries like Australia. Machine tool-based mist extractors use fans and therefore will be subject to these new directives. Reven GmbH can deliver from now on all of its air cleaners with fans and motors that already fulfil the ErP directive. All of these air cleaners, also known as mist extractors, now wear the green ErP ready sticker. Dimac Tooling, Mulgrave, VIC, offers the German-made Reven Recojet oil mist separators Ultra Cleaners and Rejet-A air cleaners, which are highly efficient mechanical air filtering units using the mechanical separating system X-Cyclone. Air pollutants and contaminants from oil, emulsions and other fluids are separated from the ambient air as aerosols to a very high extent. Many manufacturers in Australia benefit from Reven products because they require almost no maintenance and low power consumption. The new extreme energy efficient ErP version comes with much more updates and improvements. The motor has been moved outside of the airstream, which leads to a higher lifetime for the motors. The ErP version comes with a much more compact door design, therefore the door is now more resistant and is oil and water proof. The fan housing is completely welded and therefore now 100 percent oil and water proof. Go to www.demm.co.nz/enquiry quote:

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New Zealand

DUCT & FLEX Flex

In-stock for overnight delivery

Modular Duct

Widest Range Baghouse Filters

Dust Storm Filters

Fans

European Quality Fume Arms

Freephone 0508 NZ DUCT (0508 69 38 28) 13F Saleyards Road, Otahuhu, Auckland Ph: 09 276 8020 Fax: 09 276 8070 Email: info@nzduct.co.nz

www.nzduct.co.nz

D120329

• Dust control anD filtration

Combatting air particles with water mist At first sight, the Dust Fighter looks like a jet engine seeking for a plane to attach itself to, when in fact it’s the latest answer to the increasing problem of ever-present and dangerous workplace air particles. The Dust Fighter is a product that has been developed by Italian manufacturer DF Ecology who specialise in producing and marketing an extensive range of dust control equipment ideal for use by demolition contractors, recycling and construction companies. Imported into New Zealand by Youngman Richardson Co. Ltd, the Dust Fighter is designed to cover different sized areas with nebulised water. The

microparticle water produced by the Dust Fighter is the ideal solution to reduce dust in the air. Dust is dangerous if it is inhaled. It can also cause accidents in the workplace and it can be damaging to construction equipment. The Dust Fighter has a large fan that disperses a fine mist of water into the air, capturing airborne dust particles and delivering them to the ground. The fan is surrounded by a metal cowling which contains a water distribution manifold, to which are attached numerous fine, water-misting outlets. Water from a garden hose is all that’s needed. This is not only an efficient use of water,

VIKING NEW ZEALANDS MOST COMPREHENSIVE RANGE OF DUST EXTRACTION AND SPRAY BOOTH SYSTEMS.

SPRAY BOOTHS • Kit set open face booths • Auto spray lines • Heated spray and bake booths • Heated drying rooms • Paint work stations

DUST EXTRACTION • Reverse pulse bag filters • Camfil Gold series collectors • Cyclones and static filters • Fans and rotary valves • Design build, project management • Sheet metal and general engineering

• V-Duct modular ducting • Welding and fume extraction T: (09) 835 4090 F: (09) 835 4070

www.vikingltd.co.nz

March 2012

but also keeps the job site drier and helps prevent run-off into waterways. The Dust-Fighter requires around 20kva for the average model to project the water droplets on their collision course with the enemy dust particles. The maximum height of its ‘throw’ is 30 metres and the width of the column increases to around 15 metres before settling back to the ground. The effect of the water mist is immediate, with all dust in the target area eliminated. As well as suppressing dust, the noise reduction of the Dust Fighter is a big factor when working around the demolition site. Youngman Richardson’s most recent deliveries of the Dust Fighter have been to Nikau

Contractors who are using a number of the machines in conjunction with the Christchurch inner city clean-up. The added attraction of a diesel generator mounted alongside the Dust Fighter on a custom-built double axle car trailer provides more versatility for workers on the site. “This is a very important piece of health and safety equipment and very effective when in use,” says Youngman Richardson Sales and Marketing Director, Ed Richardson. “I am convinced that progressive companies will see the importance of these machines and they will be commonplace before too long.” Go to www.demm.co.nz/enquiry quote: D120330

“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

•

• Dust control anD filtration

kiwi bulk cargo engineers team up with DCL Dust Control and Loading Systems (DCL) to act as the Australasian agent for the global company. The Michigan-based company researches, develops and manufactures a full range of dust control loading systems and key components. The DCL range of discharge spouts, conveyors, valves and filter modules is suitable across a wide range of bulk material types as varied as fertiliser, cement, grain products, alumina, limestone and salt. Their application is not limited to shipping points, with increased use in quarries, grain handling facilities and bulk fertiliser storage depots. A key emphasis of DCL’s ethos is to design dust

control technology without sacrificing equipment and plant productivity. A typical DCL application is the company’s heavy duty loading spouts, designed specifically for stockpiling dusty product in warehouse or storage situations. These include bulk storage of products like palm kernel extract, fertiliser and grains. The spouts are also suitable for ship loading and capable of operating at up to 6000 tonnes per hour. Flexible sleeves and rubber skirted lining provide a high level of dust suppression, and additional suppressors offer virtually dust-free product handling. DCL’s retractable discharge

Heavy duty application: DCL load spout loading cement

Bulk handling operators across a range of industries face greater pressure globally for their businesses to conform to ever stricter environmental standards around dust and product discharge during operations. Minimising the volume of product discharged into the environment can be a challenge as bulk handling facilities increasingly compete with other commercial users for operation space, and public perceptions of dust’s environmental impact. Here in New Zealand operators also face increased penalties under the Resource Management Act (RMA) for illegal discharges. Even when air discharge is not a consented requirement, dust

layers can affect water quality, and in turn become a RMA issue. In addition, stricter health and safety requirements mean operators are also required to provide a safer, healthier environment for staff to work in, with minimal exposure to potentially unhealthy dust contamination. Dust control at the bulk transfer points increases system productivity by reducing material losses. Estimates are that those losses can be as high as five percent of the total product handled. Recognising this need for technology to manage dust issues, established Tauranga engineering firm Page Macrae Engineering has teamed up with United States company

www.page-macrae.co.nz Phone: +64 7 575 5079

• Dust control anD filtration

spouts also provide exceptional dust-free discharge for loading into enclosed rail cars and trucks. The company’s latest development, a compact filter module, provides a very low profile combination of unloading spout and dust filter, ideal for use when loading in enclosed or open vehicle spaces. The “all in one” spout and filter module eliminates the need for expensive additional ducting and ensures a flexible, easily located discharge point. Page Macrae Engineering Bulk Cargo manager Bruce Ennis says the DCL agency brings valuable synergies for both companies. “Page Macrae is increasingly focussed on developing whole chain bulk handling solutions. That can include from ship to storage, but also equipment for any handlers of bulk materials that are problematic for dust creation. Our equipment now includes our bulk grabs for ship unloading, while our EnviroMax hoppers provide a solution for discharging cleanly into trucks and rail cars, with dust control technology ensuring compliance issues are being met. “DCL discharge spouts are a key component in our hoppers, and our use of them comes after careful assessment to determine they are the best available.” He says one of the top priorities for companies seeking bulk discharge systems is dust suppression. Page Macrae’s recent delivery of hoppers to POAGS Port of Darwin and subsequent repeat order for POAGS Port of Bunbury are typical examples. “The client had to prove to authorities clearly how they were going to manage dust losses, and the DCL discharge spouts we fitted have proven to be highly effective in achieving that.” Go to www.demm.co.nz/enquiry quote:

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D120332

IT’S ONE DECISION

NOBODY WILL SECOND GUESS

Donaldson PowerCore the new standard in dust collection. ®

It’s not a baghouse. It’s not a cartridge collector. It’s a smart new way to collect dust that requires less space, less maintenance and dramatically reduces your total cost of ownership - all with the filtration performance you expect from Donaldson. A ® PowerCore dust collector is a smart choice that makes you look even more intelligent with every filter change.

Torit PowerCore CP Series

March 2012

New extraction system increases productivity

Renowned furniture manufacturers Accent Group have recently installed a new Egmont Air Dust Extraction System in their new Wellsford factory. After careful evaluation and analysis, Accent Group selected Egmont Air as their preferred supplier for the new dust extraction system. Accent Group have a long experience in the industry and were looking to combine operations from two separate locations to one central factory. A large selection of machinery and work processes were evaluated so an extraction system could be specified to provide optimum extraction for varying work processes. The Egmont Air system was supplied with the Eco-power device which provides live monitoring of the airflow requirements and automatically adjusts the fan suction to suit the machinery operating at any one time. This Egmont Air initiative provides a significant power saving and reduction in power consumption. The new Egmont Air system features a large 800mm-diameter main duct, modular filter unit with discharge conveyor and rotaryvalve feeding a bin-loading fan. Dusts are collected in a hook-bin which allows easy removal and disposal of waste. Also important to Accent Group was the ongoing maintenance of the extraction unit. The new system features an automatic filter-sleeve cleaning function which maintains the filters in optimum working condition. A ‘post-clean’ sequence also occurs at each shut-down to ensure the filters are ready for next work shift and provides a guarantee for longevity and reliability of the system. Egmont Air dust extraction systems are a favourite solution for woodworking factories such as kitchen makers, joinery shops and timber processing plants that require a good value system that offers suction performance and energy savings. The company designed, supplied and installed the centralised system at Accent Group which consists of an externally mounted Filter system ducted directly to each machine. Specialising in wood dust extraction, Egmont Air offer an on-site evaluation service to calculate and measure the extraction requirements and airflows for all applications. “Correct airflow and filter sizing is critical for optimum performance,” comments Cameron Prestidge from Egmont Air. Consideration must be given to the type and volume of dust collected, type of woodwork machinery operating and the ducting design so that the system will perform for years to come with minimal maintenance. Contact sales@egmontair.co.nz

• MAINTENANCE MATTERS

International supplier backs National Conference The Maintenance Engineering Society (MESNZ) is a non-profit society run entirely by volunteers, who squeeze their society time in-between the pressures and responsibilities of the real world. You would think that the

Christmas/New Year period would mean that not much would be achieved by these fine gentlemen (and ladies). Well, you would be wrong. While the rest of the world was focused on Christmas beaches and wet summers, the team at MESNZ has been busy working on its services and resources. New committee member Karl Hayward has taken up the reigns of newsletter editor hoping to emulate the quality reading standards achieved by Christo van Niekirk. As well as the content, Karl is driving a new delivery medium which we hope members and subscribers will appreciate. There will be more on the newsletter and our new regional networking forums next month. Enquiries are already rolling in for the MESNZ Engineering Scholarship and eduguru Bill Sole is set to release the program in the very near future, in response to the prospective participants. Talking education, the world has come

The maintenance engineering and engineering supply community meet at the NMEC 2011 in Rotorua.

a long way since we started bleating about the apprenticeship system this time last year and we cannot complain that at least it is now a topical subject. Changes are afoot in many sectors and while we await developments with interest, the good news is apprenticeships appear to have become “sexy” again and institutions such as MIT, while battered, continue to provide night classes for the current crop of engineers. The show-stopper of course is the 2012 National Maintenance Engineering Conference. Planning for this event started as patrons were leaving the 2011 event and has continued in earnest since then. Exhibition demand is unprecedented this year with a dozen exhibitors signed up already, pointing to another sell-out year. Sponsorship spots are in hot demand too, with the hot news being new event sponsor SKF. With a long and respected history of participation and support of engineers and their national conference, SKF grabbed the opportunity

Leadership has a class of its own

FLIR E-Series: Picture Perfect A new generation of FLIR hand-held ‘point & shoot’ thermal imagers is here. Packed with class leading features, the E-Series is designed for applications including electrical, industrial, mechanical, HVAC and building. Take your pick of three pixel resolutions – all with 60Hz frame rate and a 3.0 Meg visual camera built in.

The new FLIR E-Series. It’s all class. Get Connected! Connect to iPhone or iPad via Wi-Fi to use the FLIR ViewerApp for processing and sharing results.

◊ Mobile Device Wi-Fi Connectivity ◊ Large Bright Touchscreen ◊ Built-in Digital Camera & Laser Pointer ◊ Groundbreaking Performance & Affordability ◊ Superior Point & Shoot Thermal Imagery

Want to know more? Freecall New Zealand 0800 785492 or www.flir.com

ISO No. FLIR20837

• MAINTENANCE MATTERS

to step up to the plate with the ultimate support to ensure the society keeps delivering. The speaking schedule has been laid out and Barry Robinson and Larry Wiechern head up the team seeking presenters and papers. Approximately 13 papers will be presented that have a holistic relationship to maintenance and line management. The topics are drawn from: HR/ team management, employee management, employment law, health and safety/compliance, technical – generic (open), apprenticeship forum, celeb/ special interest, technical preventative maintenance, education and training, IPENZ case study, and personal motivation. If you think you would like to contribute with a case study based paper, you can download our speaker pack on the conference “call for papers” webpage http://www.mesnz.org.

nz/nmec/call-for-papers.asp or find the contacts for Barry and Larry who will gladly assist you. While the society has made a conscious decision to retain the conference in Rotorua, 2012 sees a venue change to the Novotel Lakeside Rotorua for the November 7 and 8 conference. Registrations are open for exhibitors and attendees and can be found on the website (www.mesnz.org.nz\nmec\) or by contacting Event Manager Leanne Powley on (09) 296 1333, info@adminoncall.co.nz. So, you can’t say you haven't been warned. Check out the new look conference web pages, put a circle around 7 and 8 November, get your registration under the nose of your boss now before his holiday bliss evaporates and look out for the newsletter and scholarship. Article by Craig Carlyle, Secretary MESNZ

GANTRY CRANES

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SOLUTIONS FOR ALL YOUR LIFTING REQUIREMENTS Electric Hoists -Magnetic Lifters-Spring Balancers-Lever Hoists ElectricChain Chain Hoists-Magnetic Lifters-Slings-Lever Hoists

Tel 09 263 7725 FAX 09 262 0970 10 Oak Rd, Manukau City 2241 Email sales@stratalign.co.nz

March 2012

Fit for hazardous environments A new air-hydraulic torque wrench pump from Enerpac has been introduced for reliable high performance, ease of use and safety in challenging and potentially hazardous environments including oil and gas, energy, mining and onshore and offshore infrastructure projects. The ZA4 series ZA4208TX-QE100 pump – which is ATEX 95 certified for use in potentially explosive atmospheres – features a high efficiency pump design with higher oil flow and bypass pressure and enhanced two speed operation to reduce cycle time for improved productivity. The new ZA4 modular pump is custom-engineered for extended operation in its first stage, to deliver extended performance in ranges required by users working on maintenance and fabrication applications such as pipelines, pressure vessels, tanks, metal structures, rigs and onshore and offshore machinery. Wilkerson reclassifer exhaust technology has been employed to prevent motors freezing and reduce exhaust noise, while a larger air motor piston allows the pump to operate with air input as low as 2 bar (40 PSI), says Enerpac Manager, Oil and Gas Industry, Mr Slade Greenaway. “The great advantage of lower operating pressures is that multiple torque wrenches can be operated from the one source of compressed air,” he says. The new ZA4208TX-QE100 model pump is part of the ongoing development of the broader ZA4 series, which is available in reservoir capacities from 4-40 litres. ZA4 pumps are part of Enerpac’s advanced ranges of safety-oriented,

The new Enerpac air hydraulic torque wrench pumps cut delay while enhancing safety and ease of use.

energy saving and labour-saving technologies, including lifting, pumping, fastening, bolting and maintenance tools. Enerpac has been established in Australia and New Zealand as a major supplier of high-pressure (700 bar) hydraulic equipment for 50 years, having nationwide service backup and a strong distribution network. Its ranges of 700 bar (10,000 psi) precision hydraulic cylinders, tools and safety equipment (contained in its E325A catalogue) is complemented by professional bolting technology being introduced by Enerpac to address the needs of major areas of industry, including mining and energy, infrastructure construction, manufacturing, pipelines, mobile machinery, tracked and heavy vehicles, cranage and fixed plant. Go to www.demm.co.nz/enquiry quote:

•

D120334

• MAINTENANCE MATTERS

Hydraulic jack testing - calibration Hytools NZ, a division of Hytorq NZ, is now able to offer hydraulic jack calibration and testing within their Onehunga workshop. The new test and calibration rig can safely accommodate loads of up to 700 tonnes and the maximum diameter of cylinders that it can

accommodate is 580mm with a maximum height of 2600mm. An increase in industry requirements for calibrated jacking systems led to the development of this test rig as larger jacking systems, requiring calibration, had to either be shipped to the South Island or

alternatively to Australia. In some cases certification on a system is required after every six months which is extremely costly as well as inconvenient for the engineering contractor involved. Once a jack has been calibrated to its dedicated gauge the data is processed and the relative graphs and certificates are then provided for the customer. The rig is also used for pressure testing hydraulic jacks from 50 tonnes through to 700 tonnes. Once a jack has been serviced it can be pressure checked throughout its stroke. To protect operators against any possible mechanical or hydraulic failure, the test rig is surrounded by an all-steel cage and lined with polycarbonate sheeting to protect against oil leakage.

Hydraulic & Torque Tools

Ph: 09 636 2264

279 Mt. Smart Rd, Onehunga, Alk Akl

Operators are further protected by a separate solid steel screen set away from the cage where they can safely operate hydraulic pumps and monitor the digital transducers. Go to www. demm.co.nz/enquiry quote:

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D120335

  

Sales Service Hire

BOLTING  Hand torq. wrenches  Torq. multipliers  Heavy duty sockets  Hyd. torq. wrenches  Nut splitters  Backup spanners  Calibration HYDRAULIC  Pumps  Hoses  Cylinders  Toe jacks  Heavy lift jacks  Crimping tools  Load cells  Chain cutters  Pullers

Web: hytoolsnz.co.nz 35

• MAINTENANCE MATTERS

Engineering training graduates deserve recognition Completing a high-level qualification while working full-time requires a lot of dedication, yet every year several thousand employees in industry achieve highly with little public fanfare. Companies supporting their employees through on-job training, such as apprenticeships, are equally dedicated, investing in lifting transferable skill levels throughout New Zealand industry. To recognise the efforts of learners and employers, industry training organisation Competenz has published and distributed a ‘Roll of Honour’ handbook. The handbook celebrates all graduates who completed Level 4 or higher qualifications that Competenz

THEtest THERMAL IMAGING The and measurement equipment rentalSPECIALISTS specialists CAMERA RENTAL You know what you need to test or measure - our Application Engineers can assist you select the right equipment for your application.

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0800 832 473 Rent for a day, a month, a year or more.

March 2012

oversees in mechanical engineering, refrigeration, heating, ventilation and air conditioning, and fire protection. A total of 846 graduates from 536 companies nationwide feature in the Roll of Honour. Of these, 733 are graduates from the wider engineering manufacturing sector who completed their national certificates in a three to four-year long apprenticeship, and are now fully-qualified in their trade. “All of our graduates can be very proud of their achievements, knowing their skills will stand them in great stead for their career development,” says Competenz

Skills4Work running maintenance training in more locations Due to increased awareness and demand for the training offered by Skills4Work for maintenance technicians, supervisors and managers, three new course locations have been added to the programme. To offer a more localised service, courses in Wellington, Christchurch and Tauranga have been added to the existing programme run at their Mount Wellington training centre. Skills4Work Maintenance Excellence Programme Manager, Phil Hurford explains, “While the willingness of our customers to attend courses in Auckland has always been encouraging, we find that many have to travel long distances and we are often

asked if we run the courses elsewhere. Adding locations in Wellington, Christchurch and Tauranga will make it far more convenient and reduce the cost for people to attend. I’m particularly pleased to be able to offer training locally in Christchurch, as we have many existing South Island customers and it is great to be able to support the local industry. There is no doubt that training plays an important role in improving the way we approach and carry out maintenance.” More information about the programme is available on the Skills4Work website at www.skills4work.org.nz.

• MAINTENANCE MATTERS

acting chief executive Fiona Kingsford. “Achieving a high-level, industry-based qualification requires just as much focus as anything you’d study at university or

polytechnic, with the added challenge of juggling work priorities.” It’s a small way of recognising the time and effort learners put into completing their training,

and the role of employers providing employees support throughout their on-job and off-job learning. “Companies also deserve to be recognised for their commitment to invest in training – a more highly skilled workforce with transferable skills benefits both the company and our country’s economic future.” It is a positive step toward meeting the skill gaps companies identified in research Competenz conducted last year on this issue. But according to the research, a further 3,600 skilled manufacturing workers will be needed by companies within the manufacturing sector by 2013. “The only sustainable way for companies to gain the skilled staff they need is to upskill even more of their current employees, or take on new staff to train to your requirements,” says Mrs Kingsford. “Apprentice training does require a big commitment,

and industry training organisations like Competenz offer companies expertise in planning and training support to help meet their upskilling and business objectives.” Competenz’s annual alumni magazine – ‘The Guild’ – has also been published to coincide with the handbook’s release. This latest edition features the inspirational stories of nine 2011 graduates, each with an interesting perspective on what drove them to complete a qualification on the job. “These stories show that training positively impacts the lives and career prospects of people at all levels of work experience, and it’s never too late to get tradequalified,” says Mrs Kingsford. For more information on upskilling your staff in 2012 or to request a copy of the 2011 Graduate Handbook, contact Competenz on 0800 526 1800 or visit www.competenz.org.nz.

Maintenance Best Practice - 5 Day Course. A bottom up approach to maintenance that will improve workplace culture and increase reliability. Maintenance & Reliability - 5 Day Course. Learn how to analyse and monitor plant to make positive changes to your maintenance practises. Planning & Scheduling for Planners - 5 Day Course. This course gives your planners the tools they need to increase productivity and reliability across the workplace. Introduction to RCM and HAZOPS - 1 Day Workshop. Learn what these processes are all about and how to lead and manage teams to implement them.

March 26-30 Maintenance Best Practice

April 16-20 Maintenance Best Practice

May 21-25 Planning & Scheduling for Planners

Download the full course calendar from the Skills4Work website

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• MAINTENANCE MATTERS

“Manufacturers must lift their game”

“Somebody has introduced a serious problem into their production process!” – Larry Wiechern

“Maintenance is all about maximising plant reliability,” says Larry Wiechern. The Maintenance and Reliability Centre Manager at Manukau Institute of Technology highlights the importance of upskilling the workforce, sharing expertise and choosing trustworthy suppliers. DEMM: What is your definition of maintenance? LW: Maintenance encompasses every kind of activity to ensure the plant operates as reliably and efficiently as possible. DEMM: How do you increase the efficiency of a plant? LW: Personally, I think a lot of problems could be eliminated at the stage when the plant is being designed. Often this is a result of the theory not backed up by having a solid practical understanding of the plant and equipment being designed and also too much focus on the equipment purchase “cost”, not the “total cost of ownership” over the entire life of the equipment and plant. If the design has flaws you are always going to be chasing your tail to maintain the equipment and achieve the overall operating efficiency that management expects. Once the plant is being installed, there are hopefully foundations that adequately support the equipment to maintain its alignment under load without being affected

ARE YOUR STAFF NOT ‘GETTING’ IT? IS MAINTENANCE MANAGEMENT OR HEALTH AND SAFETY GIVING YOU A HEADACHE? Unlock your staff’s potential with either of our inspiring and informative short course training sessions: •Maintenance Management Basic Training or •Health and Safety Made Simple From only $220 + GST per person check our website for details and session dates

March 2012

by outside vibrating influences. There are statistics that indicate misalignment causes the majority of damaging vibrations in reciprocating and rotating machinery. Therefore: Have it done properly the first time, and have periodic alignment checks performed during planned maintenance programmes to compensate machine movement, foundation settlement and local modifications in your production. The other critical criteria is precision balance of all the rotating components, this together with precision alignment and installation methods will eliminate as much as 80 percent of possible machine failures. Another crucial discipline that has often been neglected and not given the importance that it deserves is a better understanding of lubrication from the point of purchase to its correct application; after all it is the lifeblood of machine and equipment and plays a vital role in the overall life and efficiency of your plant. DEMM: Once the plant is set up and running, what else can be done? LW: It should go without saying that you need to adhere to good and ongoing maintenance practises. Plant operators play a decisive role as they are the eyes and ears of the plant. If trained properly they are able to recognise the first sign of anything going wrong, be it an unusual noise or smell, excessive vibration, oil or air leaks. A welltrained operator will save your company a fortune if notice is taken of their observations. I have to say I have been very impressed by the level and interest shown by the operators I have had come through the maintenance centre over these past few years. But of course the companies have only sent me those that are keen to learn and pass on that knowledge to others. Clyde Volpe, who is with the Vibration Institute of Australia, emphasises the fact that the focus of engineering should be on plant reliability – it is not sufficient to utilise condition monitoring systems. Somebody must check and analyse the gathered information and decide which maintenance activities should be scheduled, and changes implemented to ensure maximum plant reliability and efficiency. Collecting data never fixed anything unless action is taken to

effect a change for improvement. Ron Moore, an internationally recognised authority on manufacturing excellence, once pointed out to me that the biggest problem in this context is the alignment of all the technologies available. There is infrared thermography, ultrasonics, oil and vibration analysis, and in many cases the findings of each technology are not brought together, but are analysed separately. Consequently they can’t support each other to predict impending machinery failure. The industry needs to interconnect better, share their expertise and form networks; these networks include Vibrations Association of New Zealand (VANZ), SIRF Rt - Industrial Maintenance Roundtable (Aust/NZ) and Maintenance Engineering Society NZ (MESNZ). And engineers can also attend various seminars and conferences, to bring themselves up to date with new and current practises, and network with experts and peers. DEMM: Like the seminars offered at the MIT’s Maintenance and Reliability Centre? Absolutely! The one, three and five day short courses on our training programme aim to train plant staff, especially operators and fitters, to detect and repair all sorts of faults that affect the manufacturing process. What makes us really stand out are the industry experts that support our programme, because those experts have the real in depth knowledge. We are pretty lucky to have those guys on board. There is for example Barry Robinson, the General Manager of South Auckland Forgings Engineering (SAFE), who is trying to make people aware of the dangers of poor welding practises, and the necessity for pre- or post-heating welds to relieve the internal stresses that might have developed. He also emphasizes the quality of material you purchase and that it has to be fit for the intended purpose. We also work together with Clyde Volpe

•MAINTENANCE MATTERS

from the Vibration Institute of Australia, and Jason Tranter, from Mobius, who are in my opinion the best trainers of vibration analysis knowledge anywhere in the world. Phil Williams, the former Training Manager of SKF New Zealand, has been supporting our programme over many years. We have just developed, together with SKF, the Vibration Analysis Category 1 and 2 courses, along with a three-day bearing seminar at MIT. Currently we are in talks with Waikato University and Dr James Neill, for an introduction to ultrasonics one-day seminar leading into onto their existing full-week certification course. We hope to set up partnerships with other companies in order to offer more in-depth training delivered by these industry experts. These include SIRF Rt – RCA Rapid one-day and 5 Whys halfday workshops, utilising their expert trainers. There is so much help available; you just need to know where to tap into it. DEMM: Do you perceive lack of skills to be a problem for the industry in New Zealand? LW: At the moment I am very disappointed in the way we are training our apprentices. Top-end subjects such as ultrasonics, infrared thermography, and oil and vibration analysis are not taught at all at the polytechnic institutes around the country, or only on a very limited scale. If the apprentices are to get into contact with those important topics, it has to happen at their workplaces. And other topics that the guys are being taught do not relate to their trade. We’ve got to upskill our workforce, starting with the operators and then the tradesmen

and fitters, so they can pick up the necessary skills to do their jobs properly. What’s the point in having a contractor come on site to take off the inner ring of a bearing, and instead of using the right tools they use a ‘gas axe’ and burn it off. The production is up and running fairly quickly, but at what cost? This procedure introduces stress raisers into the shaft, causing it to eventually break. If manufacturers do not lift their game, and if mistakes keep happening, they will run the risk of going out of business. That’s the danger of not doing your job properly and not understanding the repercussions of equipment failure due to poor maintenance practises. DEMM: How big a threat are counterfeit bearings to the industry? LW: Well… nobody knows exactly how much damage has been caused. We have a large spherical roller bearing on display here at the centre that originally looked fine. The internal clearances/tolerances were inconsistent. We then cut out a piece and put it under the microscope to check the material; its hardness, the quality of the steel, and for any inclusions. With the help of a microscope we were able to conclusively identify it as a fake. It would have failed under load pretty quickly. The brand imprint on the bearing said ‘SKF’ and ‘Made in Germany’. After a failure you would have blamed the fitter, the operator, the lubricant; and then the bearing manufacturer, possibly damaging the brand forever. In January 2007 around 40 tons of counterfeit bearings with the brand imprints INA, FAG and SKF and a nominal value

of some 8 million Euros were destroyed in Germany. What really disappoints me is the fact that when I talk to people, they have never heard of this incident. It should be made known more widely to alert people to the dangers of counterfeit bearings and the extent of the problem. DEMM: What other counterfeit products can you find out there? LW: Basically every product could be counterfeited; bearings, gearboxes, chain sprockets, v-belts, steel, welding products – you name it. Richard Clancy, Director of RJC Engineering Consultants, reported a case where a large Indonesian paper mill had purchased counterfeit automatic transmission oil for its fork-trucks. The oil actually was transformer oil that had been dyed red and put in an original Mobil oil drum. The trucks’ transmissions failed, paralysing the production of the mill. No matter what product, you need to buy from genuine, preferred suppliers. It’s important you know the person you’re buying the equipment from. If you focus simply on the cost, it could be that you have purchased a counterfeit product and introduced a serious problem into your production process. I’d like to finish with this piece of advice: Take the time to audit the contractors that have secured the contract and ask the question – where have they purchased the items such as bearings, oil etc. that they are bringing onto your facility? My advice is: always buy from preferred suppliers! DEMM: Larry, thank you for the interview.

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UPS's keep businesses going UPS hardware can help keep business applications available, power costs manageable and data safe. By familiarising themselves with the basics of what a UPS does and how to choose the right one for their needs, businesses can ensure that mission-critical systems always have the clean, reliable electricity they need to drive long-term success.

Budgeting for electricity, securing adequate supplies of it and finding ways to use less of it are all common topics of conversation among business owners. Ensuring that the power their production and IT equipment rely on is both dependable and clean, sadly, can sometimes be an afterthought. In truth, however, power sags, surges and outages are not only unavoidable but more than capable of damaging valuable production and IT equipment and bringing productivity to a halt. Thatâ&#x20AC;&#x2122;s why planning and deploying a robust power protection solution is absolutely vital. UPS Power Solutions Limited, the New Zealand Distributor of the Eaton range of uninterruptible power system (UPS) equipment considers a UPS is the central component of any well-designed power protection architecture. Put simply, a UPS is a device that provides backup power when utility power fails, either long enough for critical equipment to shut down gracefully so that no data is lost, or long enough to keep required loads operational until a generator comes online. A UPS also conditions incoming power so that all-too-common sags and surges donâ&#x20AC;&#x2122;t damage sensitive electronic gear. UPS's come in two major varieties, which are also known as topologies: single and doubleconversion systems.

Single-conversion systems In normal operation, these systems feed incoming utility AC power to equipment. If the AC input supply falls out of predefined

March 2012

Eaton UPS product family offers UPS solutions from 500VA to 500kVA.

limits, the UPS utilises its inverter to draw current from the battery, and also disconnects the AC input supply to prevent backfeed from the inverter to the utility. The UPS stays on battery power until the AC input returns to normal tolerances or the battery runs out of power, whichever happens first. Two of the most popular single-conversion designs are standby and line-interactive. Standby UPSs allow IT equipment to run off utility power until the UPS detects a problem, at which point it switches to battery power. Some standby UPS designs incorporate transformers or other devices to provide limited power conditioning as well. Line-interactive UPSs regulate input utility voltage up or down as necessary before allowing it to pass through to protected equipment. However, like standby UPS's, they use their battery to guard against frequency abnormalities.

Double-conversion systems As the name suggests, these devices convert power twice. First, an input rectifier converts AC power into DC and feeds it to an output inverter. The output inverter then processes the power back to AC before sending it on to IT equipment. This double-conversion process isolates critical loads from raw utility power completely,

ensuring that IT equipment receives only clean, reliable electricity. In normal operation, a double-conversion UPS continually processes power twice. If the AC input supply falls out of predefined limits, however, the input rectifier shuts off and the output inverter begins drawing power from the battery instead. The UPS continues to utilise battery power until the AC input returns to normal tolerances or the battery runs out of power, whichever occurs sooner. In case of a severe overload of the inverter, or a failure of the rectifier or inverter, the static switch bypass path is turned on quickly, to support the output loads.

How to choose the right UPS To ensure that one always ends up with the right UPS for your needs, there are many considerations. Question number one concerns the choice between singleconversion or double-conversion UPS. The answer depends largely on how important energy efficiency is for an organisation relative to protection. Single-conversion UPS's are more efficient than doubleconversion devices, but offer less protection. That makes them a good fit for loads with a higher tolerance for failure. Doubleconversion UPS's, which provide the highest levels of protection, are less efficient but are usually the standard choice for protecting

• UPS

mission-critical systems. A UPS’s rating is the amount of load, in volt-amperes (VA), that it is designed to support. Eaton offers the largest selection of power protection systems available in the industry. UPS's are available with ratings as low as 500VA and as high as 5,000,000VA or more. This very basic procedure helps determine the approximate UPS rating a specific application requires: 1. Make a list of all the equipment the UPS will be protecting. 2. Determine how many volts and amps every device on the list draws. 3. For each device, multiply volts by amps to arrive at a VA figure.

4. Add all of the VA figures together. 5. Multiply that sum by 1.2, to build in room for growth. The ‘right’ UPS should have a rating equal to or greater than the final number determined in step five. Selecting and designing the correct power protection solutions for an application can be difficult and it is recommended that specialist advice be sought. UPS Power Solutions has over 20 years experience in the design, supply, installation and servicing of power protection solutions in the New Zealand market and their engineers are available to assist the customer to select the right solution.

Maintaining UPS equipment With proper servicing, a well-made Eaton UPS can operate safely and reliably for its entire design life. Without proper servicing, even the best UPS is significantly more likely to fail when you can least afford it. Companies in the market for UPS hardware, therefore, should also choose an appropriate UPS service plan from a service provider, such as UPS Power Solutions Limited, with the experience, know-how and resources to provide comprehensive, high quality support. Article supplied by UPS Power Solutions Limited Go to www.demm.co.nz/enquiry quote: D120341

•

UPS – One for all and all for one? The race for efficiency in the UPS industry threatens power quality. Paul Tyrer, Vice President Pacific, APC by Schneider Electric, provides a guide to the selection of UPS's for mission critical applications.

Escalating energy costs coupled with a drive to reduce carbon emissions have resulted in a number of changes within the UPS (uninterruptible power supply) industry. An initial development was the introduction of modular, scalable UPS solutions which enabled higher system efficiency through ‘right sized’ power protection, and recent product introductions boast up to 99 percent efficiency. While such numbers may be eye-catching to potential purchasers, ‘high efficiency’ options can increase potential risk to the critical load. This guide deals with the benefits and pitfalls when specifying UPS for data centres and critical load and highlights the potential risks of UPS systems above 97 percent efficiency. There has been a general assumption that all UPS designs and technologies are born equal. It’s not difficult therefore to see why there has been a certain tendency to conclude that all UPS topologies afford similar levels of protection. Essentially there are two generic types of UPS available at present – static and rotary covering various

topologies (VFI, VI & VFD). However, it is important to understand that static UPSs enjoy the lion’s share of a global market. Static units range from 200VA to 1600kVA as single modules which can be connected in parallel to achieve larger outputs and or redundancy of N+1 or N+N. Rotary UPS's are mainly available from 500kVA to 1600kVA as single modules and suitable for paralleling to reach larger ratings. There are a number of key areas to consider when selecting which type of UPS system will provide optimum protection at a competitive price. These criteria include criticality, UPS type, configuration/availability, load rating/battery autonomy, maintainability and installation/structural considerations.

Criticality The very first question is one of mission criticality, in other words what are the consequences for an organisation if a mains disruption or outage crashes its computer system or renders IT services unavailable. Depending on the application, consequences may extend from a temporary inconvenience to the paralysis of the entire business. Apart from continuity of power, quality of power is also very important for IT equipment. Appropriate UPS selection should therefore provide protection from gridrelated disturbances including blackouts, brownouts (sags), dynamic overvoltage, overvoltage, undervoltage, transients (surges), frequency variations, voltage distortion Hf (burst) and harmonics. In

addition, power disturbances generated within data centres, caused by lifts, HVAC, inrush current from printers or even a loose neutral connection must also be mitigated.

UPS types and codes Industry standards have been developed to describe the technical characteristics and therefore protection afforded by various UPS topologies. IEC 62040-3 provides very clear definitions for each UPS type, complete with typical block diagrams: VFI – (see figure 1) the UPS output Normal AC input

Bypass AC input

if only one AC input

Rectifier/ charger

Battery Static switch (static bypass)

Inverter

Manuel maintenance bypass

Normal mode Battery mode Bypass mode Load

Fig.1: UPS with double-conversion VFI topology.

is independent ‘of input mains supply voltage and frequency variations’, i.e. the primary power path is the inverter and not the AC mains for true double conversion on-line topology. VI – (see figure 2) the UPS output is dependent ‘on input supply frequency variations, but mains supply voltage variations are conditioned (independent)’. VFD – (see figure 3) the UPS output is dependent ‘on mains input voltage and frequency variations’.

• UPS

Normal AC input

Bypass AC input

if only one AC input

Static switch

Maintenance bypass

Battery Inverter

Normal mode Battery mode Bypass mode Load

Fig. 2: UPS with the line-interactive VI topology. AC input

Charger

Battery

Inverter

Filter / conditioner Normal mode Battery backup mode Load

Fig. 3: UPS with the passive standby VFD topology. The inverter is connected in parallel and acts simply to back up utility power.

The correct balance between efficiency and resilience Double conversion (VFI) UPS systems protect the load continuously (with no switching risks) against voltage/frequency variations from the utility. Typically these double conversion (VFI) UPS systems are up to 97 percent efficient. However, recently a number of UPS manufacturers are trying to reach unrealistically high efficiencies of up to 99 percent. Organisations are working to achieve this by sacrificing the electrical power quality demanded by servers and adding the risk of unwanted source switching at a crucial moment of UPS operation. In other words these UPS systems are expected to switch between various modes of operation – VFD, VI and VFI. This kind of operational switching can mean total loss of protection for critical server loads. It can impact on system resilience (due to prolonged switching periods) and reduce mean time between failure (MTBF) resulting in very low availability values due to increased mean time to repair (MTTR). In addition to the implications of power availability, high efficiency UPSs also sacrifice the power quality demanded by IT equipment. It’s essential never to expose

March 2012

the IT load to raw mains by running the UPS in bypass mode. Even if the bypass path has a harmonic conditioner and choke, it does not provide clean, conditioned and isolated power required by IT equipment. A series choke within the UPS bypass path will affect clearing of electrical short circuit and can cause serious damage to downstream installation. Unlike the static UPS systems, a typical diesel rotary UPS does not use double conversion and does not correct frequency swings during normal operation. Furthermore, rotary units have a very high component count resulting in very low MTBF. When used for IT loads, the units need a 150 percent oversized neutral to handle a high level of triple ‘n’ harmonics. If the neutral conductor is not oversized there is a risk of fire due to overheating of the cable. Blade servers impose a leading power factor load on UPSs and therefore this must be a key factor during selection of larger UPS systems. However, UPS systems can be highly underused making it necessary for input harmonic filters to hold the distortion level (THDI) at five percent right across the load range. There is a trend to use a power factor corrected (PFC) type active charger resulting in very low (four percent) input harmonics and almost unity input power factor. From a scalability point of view, static units are easily retrofitted within a building, but the same cannot be said for rotary UPS, mainly due to structural issues and noise problems. Further complications may have to be addressed due to vibrations, fuel storage, fire risk, wet stacking (caused due to light load running) and exhaust fumes.

Load rating/battery bank The UPS size needs to account for crest factor and harmonics from the PCs and servers, not ignoring blade servers which have leading power factor and very high inrush currents. Generally all UPS units are rated for specific kVA of load at 0.8 lagging power factor. Battery autonomy must be adequate to protect the load during blackout, and batteries need to be monitored as they are the weakest link in any power protection system. For larger systems it is worth sizing the battery for end of life and to meet ENBS6290 Pt.4 1997. Multiple battery strings are advisable for critical applications. It’s common practise to have up to

15 minutes autonomy backed by diesel generators capable of handling leading power factor loads presented by blade servers. Sites without secondary generators may need a minimum of 30 minutes autonomy plus software to ensure a graceful IT shutdown and to protect against data corruption or loss.

Configuration/availability In order to achieve high levels of power availability, built-in system redundancy (N+1 or greater) and fast service from manufacturers are recommended. It may be worth using static transfer switches near the PDU since this improves both availability, maintainability and limits fault propagation.

Installation/maintainability These disciplines are subject to an article in their own right as the siting and installation of equipment is a complex subject. However, at a top-line level static UPS systems do not require air conditioning, but battery room needs to be maintained at a temperature range of -10 to 25°C for extended life. From a maintenance point of view, this should be carried out on a regular basis either by the manufacturer’s own team to protect product liability insurance cover, or at the very least by factory-trained personnel if using a third party for this function. Maintenance and spare parts provision are important as these have a profound effect on availability.

Conclusions When selecting UPS's for critical applications the specifier must consider the impact of a loss of IT services on the organisation, since this will almost certainly cause financial loss or damage to brand. Newer, high efficiency static UPSs may achieve 99 percent efficiency, but only momentarily and with all the associated risks to the IT load posed by VFD operation. Rotary UPS systems pose a number of problems, namely limited scalability, the noise created and their long maintenance period requirements. Double conversion (VFI) UPS systems are up to 97 percent efficient and will protect an IT load continuously (with no switching risks) against mains events and outages. A small trade-off, perhaps, but compensated by a great deal of peace of mind where IT continuity and resilience is vital. Go to www.demm.co.nz/enquiry quote: D120342

•

Always secure. Always available.

Anywhere in the world you need power, Schneider Electric is there. Power loss poses a threat to the equipment, people, and processes you rely on. And with today’s strict security and safety regulations, process automation, and increasing dependence on sophisticated high-tech systems, the need for uninterrupted power is critical. Add the rising cost of energy and environmental concerns into the mix, and it becomes essential to protect your power with solutions that not only meet your availability demands, but are energy efficient, too.

Why Schneider Electric is the right power protection choice. You may know us as the market leader in delivering IT power protection. But we also offer a full range of reliable and highly efficient power protection solutions designed to safeguard business-critical applications and environments outside the IT room. Our innovative, best-of-breed products, services, and solutions provide the secure and available power you need to keep your systems up and running, while increasing efficiency, performance, and safety.

Guaranteed availability for business-critical systems. No matter what industry you’re in, our unrivaled portfolio offers a solution that’s guaranteed to suit your specific business needs and keep your power on. Thanks to Schneider Electric™ power and energy management capabilities, in-house expertise, broad investments in R&D, and global presence, you have a trusted resource for reliable power, anywhere in the world.

The Different Types of UPS Systems White Paper 1

> Executive summary

Secure power solutions that deliver the performance you need. Products: Our complete catalog of power solutions, featuring our leading brands such as APC™ by Schneider Electric and GutOr™, offers an unmatched range of single- and three-phase uPS units, rectifiers, inverter systems, active filters, and static transfer switches from 1 kVA to several MVAs. Services: Schneider Electric Critical Power & Cooling Services can proactively monitor and maintain the health of your systems, protecting your investments, reducing total cost of ownership and operating expenses, and providing peace of mind throughout the equipment lifecycle. Solutions: Choosing the right combination of products and services from Schneider Electric gives you the convenience of a total solution – systems, software, and services from a single source.

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• SINGER

Creativity, commitment, Siemens and teamwork come together to get Singer customer through

By Kevin Kevany

(left to right) Norm Wong, Graham Morris, Jannie Bekker, and Alistair Mander

It is said that there is nothing better for creating great harmony, productivity and commitment in a team than when the leader thinks they are just the best. Alistair Mander, the recently appointed Technical Services Manager in the Singer Group, would disagree. Well, sort of. “It’s even better when the client’s boss thinks the same,” he says. And, as they say in those infomercials, “there’s more.” Keith Hughes, Engineering Manager at the Mt Wellington operation of a major Australasian packaging and manufacturing giant was part of a team involved some three years back in consolidating two of the company’s Auckland operations on the site, and that gave him the opportunity to gain a good understanding of the age and condition of the production machinery. He is regarded by those in the know in the packaging industry as leading a team of some of New Zealand’s more experienced and strategically-focussed production professionals in the packaging game, according to Mander. Food packaging is one of New Zealand’s growth industries, which is a major focus of both local and national governments’ priorities. “While we didn’t have an ongoing contract with Singer, I did have occasion to ask Philip Wright, the company’s top-rated Systems Engineer

March 2012

– after the local electrical representatives of a supplier had given up – to have a look at a problem we’d experienced. Phil fixed it in minutes, confirming his reputation as one of the best around – and I’m talking internationally as well. I was immediately sold on him. But it took this latest situation, where Jannie and Graham stepped in, to convince me that I should stick with Singer going forward, because they have a really excellent team with a very wide range of skills and the experience to know when to use them,” Hughes says. Mander picks up the story again. “I had no sooner called on Keith to discuss a planned upgrade of a circa-1985 packaging machine, when it fell over and it became apparent that he simply could not wait for a replacement, which could take up to two months to ship and be installed.” Hughes is less diplomatic. “It took the supplier more than three weeks to front up with the replacement cards. That’s not acceptable. When we had originally planned the upgrade, we weren’t using the machine much, but we have a number of big customers with seasonal demands, and it so happened that this summer one of the major ones had been encouraged by new owners to go into a massive sales drive. It goes without saying that you need to have

the right amount of stock to back that strategy up; so we needed to move quickly. The machine went down under the strain. Meeting our customer needs is what we are all about, so it was good to see Singer putting their ‘Powerful Solutions’ into immediate action and ‘coming up with the goods’ – and making us look good with our customer too,” Hughes says. Inevitably, whenever a team proves to have the ability to fix what others can’t, more challenges are never too far away. While the project was well underway, another piece of critical machinery – a wire handle machine that makes handles for paint pails and the like – came to a grinding halt. Hughes again: “Bottom line, Alistair drafted in Jannie and Graham immediately. They diagnosed a problem in a particular card in no time at all and fixed the wire handle machine by the next day. That pretty much coincided with my receiving a communication from the other supplier to inform me my call for help had been noted and ‘the request was being processed’. I got a standby replacement card from the European supplier, direct, just in case we have another interim problem before Singer can install the new replacement PLC for the wire handle machine,” he says. “The new PLC is getting fitted to the DRD, not the wire handle machine. We got the spare card in, so if we have any future issues we have a spare in stock for a critical piece of equipment.” As an aside, Hughes notes that over the years his team of in-house electricians and technicians have largely had a ‘neutralat-best’ attitude to service providers. “In the case of the Singer team, I’ve heard nothing but good comments on them. I would reckon that’s probably the ultimate tribute, if you like!” Mander, who had already bagged an AUT, two-year electro technology qualification and team member, Norm Wong, earned their Electrical trade tickets together under the Singer apprentice scheme. Both of them learned a great deal from the two experts on the team, Graham

• SINGER Morris, with a superb NZCE (electrical engineering) pedigree and Jannie Bekker, a renowned instrumentation specialist. One of the first changes he made on taking up his senior position was to lure Wong from his commercial sector role to the industrial team “because I knew him to be a damned hard worker who always likes a challenge, will go the extra mile and provide some extra grunt for the guys.” The recently returned-to-the-fold Singer Technical Services Manager has packed a good deal of experience and upskilling since he took off on a three-year OE, being plunged into a management role on arrival in the UK. “I joined a Northamptonbased, family-run electrical business and was chosen to open and establish a London office for them, backed by their Irish-based financiers. I learnt a great deal about building a solid foundation which would meet all the stakeholders’ and the authorities’ requirements. The role grew to the point that I could sign-off on everything up to half a million British pounds. By the time I had to apologise and leave due to serious family medical condition here in New Zealand, the London team had grown to four and was set to blossom.” One of his first tasks on return was to take over running the family’s food business and then sell it, thereafter, before starting his own business installing HVAC controls, largely in retirement homes. “After my overnight progress into management in the UK, I found myself ‘back on the tools’, working with a good friend and thoroughly enjoying the freedom of being in business for ourselves.” External factors were again to play a role in his career. An aggravated sports injury and five operations later, Mander had to face up to the reality that a duff wrist would always limit his ability to manhandle heavy gear and tools. And that’s where Singer’s long-serving Commercial Services Manager Kevin Dunbar came into the picture. Company legend is that Dunbar has a network second to none in the industry, when it comes to being on top of developments and facilitating the recruitment of top people. ln no time at all, he had invited Mander in to chat about opportunities in Singer and introduce him to the group boss, Jeff Mclaren. In August last year, they threw him in at the proverbial deep end, to head up a project to ‘manage out’ a 20-year incumbent supplier at one of the country’s major, high-profile sites, and get a Singer

team in place, mitigating as many risks as possible and minimising any disruption to business-as-usual for the global client. The ‘Mission Accomplished’ sign went up ahead of schedule and Mander was offered a full-time slot, and plunged straight into the role, with a concerted follow-up of leads. One of them led him to Keith Hughes’s door, where the fact that Singer is Siemens’ only approved Safety Solution Partner in New Zealand immediately ticked an important box for him. “The rest was simply the fantastic commitment and dedication to not only pin down the problem, in this case to the removable card, but to then fix that card so it could meet the Singer client’s needs to back their customer’s increased production requirements – and to also keep the machinery functioning so that we could install the new equipment. “The team worked the whole weekend, without even thinking about whether or not to do that, and was really chuffed to find they had fixed the problem, before the backup card could even ship from Europe. A lot of people in this industry accumulate ‘experience’ over many years. But these guys have just so much creativity and awesome problem-solving capability, which flows from their confidence in each other, to challenge and push each other till they get the perfect solution – the ‘Powerful Solution’, which is driving Singer to the next level,” Mander says. “I already believe that there is enough nous in the team to take on any challenge in the game. That has certainly rubbed off on me, because that’s what I’m selling at the end of the day. Nothing more and nothing less, which means that I can confidently commit to budgets and deadlines. That’s a very privileged position to be in, especially in what can be a very complex industry. The customers love it and the team thrives on meeting the challenges. It all makes for a happy environment too – so customers realise quickly that they are getting even more out of the guys, as in this case where a single machine will replace two. “It’s hard to believe I’ve only been with Singer for just over half a year, including the year-end break, and everything just seems to have come together. I appreciate how fortunate I am and I do fully acknowledge that it’s the team which has gone out of its way to ease me into this position,” he says. You can just tell he’s simply popping to show off their skills and creativity to the industry.

0800 474 643 www.singergroup.co.nz

â&#x20AC;˘ WHATâ&#x20AC;&#x2122;S HOT

Power to homes and small businesses Power can go out for any number of reasons. Sometimes, a transformer simply fails due to age. Occasionally, a work crew nicks an underground cable. Other times, an accident or storm causes damage to electrical poles or lines. When electrical service to a home or small business is interrupted, a Cummins Onan generator quickly detects it, starts up, and produces quiet, clean electricity. The new Cummins Onan RS14AF residential standby generator offers a unique design that fits into your garden landscape with aluminium weather-resistant, sound-attenuated enclosure. Powered by LP or natural gas and offering 56.5 amps (approximately 14kW) of power,

it can run standard residential household appliances easily including air conditioning. Its utility grade power quality ensures the safe operation of appliances and sensitive electronic equipment such as computers and stereo systems. The RS14AF generator comes with a durable builtin polyethylene base that eliminates the time and effort or need to pour a concrete slab. Its easily removable front door enables the generator to be transported through restricted side entrances when mounting at the rear of a property. The manufacturer says it is the only residential generator with an in-home display as standard equipment. If desired, the display mounts on the unit itself,

March 2012

rather than inside the home. Email notifications inform the owner of maintenance, service and power outage alerts anywhere there is internet access. Remote monitoring enables the owner to interface

with the generator from anywhere in the world via the internet, after proper set-up by a network specialist. Go to www.demm.co.nz/enquiry quote:

â&#x20AC;˘

D120346

• WHAT’S HOT

New M12 receptacle connectors with integrated shielding

We measure it.

NEW New M12 receptacle connectors from Belden’s Lumberg Automation product range can be used to connect control units to ProfiNet/Profibus networks via bus modules as well as to transmit analogue data at field level. Integrated shielding between devices delivers a high level of functional reliability. The receptacle connectors are available with assembled control cables or with printed contacts for PCB mounting. In the printed contact versions, the integrated shielding ensures optimum flexibility for shield continuity. With the assembled connectors, and depending on the port assignment of the control units, a diagnostics interface can be implemented outside the switch cabinet using an Ethernet connection. This practically eliminates the disruptions resulting from repair or maintenance work. These receptacle connectors are simple to install thanks to standardised M12 connection technology and colour-coded bus connections. Additional features include industrial protection class IP67, high shock and vibration resistance, and a wide temperature range of -30 to +80°C. They enable highly-available data communication solutions in areas such as mechanical and plant engineering, material handling or public transport. Versions with assembled control cables are intended for rear mounting. Product manager Joachim Kiera said the new Lumberg Automation M12 receptacle connectors offer a high level of functional reliability combined with excellent flexibility. “This is due to the integrated shielding concept and the wide range of connection options. These receptacle connectors can therefore be used to create cost-effective solutions in a wide range of different automation scenarios.” Go to www.demm.co.nz/enquiry quote: D120347

•

SEE MORE : THE NEW THERMAL IMAGERS FROM TESTO

With a rotatable display, you can see into any corner: The new testo 876.

With 320 x 240 pixels, you can discover every detail: The new testo 882.

With the new thermal imagers from Testo, you are on the safe side when measuring: Thanks to sharp focus images and the 32° lens, you no longer ever miss a detail. In addition to the intuitive menu structure, you can also rely on a fast and comprehensive analysis of your image data – thus saving money in the long term. The new thermal imagers testo 876 and testo 882: See more and have more security and flexibility when thermographing!

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

• WHAT’S HOT

Earthquake resistance certification for cooling and enclosure solutions The Liebert PEX cooling solution from Emerson Network Power has been certified for earthquake resistance by Guangzhou University’s Earthquake Engineering Research and Test Center (EERTC). Designed and built in Asia, over 200,000 units of the Liebert PEX have been deployed since its launch. The unit protects critical equipment with precise, reliable control of temperature, humidity and air flow. Subjected to three controlled conditions with earthquake intensities of up to nine degrees (equivalent to magnitude 6.0–7.0 on the Richter scale), the Liebert PEX showed no signs of damage in its main structure and connecting kits. “The test results come at a favourable time when companies are beginning to rebuild, following the massive earthquakes that hit Christchurch and the 8,000 aftershocks that have since followed,” said Chris Mandahl, senior sales director, Emerson Network Power in Australia and New Zealand. “Experiencing the country’s largest-ever natural disaster has impacted businesses, underscoring the value of ‘disasterproofing’, and limiting financial losses due to downtime. Emerson Network Power has

built its name on keeping businesses in business, and the certification of the Liebert PEX lends further credence to the company’s guarantee of businesscritical continuity.” Earthquakes that register 6.0-7.0 on the Richter magnitude scale cause damage to fortified structures, wall collapse, visible ground cracks, lateral spreading and significant rockfall, all of which were seen in Christchurch. In this magnitude range, destruction is moderate to severe, with people falling over themselves as they move. “For the Liebert PEX to remain without damage in these conditions is an engineering feat. In light of recent disasters in the region and New Zealand’s susceptibility to earthquakes, EERTC’s seismic test proves the Liebert PEX is a sound economic investment,” added Mandahl. Available in New Zealand, the Liebert PEX alongside other offerings from

Emerson Network Power are subjected to comprehensive factory testing to ensure durability and reliability. The company has adopted shock testing for all its products. Emerson Network Power’s Knurr E-Series rack series, for example, is also built to seismic zone 4 standards which correspond to areas with the highest earthquake risk. These heavy-duty racks have a static load rating of 1300kg, but goes down to 664kg under full seismic zone 4 loading. Go to www.demm.co.nz/enquiry quote: D120348

•

Extended range of plugs and sockets NHP have extended their quality range of ISO plugs and sockets to include 3 Round Pin, 20 + 32 amp single phase straight plugs, socket outlets, combination switched socket outlets and surface switches – all of which are available in both grey and chemicalresistant orange. The 3 Round Pin series is ideal for applications where high current capacity is required in a single phase power situation such as data centres. Following in the successful footsteps of previous ISO products, the new 3 Round Pin series incorporates the same standout features such as AS/NZS 3123 compliance, a large ribbed locking ring and handle for easy installation in wet or dry conditions and a large latch for easy opening and closing. The range also includes a padlockable switch handle in either the on or off position and all switches come complete with two switching poles supplied as standard and an IP66 rating. Go to www.demm. co.nz/enquiry quote: D120348a

•

March 2012

• WHAT’S HOT

Protecting data and hardware against external hazards

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At 12 metres in length, the new XL-Version of the Rittal data centre container (DCC) is generously dimensioned. As many as sixteen TS 8 server racks with 752 height units can be accommodated for. With an outer width of 3m and height of 3.25m, the Rittal DCC is approximately 60cm wider and 65cm taller than the ISO standard. These considerable dimensions provide technicians and administrators with enough free space for installation and maintenance. The containers have been specially designed for IT applications and have a reinforced exterior shell, as well as fire and burglary protection features. The infrastructure and the valuable data and hardware inventory are well protected against external hazards. The DCC XL can be cooled energyefficiently. Its design allows a separation into hot and cold aisles to allow targeted cooling of the servers. The use of direct free cooling is also possible, depending on the geographical location. Where this is possible, the filtered outside air is guided directly into the container. A switch-over to a conventional climate control unit is then only made at high external temperatures. This way, a very good PUE (Power Usage Effectiveness) of less than 1.2 can be achieved. The new DCC XL is targeted at medium-sized companies that have a very high demand for computing power, as well as at large corporations or hosting providers. The equipment can be standardised, so meeting the specific requirements of server farms, which are composed of dozens of containers and which serve entire regions or continents via software services. Due to the possibility of physically separating server racks and technology, the Rittal DCC XL is especially suited for “private clouds”. A high level of physical security is guaranteed: This way, air conditioning technicians can maintain the climate control system, without having to obtain real access to the servers themselves. Go to www.demm.co.nz/enquiry quote: D120349

•

��

• WHAT’S HOT

Intelligent UPS for the control cabinet A new generation of uninterruptible power supplies (UPS) now supplements the Quint Power product family from Phoenix Contact. Five new modules that can be snapped onto mounting rails are now available: For 24 V loads, the QUINT UPS-IQ uninterruptible power supply has output currents of 5, 10, 20, and 40A – and for loads with an input voltage of 85 up to 264VAC, the QUINT UPS-IQ supplies an output power of 500VA. All modules can be combined with energy storage devices utilising VRLA technology with 1.3 to 38Ah – or for high ambient temperatures, with powerful Li Ion batteries. The buffer times are eight hours for a 5A load current or 30

minutes for a 40A load current. Generous power reserves are available for DC loads when operated by battery or connected to the main power supply. In conjunction with the Quint Power supplies, the modules continually supply up to 1.5 times the rated current in line operation. The power reserve of the SFB technology, which provides six times the rated current for 12ms, ensures that standard circuit breakers are magnetically and thus quickly tripped. Featuring the new IQ Technology, uninterruptible power supplies can ensure 100 percent power supply reliability when the line supply fails. In previous UPS solutions the buffer time was manually set. However,

in this case, the actual battery performance is not known. The supply voltage fails if a battery cannot supply the energy necessary for the selected buffer time. IQ Technology determines all of the relevant battery states, such as a voltage or temperature. As a consequence, it ensures the necessary transparency to guarantee the reliability of the

UPS at any time, taking into account battery utilisation. This allows supply interruptions and premature shutdown of industrial PCs to be completely avoided. Service can be planned and, from now on, energy storage devices no longer have to be prematurely replaced. Go to www.demm. co.nz/enquiry quote: D120350

•

Coming up in the April issue Oil & Gas Industry SFluid PowerSVibration Vibration Analysis AnalysisSHazardous AreasSAutomation Deadl i ne edi tori al 9 th M ar c h | D e adline adv e r t is ing 16t h M ar c h

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March 2012

• EVENTS

Coming events Gas Turbine Operation and Control

19-20 March 2012 Quality Hotel, New Plymouth Gas turbines are a core technology for oil and gas production, as well as power generation. Gas Turbine Operation and Control is a fundamentals level course which will teach the basic principles of operation from a practical, real world operational point of view. The attendees will gain a practical understanding of how a turbine works, how it is controlled and its applications in the oil and gas industry. www.conferenz.co.nz/training/gas-turbine-operation-and-control

RFID World Australia 2012

Safety Control Systems & Hazardous Areas Conference

02-03 May 2012 Novotel, Ellerslie, Auckland Day One will focus on safety control systems including instrumentation and machinery safety. Case studies and practical applications will be presented by specialists experienced in safety life cycle activities such as hazard and risk assessment and the determination of safety integrity levels (SILs). Day Two has been created to meet and exchange ideas for those concerned with the safe use of electrical equipment and instrumentation in hazardous, flammable or explosive atmospheres. For more information: Ph (09) 263 4759, idc@idc-online.com, www.idc-online.com

20 March 2012 Sydney Convention & Exhibition Centre, Sydney, Australia RFID World Australia 2012 is a one-day executive-level conference that will focus on RFID applications and wireless technologies increasingly associated with the control, management, identification, real time track and trace of products and solutions. Senior executives from government, manufacturing, SCM, automotive, aviation, retail, hospitality, healthcare and pharmaceutical will be attending. www.terrapinn.com/conference/rfid-world-australia/

Rockwell Automation on the Move

Production Optimisation

Austech 2012

21-22 March 2012 Quality Hotel, New Plymouth Production Optimisation is a two-day in-depth course aimed at operations personal. It will give attendees a clear understanding of the principles of process plant optimisation including the measuring of production versus targets, identifying constraints and how to overcome them. www.conferenz.co.nz/training/production-optimisation

Engineering Machinery & Electronics Exhibition New Zealand

01-03 May 2012 ASB Showgrounds, Greenlane, Auckland EMEX is the most comprehensive engineering, machinery, electronics and manufacturing industry event in the country and is seen by many as the prime professional and business tool for anyone working in industrial engineering and maintenance, control and instrumentation, machine technology, plant automation and monitoring, welding, forming and cutting, and software and computerisation. Features include on-site functioning machine technology at the Heavy Metal exhibition, and industry and business seminars. http://emex.co.nz/

Sydney (02-03 May); Brisbane (22-23 May) and Perth (06-07 June) The Rockwell Automation on the Move event will bring industry a showcase of technology, products and services. The focus will be to demonstrate how automation, process control and safety solutions can be combined to provide an integrated, plant-wide system to optimise business operations and leverage opportunities in the marketplace. Visitors will have the opportunity to see, hear and interact with industry experts, ‘hands-on’ labs and displays. www.rockwellautomation.com.au 08-11 May 2012 Sydney Showground, Sydney Olympic Park, Australia Austech is the only show specifically targeted at the metalworking, machine tool and ancillary market held in Australia annually. It covers the key areas of machine tool and sheetmetal working. In 2012 Austech and National Manufacturing Week (NMW) will line up together, providing a comprehensive display which is expected to attract 10,000+ visitors. www.austechexpo.com.au

National Manufacturing Week 2012

08-11 May 2012 Sydney Showground, Sydney Olympic Park, Australia NMW 2012 will house a record 12 product zones, including two new zones: Sustainable Manufacturing and Metals & Composites. The Sustainable Manufacturing zone will focus on opportunities for reducing industry’s environmental footprint; while Metals & Composites presents new developments in industry’s quest to develop reliable, lightweight, easily moulded manufacturing materials. www.nationalmanufacturingweek.com.au/

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 0754, 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 ______________________________________________________________________ _______________________________________________________________________

March 2012

LOOkINg FOR NEW BUSINESS AND SALES ENQUIRIES? Contact Frank Atkinson Email / frank@adrenalin.co.nz DDI / (09) 477 0362

PACKAGE DEALS HG-2504 HYDRAULIC NC GUILLOTINE

PB-830A HYDRAULIC NC PANBRAKE

• Ezy-Set NC-89 Go-To back gauge with ﬁne adjustment • 250mm throat • 2500 x 4mm capacity • Rapid blade gap adjustment • Individual hydraulic hold downs • Shadow line lighting • 4 edge 9Crsi blade for stainless steel • Stroke counter & short stroke adjustment • Three photo electric rear guarding

• 2500 x 4mm capacity • Heavy duty steel fabricated construction • Easy to use single angle programmable controller incorporating digital readout 0-130º • Rapid radius adjustment • Hydraulic clamping

19,500

18,950

$ (S934)

(S584A)

E V A S 450 $ 4, PACKAGE DEAL $ (S934 + S584A)

34,000

HG-3206 HYDRAULIC NC GUILLOTINE

PB-135B HYDRAULIC NC PRESSBRAKE

• 3200mm x 6mm cutting capacity • Ezy-Set NC-89 Go-To controller with 1000mm back gauge • Rapid blade gap adjustment • Transfer balls on table with squaring arm • Shadow line lighting • 250mm throat capacity • Individual hydraulic hold downs with nylon pads

• 135T x 3200mm • Ezy-Set NC-89 Go-To controller X & Y-Axis • Hydraulic/Mechanical ram, synchronised positive stop design • Segmented 86° offset top punch • Solid one piece four way multi vee (“v”) die block • Quick action top tool holder with wedge type adjustment • Fitted with safety light curtains

29,950

40,950

$ (S940)

(S906G)

E V A S 950 $ 6, PACKAGE DEAL (S940 + S906G)

$ √ Lockseamers √ Punch & Shears √ Ring Rolls √ Swage & Jennys √ Pipe Notchers

√ Bar Benders √ Welders √ Vices √ Band Saws √ Wood Working

√ Parts Washers √ Engine Stands √ Motorcycle Lifter √ Sand Blast Cabinets √ Workshop Equipment √ Threading Machines

√ Tooling √ Accessories √ Panbrakes √ Folders √ Measuring √ Rolls

√ Presses √ Cold Saws √ Grinders √ Linishers √ Tool Boxes

See us at stand 4017

Specifications & Prices are subject to change without notification. All prices exlude G.S.T. Valid until 31-03-12

(09) 2717 234

Unit D/38 Highbrook Dr, East Tamaki

www.machineryhouse.co.nz

3_DEMM_010312

√ Mills √ Drills √ Lathes √ Guillotines √ Pressbrakes

63,950

NOW

Novotel Rotorua Lakeside

Phone: + 64 9 296 1333 Fax: + 64 9 296 1433 Email: info@adminoncall.co.nz

Official media sponsor Official event sponsor