Demm Engineering & Manufacturing November 2011 by Adrenalin Publishing Ltd

NZ’S LARGEST ABC AUDITED CIRCULATION TO THE ENGINEERING & MANUFACTURING SECTORS November 2011 $6 INCL GST

Intelligent process valves ❏ Food Processing technology update ❏ CAD/CAM/CNC ❏ Heat Treatment case study ❏ Maintenance Matters including: Monitoring grease condition

www.demm.co.nz

CONTENTS Editor's

note

Appetite for success I spend quite a lot of time in supermarkets checking food labels. My rule of thumb is: the more often one of those nasty E numbers turns up on the label, the less likely the corresponding food item ends up in my trolley. And my wife happens to apply the same rule. Both of us disapprove of artificial stuff in our daily bread. That’s why I am very impressed with the subject of our November feature, Multivac’s new HPP technology. This innovation is very likely to help put the label “No added preservatives” on food more often. HPP, or high pressure processing, uses pressures up to 6000 bar to get rid of microorganisms, thus extending the shelf life without using preservatives, heat treatment or radiation. No artificial stuff is required. It’s only pressure! The food and beverage industry has been labelled the “lynchpin of NZ’s prosperity”, generating more than half of the country’s total exports. And the New Zealand government wants to grow food and beverage exports by 270 percent by 2025, to $150 billion. One pillar this ambitious growth strategy rests on is a network of innovative food development facilities across the country. I talked to Colin Mitten, director of the Manukau-based FoodBowl, and learned that the new HPP technology and the shelf life extensions it enables will help the NZ food industry to reach more distant markets within Asia, the American continent, and Europe. This strategy might work out well, as I happen to know first-hand that Europeans don’t like any artificial stuff in their food… And now I hope I have whet your appetite enough to have you to read our November issue!

Product Watch

It’s just pressure

Food Processing

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

Thanks to Multivacs’ new HPP technology, integrated high-pressure preservation is now available for MAP packed food items to extend their shelf life without heat, radiation or artificial additives. Stefan Richter reports.

The most recent developments and products in the world of food processing, including a visit to the Manukau-based FoodBowl.

Heat Treatment

A heat treater shares his experiences when he was approached by MOTAT to rectify a minor problem with their new tram wheels.

Stainless Production

CAD/CAM/CNC

Read about knuckling the edge of domes and how spiral coolers and freezers can increase operational efficiency.

Includes a report on how to organise the complex structural supply chain; environmental assessment software; and a new scalable CNC control solution.

Maintenance Matters News from the maintenance front and an answer to the question how a free seminar for Christchurch’s industry can set up the city's businesses for the future.

Stefan Richter Stefan@adrenalin.co.nz

Industry Watch & Coming Events

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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: Hartman Reid, Email: hartman@adrenalin.co.nz CIRCULATION MANAGER: Kim McIntosh, Email: kim@adrenalin.co.nz

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PRODUCT WATCH New biological bearing material for low-load applications Polymer researcher and bearings specialist igus has developed a plain bearing material that is based on 54 percent renewable raw materials. The basic polymer of the new iglidur N54 plain bearing is mainly made from vegetable oil rather than finite crude oil. The company’s mechanically and tribologically optimised biological plastic is suitable for universal use in the lowload range. Product manager René Achnitz: “The new, lubricant-free iglidur N54 material joins our broad range of high-performance materials for general purpose, low-load applications and is a first serious step

Edit o choi r's ce

towards ‘green’ bearings.” As well as general mechanical engineering applications, igus mainly sees possibilities in consumer goods markets, for example furniture or other items of daily use. The new bio-bearing smoothly fits in with the company’s concept of developing environmentally friendly alternatives for more and more applications that currently work with lubricated metallic plain and roller bearings. On the one hand, iglidur bearings help to protect resources and the environment due to the incorporated solid lubricants. Polymer bearings from igus do not require any oil The basic polymer of the new bio-bearing iglidur N54 is made with 54percent vegetable oil.

Suppliers of forward curve blower wheels & fan decks

and grease, are lubricant and maintenance-free, which means no contaminants are released to the environment. In addition, they have a low weight in comparison with metallic options, leading to lower masses and thus reduced energy consumption. Furthermore, the energy balance for the production of plastics is significantly better than for metals. Whereas the energy from 15 litres of crude oil is necessary to

produce one litre of aluminium, and one litre of steel requires 11 litres of crude oil calculated on the same basis, the production of one litre of plastic only needs an average of 1.8 litres of crude oil. According to igus, this value is expected to fall even further on account of the major progress currently being made in the field of vegetable oil based polymers. Go to www.demm.co.nz/enquiry quote: D111102

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Suppliers of backward curve motorised impellors V Pro

ALASKON AIRA LTD T 64 9 835 2100 F 64 9 835 2201 E info@alaskon.co.nz W www.alaskon.co.nz

November 2011

Ecological weight advantage and the corresponding energy consumption: the average density of iglidur plastics is 1.4 g/cm³. Aluminium weighs twice as much, steel is even five and a half times heavier.

PRODUCT WATCH

Diverse range of safety prescription eyewear BOC has sharpened its focus on eyeinjury prevention with its range of safety prescription eyewear for the huge number of Australian and New Zealand workers who wear spectacles. The new safety eyewear is in response to BOC figures showing 36 percent of the 11 million people employed in Australian manufacturing and industry required visual correction and that eye injury was having a devastating impact on human health and the economy. Senior Product Manager, Safety at BOC, Joe Martinez, said an ageing work population, combined with worrying statistics that up to 50,000 eye injuries occur per year costing industry approximately $60 million, had driven the company to find a solution. “About 95 percent of eye injuries treated in Australian hospitals are a result of carelessness and lack of attention to basic eye safety precautions,” says Joe Martinez. “The vast majority of eye injuries can be avoided by taking a common-sense approach to hazardous activities and ensuring you are wearing the correct eye protection during all potential hazardous tasks around the home and in the workplace, even if you are just lending a hand.” Different situations require different types of protective eyewear. The main types of protective eyewear are general purpose safety spectacles and general purpose positive seal safety spectacles. “These products are now available as safety prescription eyewear from BOC,” says Joe Martinez. Providing peace of mind for employers and employees, BOC’s certified safety prescription eyewear is a cost-effective and diverse range built to the highest level of compliance with Australian and New Zealand standards. Available with a certified Bollé prescription safety frame range, features include unique polyurethane lens material which is chemically inert, strong and lightweight. “Certification involves independent testing by a NATA accredited facility and all test results are reported to SAI Global who ‘certifies’ the products as meeting the standards,’’ says Joe Martinez. The range is supported by an onsite service by BOC including unique product selection performed by certified opticians; education and training to OHS personnel and committees and workplace assessments providing best solutions for all types of work conditions and environments. BOC recommends the following precautions and actions for workers requiring safety prescription eyewear. Visit your Optometrist every two years for a full eye examination to ensure your spectacle prescription is updated and to check the health of your eyes. Always wear safety prescription eyewear based on

your current spectacle prescription to ensure best visual performance. Ensure you are wearing certified safety prescription eyewear which complies with AS/NZS

1337.6:2007. Go to www.demm.co.nz/enquiry quote: D111103

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PRODUCT WATCH

Rugged and reliable diaphragm pumps Commonly referred to as “mud pumps” or “slurry pumps”, the AMT line of 2" and 3" diaphragm pumps are designed for the collection and transfer of waste liquids containing suspended solids. They will handle mud, slurry, sewage, as well as other thick, difficult and abrasive liquids that have the ability to flow. With a built-in, molded polyurethane flapper/check valve, AMT diaphragm pumps are self-priming up to 6m and will run dry indefinitely without damage. They have the ability to pass large suspended solids without

clogging whilst at the same time promoting a gentle, non-sheering pumping action. Each model now also features a new 90-degree rotatable base for extra versatility. The build of the AMT diaphragm pump is based on a modular component design that permits

ease of maintenance and cleanout. With a robust, sand-cast aluminum body and hardwearing single thermoplastic rubber diaphragm, AMT diaphragm pumps provide high durability and reliability, making them ideal for contracting, utility and clean-up applications. AMT diaphragm pumps will deliver flow rates up to 340 LPM and can be supplied with a choice of drives to suit the application; the most common being a Honda four-stroke, air-cooled petrol engine. Single-phase electricmotor-driven options are also available. As standard, each model is supplied with a steel suction

strainer, two NPT to BSP nipple adapters, and a wheel kit with 10" semi-pneumatic transport wheels plus handle for portability. The overall simplicity and convenience of AMT diaphragm pumps makes them an excellent choice for non-flammable pumping applications such as groundwater remediation, containment transfers, dewatering, oil and water separations, marina and campground sewage collection, as well as tank, sump and drum transfers. Go to www.demm.co.nz/ enquiry quote: D111104

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Single and multimode fibre optic cable tester now available U l t i m a t e M 2 M HSPA Co n n e c t i v i ty S o l ut ions

With the pending CDMA closure, speak to us about your replacement 3G devices. The Maxon product range offers advanced & robust features to power the M2M market. Smartmax (MA-2010S)

Advance your application with the top-of-the-range intelligent Smartmax 3G Smart Modem solution complete with RS232, RS485, USB & DNP3 options.

Unimax

(EM-770W UNI)

Distributed in New Zealand by: Pocket Solutions Ltd. 11 Rutherford Street Lower Hutt

Control and command remote applications with the advanced industrial 3G HSPA Ethernet Router.

Regus Centre Plaza Level 41 Shortland Street Auckland Tel: 04-920-6580 sales@pocket.co.nz www.pocket.co.nz

Intermax (EM-770W INT)

Smart, compact and robust RS232 Serial Modem to power the M2M market. Cost effective 3G connectivity.

For the full range of products visit maxon.com.au

November 2011

The recently released Fluke Certifiber is now available from TechRentals. Using the same platform and interface as the widely known DTX CableAnalyzer, the DTX-CLT CertiFiber optical loss test set certifies fibre according to industry standards by quickly providing four measurements on two fibres and returning a PASS/FAIL result. The Certifiber comes with interchangeable singlemode and multimode heads, performs a 12 second autotest, provides accurate fibre length measurement and also includes a visual fault locator. A certificate providing documented proof of the pass/fail analysis is available. Fibre optic cable usage is increasing and with the test equipment being expensive, TechRentals has added this to its rental fleet, so it only needs to be rented for the period required. Also available are common reference leads, fibre cleaning materials and a JDSU fibre inspection camera. Clean fibre heads are critical to the performance of the cable which is why all reference leads supplied come with certificates confirming their compliance with IEC-61300-3-5. With the addition of the Certifiber all the equipment is

available to ensure you can follow the process all fibre manufacturers recommend – inspect, clean only if necessary, inspect again then connect when a pass result is obtained. The Fluke Certifiber and other items are available from TechRentals for rental periods of one day upwards, and can be couriered to nearly all NZ locations overnight. Our experienced Application Engineers are available to discuss your particular application and recommend the right equipment to meet your requirements. Go to www.demm.co.nz/enquiry quote: D111104a

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PRODUCT WATCH

Reliable partner for the wine processing industry

New pressure sensors

Aurora Process Equipment offers an efficient and reliable range of wine processing equipment, including tubular and plate heat exchangers and immersion plates for must chilling, temperature stabilization, fermentation control and pasteurization, liquid mixing and agitating equipment, and receivable bin magnetic separators for extracting fencing staples, nails, harvester parts, pieces of wire and wear particles. Aurora also provides high-quality product recovery pigging system from the world’s leading suppliers. The LIAG pigging systems deliver outstanding results offering less product wastage and water consumption and a healthier environment. Hydrocyclones are a great system for removing all unwanted solids which Aurora provides. They will remove sand, bentonite, seeds and other solids from the customer’s waste or bore water. This reduces DAF operating costs, trade waste charges and can allow the user to recover bentonite and other solids to be used for other applications. They are an interesting solution to improve water quality, increase income, and reduce costs. Along with the liquid processing equipment, Aurora also provides complete conveying and palletising systems. With this equipment, the user can ensure that his process is of high speed, reliable and efficient with time and labour. Aurora emphasizes that each of their systems is carefully engineered to provide years of strong and reliable service. Simple and durable

Balluff introduces BPS, a newly developed series of pressure sensors with IP67 protection for use in gaseous and liquid media. The rugged devices feature a high-quality, long-term stable ceramic load cell and an attractive price/performance ratio, simple installation, high operating comfort and high precision. A large, bright and easily visible display ensures immediate status overview. This shows not only the current system pressure in bar, mbar, PSI and MPa, but also features fast and simple configuration of the sensors according to the VDMA standard, using two keys and intuitive menu guidance. With eleven pressure-range versions the BPS sensors cover all the important ranges from -1...0 bar up to 0...600 bar for monitoring process media in factory automation. Typical applications include hydraulics monitoring as well as pneumatics equipment. The new pressure sensors, available in the standard model with plastic housing and in the high-end version with stainless steel, offer either two switching points or one switching output plus analog channel (0...10V or 4...20mA). Thanks to their highly compact design the sensors can be easily located in the control cabinet without taking up valuable space. The display with operating panel and electrical connection can be rotated independently of each other by 320° with respect to the flange. Adapting to different process terminations using G ¼ internal threads is easily accomplished using optional adapters in various sizes and styles. The high-end models with their stainless steel housing and expanded temperature range were designed for demanding applications. Go to www.demm.co.nz/enquiry quote: D111105a

equipment constructed to withstand years of industrial use, compliments basic mechanicals for ease of maintenance. Full stainless steel systems are suited to food grade wash down situations, meeting IP requirements and hygienic standards where necessary. The company points out that they stand close behind their products and all their industry leading brands are backed by expert advice, a bank of product knowledge, installation capabilities and scheduled servicing that is second to none. Go to www.demm.co.nz/enquiry quote: D111105

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Attract, Separate, Protect, Aurora make us part of your process www.aurora-nz.com

MAgnAttAck

AADEMM20111014

protection from imperfection...

MAgnEtic SEPArAtorS Ultra High Strength Magnets 10,000 gauss+ Long Life, rare Earth rE80 granular magnets Powder Magnets Liquid Magnets HAccP Endorsed Plates-grates-Bars-traps Easy-clean, Quick-clean features/Self cleaning Magnet Validation Audit & report Documentation Services

0800 55 77 33

sales@aurora-nz.com

PRODUCT WATCH

Precision wireless instrument range released Yokogawa has released its precision range of wireless instruments. According to Steve Poole, Yokogawa Regional Sales Manager New Zealand, the new Yokogawa wireless pressure, differential pressure and temperature sensors are the perfect solution for large and widely spaced plant equipment and challenges presented by moving equipment such as rotating kilns. “Like all Yokogawa products, the Yokogawa wireless instruments are extremely accurate – providing accurate transmission of data with virtual zero bit rate error up to 600 metres, without the need for special antennas.” Yokogawa’s wireless instruments eliminate the need for slow and costly cable runs and support multiple industrial protocols – Hart,

Profibus, Modbus and Foundation Fieldbus. New instruments can be quickly installed and integrated into the network. “The ISA100.11a standard employed in the Yokogawa wireless instruments talks to all other certified ISA100.11a devices. ISA100.11a is an end-user protocol, designed by end-users for end-users, which does not lock users into any proprietary protocol,” said Steve Poole. Yokogawa’s ISA100.11a wireless products provide unlimited networking capabilities using the IPv6 protocol, which supports an almost infinite number of addresses. This means there is no limit to the number of devices in a network. Steve Poole: “Yokogawa’s transmitters are the only instruments

with the digital DPharp advanced silicon resonant sensor.” This advanced sensor uses two resonators embedded inside a silicon diaphragm to measure the applied pressure. “It allows simultaneous wireless measurement of differential and static pressure, providing vital information delivered when and where you need it over a completely wireless network.” The instruments are IECEx certified ‘intrinsically safe’

and include Yokogawa’s Integrated Gateway (YFGW) which functions as a backbone router, system manager, security manager and gateway with IECEx Type n certification. The wireless instrument system is easily configured with Yokogawa’s field wireless tools comprising FieldMate device management and provisioning tool, Network Management tool and Field Wireless configurator. Go to www.demm.co.nz/ enquiry quote: D111106

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Mini version of Enerpac synchronous heavy lift system

Enerpac Integrated Logistics Manager Colin Chapman (left) and Enerpac National Manager (Australia and New Zealand) Tony Brooks, with the new mini SLC8 system.

A mini version of their own heavy lifting system has been released by Enerpac for applications involving precision civil, mechanical, industrial and maintenance engineering tasks. The SLC8 Enerpac synchronous hydraulic lifting system is a simplified four-point synchronous jacking system based on the full-size PLCcontrolled synchronous system used with 4-64 cylinders to hoist loads of many thousands of tons, including draglines, dredges, machinery and onshore and offshore exploration and production technology. The new SLC8 system also controls and monitors movement during the hydraulic raising, lowering, positioning or testing of heavy objects

Supplying N New Zealand indust industrrryy with pallet rracking, Longspan general shelving and much more.

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

November 2011

such as manufacturing machinery, manufactured structures, building components, bridge components, ship components, mining and energy equipment and heavy but delicate computerised/electrical equipment. The mini system, which can also be upgraded to eight-point lifts, controls the difference in millimetres and fractions of millimetres between each cylinder being employed in a synchronous lift of weights limited only by the size of the cylinders involved – thousands of tons are possible using large (500-1000 ton) cylinders. “The system is only limited by the size of the cylinders attached and therefore by the amount of oil available and the flow rate of the pump,” says Enerpac Integrated Solutions Manager Colin Chapman. “The benefit of the SLC8 system is that it can be attached to any electric pump that has an electric solenoid valve for raising and lowering control. Essentially the unit can be changed from pump to pump dependent on the application.” Another benefit is that the unit can be connected to the user’s existing pump, therefore reducing the capital outlay required for a complete system. “If the client has a jacking operation that does not require precision control, the SLC8 can be easily removed from the pump and kept until the next precision operation is required.”

Simply operated by one person, it features selectable inputs such as measurements in mm/inch and stroke sensor type and a manual mode screen used to set the cylinders against the load. Also on the feature list are on-screen readout of target height, allowable deviation among cylinders and relative reset for datum position, solenoid control valves and pressure indicator gauges and an Enerpac VE 43 valve mounted to Enerpac pump for interface with system. The system comes with a cart to ensure easy transportation around the site. Synchronous lifting systems eliminate manual monitoring and control of hydraulic lifts, which can give rise to considerable problems in some applications, says Colin Chapman. “With manual control, differences arising between the lifting points are unavoidable, because measurement of the movement and control of the lifting points are never optimal. Internal stresses resulting can ultimately cause hidden damage compromising serviceability and safety.” Synchronous lifting systems permit lifting, lowering or positioning to be carried out automatically to a high degree of accuracy. The systems control unevenly distributed loads as well as various cylinder capacities. Go to www.demm.co.nz/enquiry quote: D111106a

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SEW-EURODRIVE—Driving the world

Controller

Engineering Software

MOVI-PLC®

MOVITOOLS® MotionStudio

CCU – Configurable

Application configurator

Control Unit Gear units

Servo Motors

Servo Inverter

Integrated

HMI DOP

Positioning IPOSplus®

Option Cards CMP 71/80/100

Accessories

Additional I/O

Braking Resistors

Fieldbuses

MOVIDRIVE®

Chokes

MDX61B

ND/HD Filters

CMP 40/50/63

W 7 Series

Pre-fabricated cables

Available options: – with brake

Motor

– with terminal box

Feedback

ET11/2

Motor types – Ex-Stock in New-Zealand! 3000 rpm speed class Motor Type

Rated Torque

Motor Type

Rated Torque

CMP50S

1.3 Nm

CMP71M

9.4 Nm

CMP50M

2.4 Nm

CMP80S

13.4 Nm

CMP50L

3.3 Nm

CMP80M

18.7 Nm

CMP63S

2.9 Nm

CMP80L

27.5 Nm

CMP63M

5.3 Nm

CMP100M

31 Nm

CMP63L

7.1 Nm

CMP100L

47 Nm

Driving the world – with Servo Technology Complete Servo Technology solutions from SEW-EURODRIVE in New Zealand from local assembly of stocked Servo Motors / Servo Gearmotors and Drive Control equipment. For all applications from Food and Beverage Industries (labeling, sealing, general processing etc. with up to 1200 operations per minute) to Timber and Construction Industries with high mass loadings. We can select and design the right system for you.

www.nz.sew-eurodrive.com

Phone: Auck. 09 274 5627 Chch. 03 384 6251

PRODUCT WATCH

Longer-lasting, cost-efficient fall protection lifelines

Capital Safety has announced the launch of a new range of Rebel self-retracting lifelines (SRL’s). The new range from Protecta features a top-of-class weight capacity, with the ability to accommodate up to 140 kilograms, and a sturdy, robust design to ensure a longer product life to lower the cost of ownership. With an improved ergonomic design, the Rebel SRL is

available in either aluminium or composite housing models. Additionally, the device is equipped with a special carrying handle that makes transportation to and from the job site easy, and is designed to be stackable for simple, spacemaximising storage. The SRL is also designed with the worker in mind, featuring an impact indicator to ensure the equipment has not been involved in a fall. A top anchorage swivel holds the SRL in line with the worker’s motion, allowing for ease of movement and increased mobility. The new models are also sharp edge compliant, making them suitable for use in horizontal applications with an SRL shock absorbing unit. “Our newest SRL range builds upon the quality that Capital Safety’s family of SRLs are known for, while responding to industry demands for these lifelines that are increasingly

tailored to individual needs,” says Rick Millar, Technical Manager with Capital Safety Australia & New Zealand. “These options allow customers to choose the exact Rebel SRL that is right for them, down to the type of material it is made of and the exact lifeline type and length the job site dictates. As an added bonus all of the newly designed SRLs ship with a

free service voucher.” The complete line of SRLs is an extensive family of products with many options, such as nylon web, galvanised or stainless steel lifelines ranging in length from 3.3 to 30 metres, providing more choices to meet customer specifications. Go to www.demm.co.nz/ enquiry quote: D111108

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Cost-optimised and intelligent telecontrol

Beat the skills shortage ATNZ has high calibre apprentices ready to meet your business needs. We’ll deal with the hassles so that you can concentrate on teaching them real skills. Call 0800 526 1800 or visit atnz.org.nz to find out more. For data transfer via GPRS, Phoenix Contact offers Open Data Port (ODP), an intelligent solution to monitor and manage telecontrol stations. The advantages of this solution lie in the reliable data transfer, the use of standard PLC and modem components, as well as standard industrial interfaces and protocols. Using the mobile General Packet Radio Service (GPRS), an inexpensive, reliable, and effective solution is open to all applications that involve data exchange with distributed stations. The core of this data transfer includes permanent online connection as well as invoicing the data packets exchanged according to data volume. ODP therefore facilitates communication – based

November 2011

on GPRS, DSL, and Ethernet – from the master control system via the open OPC interface and harmonised components such as the safety GPRS router, all the way through to the PLC from Phoenix Contact. Data is transferred online, or is saved and transferred as time-stamped historical data. As sector-neutral solution, ODP can be used in classic telecontrol technology in environmental and energy-related applications. Further, it can also be used in energy data acquisition, transportation technology, building systems, and asset security systems. Go to www.demm.co.nz/enquiry quote: D111108a

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PRODUCT WATCH

New twist on leak-free hydraulic connections The Gates Live Swivel couplings use a new patented technology eliminating the weaknesses present in traditional ball bearing design swivels. The coupling’s double O-Ring design protects against contamination and premature seal deterioration. It is engineered to weep as an indicator of service interval eliminating emergency breakdowns. According to the manufacturer, the couplings take less than five minutes to rebuild and are 10 times longer lasting than traditional swivels. When evaluating the cost of a swivel replacement, most users will only think of the cost of the parts being replaced. This is far from accurate, due to the many other costs which have to be taken into consideration and integrated into the overall cost picture:

Component replacement, replacement of hydraulic fluid, possible contaminant ingress each time you dismantle a hose, non-productive downtime, clean-up of leaks and spills and environmental issues, disposal of contaminated material, damaged hoses and worn out swivels and the safety of having to work on the hydraulic systems. The coupling features 270° swivel rotation, self-lubricating with high sealing capacity, increased component service life (290,000 impulse cycles at max. PSI) and a temperature range from -40ºF to 212ºF. It handles high operating pressure up to 6,000 PSI rating. The coupling’s no ball bearing design eliminates metal to metal fatigue. Go to www.demm.co.nz/enquiry quote: D111109

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Puncture proof solution saves downtime and money

Whether it be broken glass, thorns or nails, punctured tyres mean costly downtime whatever the cause. A flat tyre has hidden costs other than just the call-out charge and puncture repair. The cost of salaried staff and any overtime required to get machinery back up and running has to be taken into consideration. These costs multiplied by the number of punctured tyres per year will quickly add up to thousands of dollars. And if a puncture or the tyre being run flat causes the tyre to be destroyed prematurely, it will cost the operation even further. Puncture Proof is a non-toxic, water soluble compound that is designed to provide permanent puncture repairs in almost any pneumatic tyre. It

is suitable for most applications from wheelbarrow wheels to heavy mining and road transport tyres and comes in two formulations to offer maximum protection in differing situations. Puncture Proof 50 has been formulated to suit low-speed industrial or agricultural applications whereas Puncture Proof 100 is suited to high-speed transport applications. Puncture Proof 50 is an ideal cost-effective solution formulated to provide added protection to both sidewall and tread area of low speed and off-road applications. The compound recognises that tyres used in such applications are often prone to larger and/ or more frequent punctures than those used on road. Puncture Proof 100 is a less viscous product that flows freely around the inside of the tyre allowing high-speed tyres to maintain their balance and pressure while protecting the tread area of the tyre. Puncture proof works by being pumped into the tyre in liquid form and remaining liquid inside the tyre. Once the tyre is punctured, the compound is forced into the hole and immediately sets to provide a permanent repair. It contains 10 percent recycled rubber and it is this rubber, in conjunction with the other ingredients, that creates a successful repair. The compound is manufactured using Polypropylene Glycol, a non-hazardous substance often found in food manufacture.

Most competing products use either latex, or Ethylene Glycol, a poisonous substance commonly found in Antifreeze. Other benefits include prolonged tyre life, reduced heat build-up and reduced fuel

consumption by maintaining the correct tyre pressure. Puncture Proof is distributed exclusively by TRS Tyre & Wheel Ltd. Go to www.demm.co.nz/ enquiry quote: D111109a

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PRODUCT WATCH

Space-saving flow meter for upstream production in mature well sites

The new McCrometer’s V-cone flow meter is designed for process engineers in charge of creating WAG injection systems for mature oil/gas reservoirs. It features a space-saver design that reduces both installation and operational costs while improving oil production efficiency. Wateralternating-gas (WAG) injection is an enhanced oil recovery (EOR) technique that helps recover the oil in a mature reservoir, which has been in production for many years. This technique makes it possible to recover significantly more oil by alternately injecting carbon dioxide (CO2) gas with water. The CO2 gas helps mobilise the remaining oil, while injecting water displaces the remaining oil and gas. In a typical WAG system, the V-cone flow meter is installed as a master meter at the CO2 source with stainless steel piping split run to as many as 16 injection wells. Even with 16 pipe runs, the V-cone master meter

maintains high accuracy when the volumes of the 16 pipe runs are added together. The meter itself also requires virtually no maintenance, only a simple calibration check of the transmitter. Engineers in the oil and gas industry rely on the V-cone flow meter to remain accurate in the toughest applications. Its low-maintenance, no-movingparts design is, according to manufacturer information, proven to remain accurate for 25 or more years and all but eliminates the need to shut down production for calibrations, inspections or regular primary element replacement. It saves money by increasing production up-time and in parts and labour. With built-in flow conditioning, the device features advanced differential pressure (DP) technology to nearly eliminate the up- and downstream straight pipe runs required by other dP instruments, such as orifice plates and venture tubes. Requiring only 0-3 straight pipe diameters upstream and 0-1 downstream for precise operation, it reduces typical straight run by 70 percent or more as compared to traditional flow measurement technologies. WAG CO2 gas requires stainless steel piping, which makes the shorter

ROTARY SCREW COMPRESSORS

INDUSTRIAL

COOL CLEAN DRY 0800 555 018 10

November 2011

years 'Stands the

test of time

pipe runs required with the V-cone meter even more economical versus orifice and other types of meters. It significantly lowers installation costs both in terms of expensive stainless steel piping and the physical size of the CO2 pump room. The V-Cone Flow Meter is inherently more accurate than traditional dP instruments because of the flow conditioning function built into the sensor design. Its centrally located cone interacts with the fluid steam, reshaping the velocity profile to provide a stable signal that increases measurement accuracy. The pressure difference exhibited between the static line pressure and the low pressure created downstream of the cone is measured via two pressure sensing taps, one placed slightly upstream of the cone and the other located

AIR SYSTEMS NZ

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New leak inspection machine for bottles ALPS (Air Logic Power Systems) introduce their new SX linear bottle leak inspection machine. The SX Flex linear leak testers are single station leak testers that can be placed directly over existing conveyors and use inbuilt gate cylinders to gate and stop bottles. The containers are continuously fed by the conveyor. A gate cylinder regulates bottles into the testing area. Precise programmable sensors are used to monitor bottle travel through the gate, test station and reject areas. An integrated air-jet or cylinder ejects defective product from the conveyor. Handling consists of rugged, adjustable stroke stop cylinders. The unit is suitable for stable bottle designs that gate and stop effectively with a continuously moving conveyor; and for production lines where a separate leak tester conveyor is not desired. ALPS are represented in Oceania by HBM Plastics & Packaging Technologies. Go to www.demm.co.nz/ enquiry quote: D111110a

• INDUSTRIAL

in the downstream face of the cone itself. The pressure difference is then incorporated into a derivation of the Bernoulli equation to determine the fluid flow rate. The versatile V-cone flow meter is available in line sizes from 0.5 to greater than 120 inches in materials and with flanges compatible with any application. It operates over a wide flow range of 10:1, is accurate to +/- 0.5 percent and offers repeatability to +/- 0.1 percent . It features standard beta ratios of 0.45 to 0.85 with custom betas available. It is constructed of rugged Duplex 2205, 304 or 316 stainless steel, Hastelloy C-276, 254, SMO and carbon steels with special materials and testing available on request. Go to www.demm.co.nz/enquiry quote: D111110

PRODUCT WATCH

Customised solutions for automation applications

Commercially available standard units can prove to be too heavy for some applications. Every gram saved achieves better dynamics, particularly for grippers with several rotary units. Fipa’s newly-developed miniature rotary unit is just larger than a matchbox, making it around five times smaller than rotary units previous available on the market. The weight has been reduced from around 900g to 85g per rotary unit. This allowed cycle times for workpiece removal equipment to be increased by 70 percent , and the massive weight savings

across a total of 25 rotary units allowed a smaller robot to be used. The new solution scores points with its lower energy costs, smaller space requirements and minimised piping due to the integrated vacuum duct. And as a positive side effect, the low number of compressed air hoses makes the system more reliable. A company in the plastics industry needed equipment to insert threaded bushing into an injection mold. The bushings could only be gripped from the inside, and the available space was minimal. Fipa’s solution was a pneumatically controlled cylindrical insertion tool with stripper and contact plate – precisely adapted to the geometry of the threaded bushing. It can be easily integrated with Fipa gripper modules due to a clamping shaft. The functionalities at a glance: First, the threaded bushing is pressed onto the contact plate which holds it in place then the tool is moved. At the insertion point, the piston-like stripper is deployed, placing the threaded bushing into the target contour. The second compressed air supply returns the stripper to the starting position. The bushing detaches from the tool, which is then ready for the next insertion part. Fipa also features new customised grippers.

These grippers are characterised by a productspecific design, low weight, and flexible manufacture in a polyamide-based highperformance plastic using a generative process. This makes vacuum cups and other tools for optimised product handling financially feasible even from single batch size and allows any geometry to be created. Even unusual handling tasks can be performed, such as gentle handling of apples or baked goods. The extremely lightweight construction with minimum wall thicknesses reduces energy costs. Smaller robots can also be used in many applications. A further characteristic of the customised grippers is their standardised basic design with a variety of exchangeable heads. The integrated robot-gripper interface with media feedthrough and electronic transmission allows the gripper system to be changed quickly and with protection against reverse polarity. Users benefit from short set-up times and high flexibility of use. Almost unlimited combinations of vacuum and pneumatic grippers are possible with the customised gripper. The solution is compatible with components from the Fipa range and allows custom components such as miniature rotary units or insertion tools to be easily integrated. Go to www.demm.co.nz/enquiry quote: D111111

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PRODUCT WATCH

Noise reducing protection Electrical circuit for industrial applications mapper for up to 24 branch circuits

Howard Leight by Honeywell Safety Product (previously Sperian Protection) presents the Leightning L0N neckband. The new product features Leightning ultraslim earmuffs and utilises Bilsom air flow control technology. This technology delivers high attenuation and provides consistent noise diminution across a range of frequencies, including low frequencies. Welders are often exposed to harmful noise levels generated by various welding processes; however most workers are restricted to using earplugs after finding that traditional earmuffs are unable to fit under their welding helmets. The lightweight Leightning L0N Neckband is slimline enough to fit under most welding helmets. Featuring a lightweight steel-wire construction design that offers high performance sound defence and

robust durability, the neckband withstands demanding use in tough conditions, without compromising on comfort. Snap-in ear cushions make cushion replacement quick and easy. The design of the neckband includes a distinct padded foam headband and soft ear cushions which ensure the highest possible level of user comfort. A patented baseplate chamber and high-tech non-woven layer manage the flow of air inside the earmuff to control how sound reaches the ear, ensuring consistent and safe noise reduction for all industrial environments. Ideal for situations where compact earmuffs and reliable noise-blocking protection is required, the Leightning L0N Neckband is approved to AS/NZS 1270:2002 standards. Go to www.demm.co.nz/ enquiry quote: D111112

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The circuit mapper is the first device of its kind that maps up to 24 branch circuits of wiring systems concurrently with a single transmitter and receiver. The transmitter connects to the branch lines at the panel, and the receiver displays the corresponding circuit number through digital signal processing, with or without direct electrical contact, so you know exactly which breaker is connected to each transmitter lead. This circuit mapper offers considerable advantages over traditional methods. It is labour saving, eliminates downtime, protects sensitive electronic equipment and the user can map the circuits on their own. There is also no more need to turn breakers on and off. Last but not least, circuits can be tested with or without power. The circuit mapper is available from TechRentals for rental periods of one day upwards. It comes complete with the transmitter, receiver and 24 clamps and can be delivered to most NZ locations overnight. Go to www.demm.co.nz/enquiry quote: D111112a

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Palletising in deep-freeze environments

(Previously marketed as Lenze)

Industrial clutches and brakes Intorq BFK458 The versatile modular system INTORQ BFK458 The BFK458 spring-operated brake is a modular design that offers versatility of flange or shaft mounting making it suitable for retrofit and new applications Features: - Braking torques: 2-600Nm - DC voltages: 24, 103, 180, 205 V - Preset air gap - Manual release devices for all

Following types available on indent: BFK458: Long Life Design - 1.5 - 32Nm BFK457: Simple Design - 0.12 - 125Nm BFK461: Sealed Design, IP65 - 4 - 235Nm BFK468: Multipole - 100 - 2400Nm BFEX58: Explosion Proof

TRANZ CORPORATION LTD

343 Church Street, Penrose, Auckland, New Zealand P.O.Box 12320 Telephone: 09 634 5511 Fax: 09 634 5518 website: www.tranzcorp.co.nz | email: sales@tranzcorp.co.nz

November 2011

The Kuka palletising robot with a 700 kg payload is now available in an Arctic version. Specially developed for use in deep-freeze environments, the KR700PA Arctic reliably palletises frozen products at temperatures as low as -30°C without any loss of quality due to temperature fluctuations in the freezer room. The formation of ice on the frozen goods is therefore avoided. Like its traditional counterpart, so the manufacturer says, the KR700PA Arctic has the

largest range of motion of axis 1 in its category, and also an enormous horizontal and vertical reach. High speed by design and the ability to palletise an entire layer, the Arctic equipment ensures reliable functioning and protection of all drive units and power cables at these low temperatures with a specially adapted energy supply system from axis 1 to axis 4. The Arctic robot requires no protective suit or additional heating of the robot arm – this saves procuring extra equipment such as special suits which requires extra maintenance time, and saves on the ever more important energy costs. Palletising full loads directly in the freezer avoids additional components such as conveyors out of, and back into the freezer. The KR700PA Arctic also comes complete with a hollow wrist for added reliability. Headland represents Kuka Robotics in Australia. Go to www.demm.co.nz/ enquiry quote: D111112b

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PRODUCT WATCH

Lightweight and rigid aluminium air piping system

The strong nylon push-lock style fittings can be disassembled and reused.

Industrial Air Systems announce the release of the smart new Sicoair aluminium compressedair reticulation pipe system. Smart because it combines the huge benefits of a highly effective air transfer piping with ease of installation, giving the best of both worlds – efficiency and economy. In fact, in most instances the new piping can be quickly and easily installed without the need of professional labour. Sicoair aluminium piping is both lightweight and rigid, requiring

less than half the usual support as needed by equivalent poly pipe systems, so the manufacturer says. There is no risk of sagging (and resulting water accumulation) as in poly piping, and even in adverse climates the aluminium piping maintains absolute rigidity. The thin-walled pipe construction makes for very high air flow rates and, when compared to poly pipe, will transfer up to twice the airflow for the same outside wall diameter. The piping is extremely lightweight and in most cases can be hung by a single installer, saving on expensive labour charges. The smooth internal wall creates very little resistance, reducing pressure drop to an absolute minimum, which increases the air efficiency and leads to significant energy savings, especially with larger compressed air set-ups. Sicoair 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 or altered as is so often the need with growing compressed air requirements. Industrial Air NZ’s director Richards says that “of the many compressed air pipe systems we have seen over the years, the new Sicomat piping would ‘take the cake’ as it’s not only a high quality and efficient fluid transfer system, it is also very fast and simple to install. I would predict that most companies would choose to install this system themselves, as it requires no glue, no special tooling, and it is

The thin walled pipe construction makes for very high air flow rates.

very easy to assemble. And unlike other aluminium piping systems we have sold and used, Sicomair is very, very competitively priced.” The system 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:

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D111113

Rapid Acting Doors High Performance Doors from Italy! What makes Ditec doors so attractive… NZ assembled – short lead times, minimal freight costs Low maintenance, cost effective design Competitively priced with models to suit all applications High quality European engineering Doors for: Process Rooms, Airlocks, Freezers, Loading Docks and Truck Bays

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FEATURE

It’s just pressure Thanks to Multivac’s new HPP technology, integrated highpressure preservation is now available for MAP packed food items to extend their shelf life without heat, radiation or artificial additives. Up to 6000 bar rids the treated food of harmful microorganisms without affecting its nutritional value. Stefan Richter reports.

When Sepp Haggenmüller and his friend Artur Vetter built their first vacuum chamber machine in a garage in 1961, they named it Multivac. From these humble beginnings in Böhen, a small town in Southern Germany, the company Multivac has grown into one of the world’s leading suppliers of packaging solutions for food. 50 years later the company employs more than 3200 staff, allocated to over 60 local companies and branches around the world. In their 50th anniversary year Multivac launched an interesting innovation at Interpack 2011 in Düsseldorf, Germany, that must have made a lasting impression on the representatives of the New Zealand Food Innovation Network (NZFIN). Multivac sold its first HPP (high pressure processing) system to the FoodBowl, which is NZFIN’s Manukau-based hub, and this technology now constitutes the key part of Hall 4 (see also interview on page 16). High pressure processing as such has been around for quite a while. It has been known since the end of the 19th century that high pressure, exerted on certain food items, destroys pathogenic microorganisms. The pressure interrupts various important cellular functions, resulting in the harmful organism’s inability to survive. No heat or chemical additives such as preservatives are needed to extend the food’s shelf life. What is more, at the same time sensorial properties and nutritional value, taste, texture, and appearance of the HPP-processed food are almost entirely retained. “The benefits of HPP have been known for a long time, but the technology has only recently become commercially viable,” explains Stephen Holmes, Managing Director, Multivac NZ Ltd. “And now Multivac, together with Uhde High Pressure Technologies, have further developed and refined the process. Thanks to a controlled decrease of pressure during the treatment, it is now for the first time possible to process MAP packs without loss of quality.”

HPP – the technical principal The technical principle behind HPP does not sound very complicated. The already packed food items are placed in a loading tray and then put

November 2011

Multivac’s new HPP system can preserve food without any chemical additives or heat treatment.

“It is now for the first time possible to process MAP packs without loss of quality.” Stephen Holmes, Managing Director, Multivac NZ Ltd

into a pressure chamber. This chamber is sealed, flooded with water, and pumps generate a pressure of about 6000 bar. After a certain holding time, which depends on the food item, the chamber is depressurised and the food packs can be taken out. But the devil, as so often, is found in the details. “It is not so much about how we take the pressure up to 6000 bar, but how we control it coming down again,” says Stephen Holmes, “If you release the pressure too rapidly, the gases that have been forced inside the food and the packaging material escape very rapidly, and both can suffer damage. The damage caused to the barrier layer of the packaging material can allow oxygen to penetrate the MAP pack, which reduces the product’s shelf life. The quality and appearance of the food item might also be affected by little blisters forming on the surface due to erupting gases.” That’s why it was not possible so far to treat MAP packs with HPP technology, but only vacuum-packed food items. Modified atmosphere packs have a lowered amount of oxygen, which in the packaging process is replaced by nitrogen, carbon dioxide or monoxide to slow down the growth of microbes. Ultimately, the shelf life of an item with modified atmosphere is extended and the overall presentation improved.

FEATURE The new technology by Multivac and Uhde exactly monitors and controls the pressure release, a feature which Stephen Holmes calls “soft depressurisation” and which requires intimate knowledge of the mechanisms taking place under high pressure and a good grip on the technology involved. “For the first time food packs with modified atmosphere can be processed without the mentioned side effects,” says Stephen Holmes. The individual parameters for each food item and package can be stored in the machine control of the HPP system. But there was another technological obstacle to overcome to make the technology economically attractive. “Until now, the HPP process mostly had to be performed offline, separated from the packaging procedure,” says Stephen Holmes. “Most containers that are available present only a small opening at one side of the cylinder, too small for handling modules or robots to load or unload the containers. In order to integrate this process step into the packaging line we needed to come up with a solution that allows for automatic loading and unloading.”

New tray design enables automated handling The company’s idea consisted in constructing a cylindrical tray that can be unfolded into two halves and closed again automatically, making it accessible for automated handling devices. “Customers can now process up to four tons of packed food items per hour; the new trays ensure

maximum throughput and continuous product flow and significantly reduce processing costs per pack.” All these developments have already paid off, the company reports to have sold six units worldwide so far (including the one operating in Manukau’s FoodBowl). Multivac has also registered several technical solutions, such as the soft depressurisation and the innovative tray design, for a patent. Multivac’s new HPP technology might have come at the appropriate time. Consumers worldwide are becoming more and more interested in the quality of the food they put on the table every day. Nutrients are in, preservatives and other artificial ingredients are out. HPP can provide the food industry with a sophisticated tool to produce high-quality food items without using chemical additives, radiation or heat treatment to extend shelf life. Stephen Holmes gives an example: “Orange juice that has undergone heat pasteurisation retains only 40 percent of the initial vitamin C after 20 weeks at 4˚C. After treatment with HPP, 85 percent of the vitamin C can still be found in the juice after 20 weeks at 4˚C. The cold pasteurisation process is completely natural, it’s just pressure.” Multivac NZ was established in 2005 and has grown into a company of 13 people working in the Pukekohe and Christchurch offices. At the moment the company has a new building under construction near the airport, close to the FoodBowl. “We are well established in New Zealand, about 110 of our machines are working

throughout the country. Our main customers are meat and seafood producers, dairy industry and bakeries,” reports Stephen Holmes. The managing director perceives a trend towards value-added products in the meat industry. “Instead of vacuum packing and sending whole carcasses overseas, the meat industry is starting to cut the carcasses into retail-ready portions and pack it nicely. That way producers can demand higher prices and increase their profits. In this area of value-added production there is a big market opportunity for our thermoformers.” Another industry trend, increased automation, is somewhat inhibited by one peculiarity of the NZ market. “European food producers set up their machines once and then continually produce the same item. Here in New Zealand, there is no such mass production, the machine setup has to be changed all the time as there are so many different items to produce. Due to all the frequent changes it can be a quite challenging task to use robots,” says Stephen Holmes. But growing cost of labour, decreasing cost of technology and higher reliability make automated production increasingly attractive to companies. “And that is good for Multivac, as we are able to supply complete packaging lines including weighing and feeding systems, packaging machines with identification systems, labelling and visual quality control and package sorting systems.” Go to www.demm.co.nz/enquiry quote:

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FOOD PROCESSING

Appetite for success The New Zealand government has set the goal of growing food and beverage exports by 270 percent by 2025, to $150 billion. One pillar this ambitious growth strategy rests on is a network of innovative food development facilities across the country. Stefan Richter talked to Colin Mitten, director of the Manukau-based FoodBowl. DEMM: The Food Bowl just opened its gates to the NZ food and beverage industry last month [October]. What role does this facility play in achieving the Government’s ambitious growth agenda? CM: The biggest lever NZ has to increase its exports and achieve economic growth is the food and beverage sector. This industry accounts for more than half of our total exports. The FoodBowl, operated by New Zealand Food Innovation (Auckland) Ltd, or NZFIA, is part of a nationwide open-access network of innovation centres designed to enable food and beverage businesses of all sizes to grow. These centres are supposed to fill the gap between a new product idea and a successful product on the supermarket shelf. The NZ food and beverage industry will be enabled to respond more easily and swiftly to consumer demands and market

opportunities – national as well as international ones. The capital and expertise investment for companies is straightforward, minimising the risks normally attached to innovation. DEMM: Who initially conceived the idea to set up a food innovation centre? CM: The idea was first mooted in 2001 by Professor Ray Winger, formerly Professor of Food Science and Technology at Massey University, whose vision was to provide a facility for small and medium food and beverage companies to use while developing their ideas into commercial products. The realisation of this idea finally cost $16 million to build and fit out. DEMM: What does the FoodBowl have in store for its industry customers? CM: The FoodBowl supports product and process development with pre-production pilot facilities and expertise. The resources available to customers include commercial and test kitchens, laboratory facilities, pilot plant testing and shortrun processing capability to allow in-market testing of new product concepts. The network also provides an “expertise bank” of experienced and skilled technologists, scientists and consultants to support customers’ use of our facilities, and a knowledge base to identify and develop opportunities for

companies to cooperate. DEMM: What are the reactions of the NZ food and beverage industry so far? CM: The overwhelming response has been that the FoodBowl is one of the more significant developments in the food processing industry since most food manufacturers can remember. We advertised that it was possible for potential users to come and have a look through the facility before we switched on the internal security systems and prepared the facility for food manufacturing. We have been stunned by the interest, with more than 500 visitors having come through the facility in just one week. DEMM: Which are the most important export markets for NZ’s food and beverage industry, now and in the future? CM: The export market where New Zealand has seen consistent growth over recent years has been Australia, however with the innovative shelf life extension manufacturing equipment, many of the more distant markets within Asia, the American continent, and Europe are now more readily accessible. DEMM: NZFIA chairman Tony Nowell emphasises new added-value products as key ingredients of economic growth. In what way can

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November 2011

FOOD PROCESSING Committing to the future

(L-R) NZFIA chief executive Stuart Walker, NZFIA chairman Tony Nowell and NZFIA executive director Colin Mitte

the NZ food and beverage industry add value to our primary products? CM: By exporting processed food products, products in their final retail form, rather than prime food that another country subsequently converts into a fast, moving consumer good and hence takes the economic benefit. DEMM: Earlier this year NZIER warned that high food prices would harm the NZ economy, predicting that any gains to the export sector are overshadowed by a reduction in household spending, resulting in a welfare loss of $3.3 billion or 2.0percent of NZ’s GDP. Do you agree to this prediction? CM: Increasing food prices is a worldwide phenomenon, and so the opportunity for New Zealand to take increased margin from higher export prices now exists. DEMM: Another obstacle to NZ’s growing prosperity might stem from an acute skill shortage that affects productivity, innovation and quality of product. According to a survey conducted by Competenz, 27 percent of food manufacturing companies strongly believe they have a skills shortage and 53 percent believe they will need more skilled staff in the next two years. How do you assess the situation? CM: Food manufacturing as volume increases will inevitably become more automated, everyone will work smarter. In addition many of the tertiary educational institutes are introducing food-related training courses to meet the increasing needs of the employers. DEMM: Thank you very much for the interview.

The four regional hubs set up by NZFIN are:

• Auckland/Manukau – focusing on processed foods; • Waikato – focusing on meat-based products and dairy ingredients (scheduled to open mid-2012); • Canterbury – aimed at scaling up South Island producers and facilitating the move into overseas markets; • Palmerston North – draws on expertise of 600 scientists and technologists in NZFIN partner facilities, including Massey University, Riddet Institute, AgResearch, Plant and Food Research and Fonterra Innovation.

The Auckland centre includes seven process halls: 1. Equipment for extrusion and milling/blending, filling equipment to handle bulk bags or retail packs for both extruded product and powdered blends; 2.UHT/aseptic filling line and other equipment for beverage development and production; 3. General purpose, for consumer goods including cans, retort pouches, stand-up pouches, bottles and jars; general purpose food processing; and bar extruder to bake biscuits, health bars and novelty items; 4. High-pressure pasteurisation; 5. Freeze drying; 6. Microwave thawing; 7. Production kitchen.

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FOOD PROCESSING

Intelligent automation for modern compliance Processing environments which have to comply with HACCP and other standards can benefit from intelligent process valves with integrated automation functions. In the production of food and beverage additives such as concentrates and flavours, excellent process hygiene plays a key role. This is enforced in Australia and New Zealand by stringent specifications and governmental regulations aimed at protecting consumers, with many companies working to HACCP. Companies operating in the competitive global market are also forced to make production processes as efficient as possible. Combined, this has led to an increased demand for automation solutions at the process level. However, process owners are increasingly finding that conventional centralised process automation solutions are incapable of meeting ever-stronger industry requirements. Intelligent process valves with integrated automation functions offer a viable and efficient alternative, driving efficiency and

delivering the reporting capability necessary for HACCP and other compliance standards in modern processing environments. In the field of process valves, conventional automation solutions including control cabinets with valve terminals, I/O systems and fieldbus interfaces normally require costly hose connections and wiring. Valves are connected to the central control unit through a large number of long control air lines and discrete feedback connections. In addition to high planning and installation cost, such solutions are not entirely without problems as regards hygiene. A recently upgraded plant for fruit juice concentrate and other basic food and beverage ingredients demonstrated a better way: the new facility includes intelligent process valves from the fluid technology specialist Bürkert. These valves are used by the drink manufacturer across the entire production area, with the company opting for automation by means of decentralised control head solutions with ASi communication. In

The status of valves is clearly visible across the processing floor.

addition to hygienic seat valves and butterfly valves controlling the product flow, all on-off valves of the auxiliary circuits for water, steam, sterile air and cleaning are also automated in a decentralised manner by means of intelligent valves.

In contrast to control cabinetbased automation concepts, the only tasks left to the central process control system in Bürkert’s decentralised solutions are control and status monitoring. At field level, pneumatically operated process valves

Floor coatings for food and beverage applications Regis Coatings, NZ manufacturer of the Epotread floor coatings and Cretex repair products, recommend the summer months as the ideal time to repair, refurbish and coat the floors of workshops, garages or industrial floors. Hardwearing and chemical resistant finishes are the specialty of this company. The Epotread and Cretex products provide an effective system to renovate floors. The products are used extensively throughout New Zealand in both new and older buildings, even at times where the client has virtually given up hope of upgrading. Although the products will cure in the colder winter months quite satisfactorily, it is easier to achieve a consistent result when ambient temperatures are higher. The Epotread and Cretex products have the advantage of being low toxicity materials. This not only benefits the applicator, but also allows work operations to continue; usually eliminating the problem created by the presence of easily-tainted products such as food or beverages. The company provides a nationwide applicator service or can supply the products for the user’s own application. Go to www.demm.co.nz/enquiry quote: D111118

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November 2011

FOOD PROCESSING clearly seen from across the plant floor, further enhance process transparency. The status of each individual valve can thus be checked on site even from a distance. As the process valves can be manually operated through the pilot valves at the control head, the operation of the machine is made even simpler. Bürkert’s valves offer a clear graphical display and direct parameterisation.

are used. These can be equipped with all required top-works, including pilot valves with manual actuation, electrical feedback units and optical status indicators, fieldbus interfaces and even positioners and process controllers.

Less cabling – greater transparency Decentralised automation of the control system for production and auxiliary processes proved extremely reliable at the plant, so the company rolled the concept out to new plant sections being installed for an extension of production facilities. Today, the raw product intake unit, homogenisation and pasteurisation stations plus raw product distribution system featuring valve nodes are equipped with intelligent process valves from Bürkert. Angle-seat and diaphragm valves control the flow of cleaning media, including acid, alkaline and water as well as the steam and sterile-air supply. All drivers are equipped with an element control head with integrated automation functions plus ASi for communication via fieldbus. Thanks to the integration of the field bus interface, the advantages of decentralised automation can be utilised to the full. All that is required for power supply, feedback and communication is a two-wire line connecting the PLC with up to 62 valves. Each process valve is individually connected to the main compressed air supply line installed in the field, whereby these connections are kept as short as possible. This reduces the number and length of hose and wire connections as well as the number of required control cabinets to a minimum. Some of the plant components are extremely compact in design and highly automated, which means that there are less lines and hoses. Super-bright LED valve status indicators, that can be

Hygienic, compact and safe The units consisting of a valve actuator and a control head are manufactured according to the EHEDG guidelines for hygienic design and easy cleaning. In addition, they feature the high IP protection required for the actual application and are made exclusively of detergent-proof materials. The IP protection is therefore not affected by long-term use under conditions of high air humidity or by frequent cleaning with aggressive chemicals. This is of great advantage, especially to valve nodes, as there is often a problem of detergent solution or water escaping through the leakage valves, requiring frequent cleaning of the outside for hygiene reasons. The design of the entire production facility is aimed at achieving trouble-free operation and minimising maintenance while prolonging the machine’s service life and ensuring that it retains its value. High reliability, availability and durability of the process valves thereby play a key role. In Bürkert valve systems, this is achieved by means of an integrated control-air inlet to the actuator chambers that ensures that the spring chamber of the pneumatic driver is supplied only with clean control air. Moisture, dust and contaminants in the ambient air cannot enter the actuator units. This in turn effectively prevents contamination of the piston seals and corrosion of the drive springs by cleaning solutions. There is also no risk of moisture from the spring chamber entering the feedback module or the control head along the spindle extension. While this design significantly prolongs the service life of the driver, it also enhances the hygiene of the process. As product cannot enter the driver, both the spreading of germs and contamination of the driver by mould are effectively prevented. The risk of pores produced in the spring chamber being ejected into the ambient air at each switching process, which is a common problem

with conventional valves, is thus eliminated. The actuator housing is flushed with control air at each switching process as some control air is fed through the pilot valve. This means that, upon switching, a small volume of control air enters the housing. This process takes less than 10 milliseconds. As a result, a slight overpressure is built up in the housing, further improving its IP protection and preventing the penetration of humid air, for example in the event of a change in temperature or rinsing with cold water. Should the pressure, after several switching processes, increase above a set limit, the integrated pressure-relief valve automatically releases pressure from the housing. Through this combination of controlair inlet and release, a constant overpressure is maintained inside the housing, while a certain volume of air is regularly replaced. This ensures that no condensate can build up inside the housing.

Extension of a tried and tested concept

decentralised automation concept across the entire system, using their intelligent valve systems. As the operating and maintenance staff were already familiar with the fieldbus system and the connecting and wiring concept, the new plant sections could be commissioned without any difficulties. To sum up, the practical integration at field level of automation functions in the pneumatic drivers of the process valves allows for a high degree of automation at minimum costs and ensures excellent transparency. Thanks to the modular design of the valve systems, customised automation solutions can be devised easily and quickly. This is not least due to the fact that Bürkert offers not only process valves, but also digital electro-pneumatic positioners and process controllers that can be combined in the same manner to provide complete control valve systems. Article by Chris Hoey, Managing Direct at Bürkert Fluid Control Systems Go to www.demm.co.nz/ enquiry quote: D111119

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For the extension of the plant, Bürkert were able to pursue the

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FOOD PROCESSING

Fresh on the table with automation technology

Processed food often has to travel a long way before it reaches the safety of a home refrigerator â&#x20AC;&#x201C; a journey which involves numerous risks of contamination or microbial attached, such as salmonella or listeria. To prevent this from happening, machine and installation builders equip their processing filling machines with hygienic automation technology.

Consumers are looking for reliable quality when they buy their groceries. Hygienic manufacturing, filling and packaging in the food industry ensures firstclass products. Customer-specific solutions from Festo constitute an important factor in the hygienic value creation chain. They key phrases in automated food production are cost-effective solutions together with high hygiene standards. However, the decisive factors also include variety in products, taste and packaging, which has consequences for the set-up times and modularity of production facilities. The examples described below show how automation technology can make food production safer and more efficient. It is advantageous for a single sourcing policy if the automation supplier can provide both process and factory automation.

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The production process itself involves many different activities: mixing and stirring, sterilisation, pasteurisation, homogenisation, filtration, dosing, weighing, filling and storage. Automation ensures the reliability of these processes. Semi-rotary actuators and linear drives or cylinders DFPI with integrated guides and displacement encoders open and close ball valves and butterfly valves. In order to control the many pneumatic semirotary actuators and linear drives installed in many breweries, central stainless steel control cabinets are used in the fermentation cellars with CPX valve terminal and service units for compressed air preparation, together with appropriate sensors.

The stainless steel cylinder CRDSNU is easily cleaned.

damage drives and valve terminals, proximity sensors and fittings. If the installation concept calls for decentralised valve terminals, splashproof clean design valve terminals (CDVI) and individual valves (CDSV) can be installed close to the drives which are to be controlled and require no protective control cabinet. The clean design cylinders CDC are modular and constructed without sharp edges or corners, ensuring that dirt residues or germs can be completely removed during cleaning. For the handling of workpieces, guided cylinders DGRF are now used, which are available with the option of dry running seals. The cylinder lubrication and seals have FDA certification. The associated proximity sensors are resistant to cleaning agents, heat and mould.

The star with gentle curves The star performer in the food zone is the stainless steel cylinder CRDSNU. It is easy to keep clean. Its self-adjusting end position cushioning PPS saves users alot of time during set-up. The CRDSNU also proves its worth in a machine for sorting salmon. Saline sea water and fish substances mean that the round cylinder is put to a hard test. What is more, it is cleaned daily with chemical additives. A standard round cylinder would give up the ghost in this application after just a few weeks. The CRDSNU however, is in its element in this humid and aggressive environment. To ensure that drives do not fail in harsh environments, users

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In the splash zone of food processing operations, the automation technology does not come into contact with food. Nonetheless, corrosion-proof design is mandatory, since water splashes, cleaning agents or dripping food may otherwise

For the handling of workpieces, guided cylinders DGRF are used.

FOOD PROCESSING

can choose seals from the Festo modular seal system. This includes FDA-compliant standard seals suitable for food use with normal cleaning. seals for unlubricated operation and seals for applications with intensive cleaning, FKM seals are available for high temperatures up to 120°C and for acid environments while there are hard scrappers for low temperatures down to -40°C and for applications involving sugar crystals.

End-of-line packaging Festo can provide a variety of handling solutions with a choice of drives to meet individual customers’ requirements with regards to packaging, labelling, testing and monitoring in the non-food zone at the end of the value creation chain. Its handling experts can select from more than 30,000 products and use appropriate servopenuamtic, electric or pneumatic drives for the customer application in question, together with the associated controls on valve terminal technology, sensor technology and vision systems. These are fully assembled and tested and delivered directly to the machine as ready to install system solutions – complete with all the design data and circuit diagrams as well as a comprehensive functional and fixed price guarantee. Users receive not only hardware in the form of a connection ready module or subsystem but a complete value creation package. Complete solutions mean less work for customer personnel, reduce system design costs, simplify the procurement process and reduce process costs. It is rare that two handling systems are the same. The spectrum ranges from simple pick and place systems through to linear gantries, cantilever gantries, 3D gantries and rod kinematics robotic system tripod, high speed gantries and individual applicationspecific gripper systems.

Putting an end to waste Less machine downtime through detection and elimination of leaks in compressed air systems is crucial. That is why services such as total productive maintenance condition monitoring and energy-saving services are becoming key factors in food processing. Many companies have declared war on waste and high

Application example for hygienic automation: meat processing.

energy prices. Food safety and energy efficiency are not mutually exclusive. On the contrary, just

as food remains fresh for longer through the use of hygienic automation technology, the plants in which they are produced always

stay modern, reflecting state of the art technology. Go to www.demm.co.nz/ enquiry quote: D111121

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Triton Commercial Systems has developed and proven a method for immediate yield gains in meat deboning. PAYS, an acronym for Productivity and Yield System, works on the basis that by showing a boner and trimmer what they have actually achieved at the instant they do it, they can improve on this. Currently, nobody knows what they actually achieve until the work is finished and reports run, and the results are generally averaged over all workers. Averages by their nature include the good performers and the poor performers. If it was possible to show instantly that one worker is yielding poorly, they could self-improve and maintain a lifted yield result. Suddenly, averages shift. This is now possible by using a feedback loop that shows what has actually been achieved, compared to a target value. It also shows the change in performance for subsequent events that reflect how a worker has responded by changing their behaviour and the result achieved. The pictured example shows two specifics: 1. Wildly variant and low cube roll yields are lifted, narrowed and maintained. 2. The trimmer has lifted “Cut to Primal” yield, but the boner yield seems low. This is instant information, understandable and actionable, for boner, trimmer, and supervisor. Criticism levelled at “average yield performance” is not specific to who is doing well, or who is doing poorly. That is like taking high average road speeds, then applying speeding fines to every motorist regardless of their actual speed. PAYS presents specific achievement as it happens for the boner, trimmer and supervisor to all use. Once something is measured, it can be evaluated and managed, either by the person themselves or by their supervisor. Able to be deployed in existing plant layouts, PAYS makes the best use of proven process patterns, manning levels and flows in existing sites. Go to www.demm.co.nz/enquiry quote: D111122

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November 2011

FOOD PROCESSING

Peristaltic pumps unscramble production problems

Solutions for homogenisation processes Wika has developed the diaphragm seal model 999.30 especially for homogeniser applications. This high-quality product is now available in combination with an intelliGaugeseries mechatronic pressure gauge (PGT 23.100) or the new pressure switch PSD-30. The complex design of the diaphragm seal is tailor-made for the extremely dynamic homogenisation processes. The damped instrument is designed for a static pressure of up to 2,500 bar. Its high load capacity guarantees a robust and durable measuring assembly. With the PSD-30, in combination with the diaphragm seal, a highly functional pressure switch is available also for homogenisation processes for measuring ranges up to 600 bar. The compact instrument is easily mounted and is simple to operate via three keys and an intuitive menu navigation. The large LED display, with a digit height of 9 mm, can be easily read even from greater distances. The combination with the intelliGauge pressure gauge provides a local display via a bourdon tube pressure gauge and an electrical output signal without the need for an external power supply. Go to www.demm.co.nz/enquiry quote: D111123a

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A major food manufacturer have replaced their air driven diaphragm pumps with Watson-Marlow peristaltic pumps for pumping raw egg in the manufacture of fresh pasta, because of their low cost maintenance capabilities. The diaphragm pumps’ non-return valves slightly degraded the product, and at the end of a working shift, a technician was required to strip and clean each pump, greatly adding to production costs. Pumping the egg mixture is also challenging as it will foam if handled roughly making it difficult to meter, and will actually cook inside the pump if the running temperature is too high. Peristaltic pumps avoid these problems because they are very gentle on the product being pumped, and because the mixture passes through a tube (avoiding contact with the pump mechanism), cleaning and maintenance requires

only a sterile tube to be replaced. They also easily cope with viscous and highly perishable egg mixture. Two high flow 720 series pumps transfer the egg from delivery tankers to refrigerated holding tanks, prior to fifteen 620U/R pumps metering it to production lines. Both the 700 and 600 series pumps are manufactured to IP66 standard so that they can be washed down on-site, and they are fitted with food grade Bioprene tubing. Fitting new tubes in the pumps is a quick and easy procedure which can be done without any tools. No additional pipework, valves or filters are required for use with the peristaltic pumps, and they can be installed in a minimum amount of space where they are needed to operate, so providing further purchasing and maintenance cost. Go to www.demm.co.nz/enquiry quote: D111123 C

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HEAT TREATMENT

The importance of talking heat treatment Heat treatment is simply a function of ingredients, temperature, and time and therefore the outcome is pretty predictable. But sometimes it’s just not that easy. Barry Robinson shares what happened when he was approached by MOTAT to rectify a minor problem with their new tram wheels. Everyone seems to know that if you heat a piece of steel to “cherry red” and quench it in water it will come out hard. Fewer people know that it is dangerously useless in that state, and that it must then be tempered in order to make it usable. After quenching it is at its hardest and most brittle, but only after subsequent reheating for tempering will it be in its toughest state. Tempering does three very important things: It changes the brittle quenched microstructure to a tough tempered microstructure; it lowers the hardness; and tempering also importantly relieves the stresses caused by quenching. Some engineers will know that all mainstream high-tensile bars and plates available in New Zealand are supplied in the already “hardened and tempered” condition. Steels such as 4140, 4340, P20, and Bisalloy 80 are all supplied hardened and tempered to around 26 to 34 Rockwell C. This is roughly equivalent to 800 – 1150 MPa breaking strength. Why is this important to know? Because if your steel merchant does not stock the size of hightensile steel you need, you may get it cast at a foundry. And at that stage you absolutely must have the heat treatment conversation with the foundry. Somebody must remember. Failure to discuss heat treatment usually results in tears and lots of money being spent. Quite simply, unless properly heat treated the strength of these materials will not be the same as when purchased from the steel merchant.

A challenging assignment But it’s not only high-tensile steels that can lead these unpleasant situations. Recently MOTAT (Museum of Transport and Technology) approached S.A.F.E Ltd to rectify a little problem with their new tram wheels. MOTAT had purchased 16 new tram wheels, cast in a medium carbon steel similar to good old 1040 (En8) medium-tensile steel. The wheels were supplied machined and press-fitted to the axles, all ready for fitting to the venerable old trams that shuttle visitors around MOTAT. But after

November 2011

Hardening process: general arrangement of the tram axle in the rig. This rig rotates the entire axle assembly.

some use it became apparent that the wheels were wearing out rapidly. A conversation with the supplying foundry revealed the wheels had not been heat treated to the required 32 Rockwell C hardness before machining and fitting. The heat treatment conversation had not taken place. The question was: How to harden and temper the wheels now? The heavy cast steel wheels, with a diameter of 730mm, had been precision machined and pressed onto the axles with a force of 50 tons. Even if the wheels were removed from the axle for full heat treatment, the slightest distortion during quenching would upset the precision press-fit. The only real option was to harden the outer rim using either flame heating or high-frequency induction heating. It is important to note that at this point there existed a great conflict in the project: The customer would like a really deep hardened layer. But these wheels are only held on the axle by compression-fit. If you heat to high temperature for a great depth the wheel will expand and remove itself from the axle very nicely indeed – in fact this is exactly what S.A.F.E do to gently remove shrink-fit, press-fit or seized items. Even if the wheel was restrained

from falling off during heating, the heat could still stress-relieve the press-fit to an unknown extent – creating a possibly dangerous situation.

Finding a solution It was clear that the heat input had to be hard and fast; S.A.F.E had to heat the outer layer as fast as they possibly could, and then quench before causing any problems with the press-fit to the axle, and all without melting the surface. S.A.F.E advised MOTAT that whilst their high-frequency induction heater was powerful enough at 250kW, the largest diameter previously processed was 410mm – significantly smaller than the tram wheels’ 730mm. It was doubtful they could achieve the required power density to simultaneously heat the entire wheel running surfaces (including the flange) to the minimum 850 degrees Celsius required for hardening without risk of the high heat migrating to the boss area. So the flame hardening option was then looked at in-depth. Flame hardening would require a lot of high-energy burner nozzles and some serious array of high-flow regulators and pipework. Unfortunately it transpired that whilst the technology for full-rim heating possibly existed

in Germany, the high cost and time requirements made it impossible for this to be an option for a one-off time-constrained project. A second “cop-out” flame option was to progressively heat around the rim with a single burner, quenching behind the burner as it travelled. But this option always leaves a soft spot at the start-stop point – and there is absolutely no way to avoid it. MOTAT quite rightly were not keen on their trams having wheels with a flat spot on the rim. With time and options rapidly disappearing, S.A.F.E decided to give their 250kW high frequency induction heater a go, but with coolant spray nozzles specifically targeting the boss section to avoid it getting hot. No full size trial wheels were available, so testing had to happen on the job. A rough trial heating coil was made from copper pipe and fitted over the first wheel. Power was applied, and the heat results were promising. Several adjustments to the capacitor tapping were made, and eventually the results were promising enough to encourage S.A.F.E to make a close-fit coil that “hugged” the wheel contour. Further trials and capacitor adjustments, and finally the right combination of inductance, capacitance and frequency got the wheel rim hot enough to quench. Hardness testing on the rim gave 55 Rockwell C – an excellent result. But there were several more hurdles ahead.

The devil is in the detail It was obvious during the trial heating that the wheel would have to be rotating within the close-fit heating coil in order to “smooth out” the hot and cold spots evident in the final trial. S.A.F.E had the rig to rotate the entire axle assembly, but the challenge now was how to have a close-fit high voltage coil held just clear of a rotating wheel just above the surface of a water tank, and able to be rapidly removed downwards into the tank an instant before the hot wheel was plunged into the same tank. To complicate matters the boss coolant spray rig plus a subsurface bearing arrangement were also fitted just below the wheel. The final solution thankfully turned out to be wonderfully simple. With the big hurdle of

hardening the wheel rim successfully behind, the next even higher hurdle of tempering loomed. Tempering requires a much lower heat, but it must be precise, gentle, deep and long. Remember that the enemy on this particular job is a heat that is deep and long. The brutally efficient heating coil S.A.F.E created for the hardening was completely the wrong coil needed for tempering. A second coil was made specifically for tempering. Thermocouples were fitted to the rotating wheel rim to accurately monitor temperature while a very low power was applied to the heating coil. The rim was slowly brought up to 500 degrees Celsius and the power adjusted to hold it at this temperature long enough to allow for deep tempering and stress relief to occur in the entire outer “tyre”. Power was switched off, and the wheel cooled quickly to prevent the deep heat travelling to the boss. And finally the hardness was tested to measure the result of all previous efforts.

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A new challenge lies ahead At the start of this story it was explained that heat treatment is largely predictable, simply a function of ingredients, temperature, and time. But in this case the ingredients turned out to be the wild card, as the wheels had been cast in several melts with minor variations in chemistry, and no means of tracing any wheel to any given chemistry. This then caused unpredictable results. The default in this situation then becomes “trial and error” – but with no room for error. The first half of the story ends well, with one tram being re-shod with eight new wheels with properly hardened and tempered rims, with the wheels still attached to the axles for good measure. The second half of the story has yet to happen. The second tram has worn its soft wheels down. All the induction hardening parameters have changed. This story impressively illustrates the importance of talking heat treatment before manufacture – even if you do not know what you are talking about. Barry Robinson is General Manager of S.A.F.E Ltd in Drury.

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STAINLESS FABRICATION

A well-rounded business A spherical mirror sculpture fabricator based in Hawera, who exports their stainless steel spheres to famous artists on the other side of the world, have found their niche market in manufacturing other double curve shapes for many steel

Global Stainless’ sculpture is on display in the courtyard of the Royal Academy of Fine Arts, Piccadilly, London, prior to it being shifted to the Guggenheim Museum in Bilbao, Spain. (Photo taken by Cherry Park, UK)

fabricators around New Zealand. Global Stainless Ltd now manufacture oval dome ends for road transport tankers. Company director Lincoln Raikes says,” we have produced round dome ends for some time now for other tank builders around the country and it is our expertise in knuckling the edge of domes that has led us into the road tanker dome ends market. “To produce an excellent tanker end is demanding as a road tanker is a showpiece nowadays with the stainless steel tankers displaying a reflective polish, so they must be perfect,” says Raikes. “We don’t have any forming ripples with our manufacturing process and the knuckle edge is superb due to our years of experience in forming the radius edge also known as the knuckle of the dome.” The company also manufactures round domes for nearly any sized tank or pressure vessel up to a thickness of 12mm in mild steel and aluminium, and 10mm in stainless steel. Construction of the domes to pressure

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November 2011

vessel codes and statutory approval is also offered by the company. “The circumferential accuracies that we can achieve now in knuckling the edge, which is also known as flanging, allow our customers to fabricate the shell of their vessel before our domes arrive,” says Raikes. Global Stainless also offers lighter wall domes with their spinning machine which will handle up to 3.5 metres diameter. This ability has opened the door to supply a greater range of industries such as rotationally moulded plastic tank dome top moulds, hot water tank ends, milk vat tops, brewery tank ends and vacuum vessel domes to name a few. Their experience in making spheres for the artists around

the world also means that they can produce hemispherical bowls for mixing vessels. The ability of the company to cold form double curved shapes in metal has meant they can produce long radius bends. “We don’t try and compete with standard short radius off the shelf bends,” says Raikes, “but if a customer needs a smooth flowing extra-long radius bend, then we can produce it.” The bends made by the company end up in various process industries such as milk powder conveying, potato chip processing, and barley mash piping for the breweries. The bends even have architectural applications. Go to www.demm.co.nz/enquiry quote: D111126

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Conveying systems increase efficiency Mercer Stainless has been well known in the New Zealand food industry for many years as a quality supplier of tanks, silos and pressure vessels. What is less well known is that within the team, there is also a group of experienced engineers capable of designing and building conveying equipment including spiral coolers and freezers. Spiral coolers and freezers are typically used in the food industry for efficient cooling when there is limited floor space and to maximise heat transfer. As energy costs tend to be a significant operational expense for most firms, the installation of a spiral conveyor provides excellent payback and operational efficiency. Mercer Stainless’s spiral coolers are available in many space-saving configurations to best suit the user’s application. Using high quality components and reputable partners with regard to belt supply, Mercer’s spiral conveyors are the equal of any supplier in the industry. The spirals are suitable for raw products (such as snack foods, dairy products, bakery products, seafood, poultry/meats, etc.), bottles, ready meals and cartons. They can be equipped with belt washers (clean-in-place units) to ensure the optimal hygienic environment. The durable stainless steel or galvanised steel construction is suitable for continuous production in harsh wash-down environments. The efficient and smooth drives result in uniform cooling of products to minimise process time. Mercer will work with the customer to scope their spiral, and then design, construct and install a specific solution. The following configurations are available: single and twin spirals, coolers and freezers, elevators/lowerators, low and high tension systems. As for the drive system, there are chain drives and pinion and ring gear drives available. The chain drive is an inexpensive system to manufacture and is very easy to replace. While this system is a lower cost option, it will require more maintenance than the pinion and gear drive. The pinion and ring gear is a smooth and quiet system. The load carrying capacity of the slew bearing can minimise dependence of additional structures for support. The simple design results in a longer service life and is better suited to below zero conditions. We can supply a design that incorporates a quick release motor mounting system for servicing, reducing downtime and maximising productivity. For the full story go to www.demm.co.nz Go to www.demm.co.nz/enquiry quote: D111126a

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CAD/CAM/CNC Can you design a lower impact airport terminal chair? Russell Donovan of Auckland took on this challenge and, with the help of SolidWorks SustainabilityXpress and SimulationXpress, won the commercial grand prize in the DS SolidWorks’ Green Design Contest.

Russell Donovan’s prize-winning design of a “green” airport terminal chair.

The wealthy entrepreneur Sir Richard Doylson has decided to launch a new airline powered solely by algae-derived biofuels, called Greenair. Now Sir Richard needs to find somebody who can design the new “green” airport terminals for Greenair, and terminals also need chairs. Who is able to

SolidWorks SustainabilityXpress technology helps designers understand the impact of their design decisions.

design a chair worthy of the Greenair name? But keep in mind, Sir Richard’s execs will be judging your work. With this fictive scenario Dassault Systèmes (DS) SolidWorks Corp. challenged designers around the world to think outside the box about sustainability. The Green Design Contest, which kicked off in honour of Earth Day on April 22, required contestants to use SolidWorks 3D CAD software to design a low-impact airport terminal chair suitable for mass production. Recently the winners of this competition were announced. The commercial grand prize winner is Russell Donovan, of Auckland, and he will travel to Chaa Creek rainforest eco-resort in Belize in recognition for his “Leaf” chair design. Among other entry rules, the designs had to be tested with SolidWorks SustainabilityXpress, the environmental assessment software included within the license for SolidWorks CAD software. With this software, contestants were asked to measure the design’s carbon footprint, air and water impacts, and energy consumption throughout the product life cycle. In addition to sustainability tests, every design had to be analysed with SolidWorks SimulationXpress, an analysis tool built into SolidWorks, to help ensure that the chair design could withstand the stresses of everyday use. A panel of industry and SolidWorks software experts reviewed every design and entry against judging criteria broken up by sustainability, “green” aesthetics, creativity, and manufacturability. “This contest really showcased

some extremely creative and talented designers, who exhibited great understanding of the possibilities of different shapes and materials,” commented Asheen Phansey, sustainability product manager at DS SolidWorks. “Through the design entries submitted, we saw that the SolidWorks community knows that the first step toward greener products is a fundamental understanding and appreciation for effective design. Sustainable design is a very complex subject, and it is hard to understand and reduce environmental impacts that we can’t see every day,” said Phansey. “We sponsored the Green Design Contest to create greater awareness of how SolidWorks Sustainability can enable users to incorporate product life cycle thinking into their designs and tangibly reduce the environmental impacts.”

Understanding the impact of design decisions SolidWorks SustainabilityXpress technology performs lifecycle-based sustainable design assessment directly on individual part designs to help designers understand the impact of their design decisions. The software considers four key environmental indicators: carbon footprint, total energy consumed, impacts to air, and impacts to water. An initial analysis of a part design provides a baseline for direct comparison with any subsequent changes. The designer can find suitable alternative materials or search the included database for others that match the mechanical and environmental criteria. Therefore it is easy to ask “what if” questions as you design. SolidWorks SustainabilityXpress software generates reports on the designer’s findings, so they can quickly assess, build, and communicate their greener designs. The software is included with each of the SolidWorks 3D CAD design packages – Premium, Professional, and Standard. SolidWorks SimulationXpress is a first-pass analysis tool that comes with every SolidWorks Standard and Professional software packages, providing designers with a tool to conduct basic stress analysis on individual parts. They can quickly determine effects of force and pressure, and generate reports to document results. When the designer is ready to test full assemblies, it is easy to upgrade to advanced SolidWorks Simulation packages. Go to www.demm.co.nz/enquiry quote:

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D111127

CAD/CAM/CNC

CNC machine line-up extended Myriad Engineering’s most recent machinery purchase was in August when they took delivery of a Puma 280LM mill turn. This has given them increased capacity for bar feed work up to 76.2 diameter and 1m length. Already the workflow has improved and the ability to react to urgent demands without compromising other customers has improved further. The current machinery line-up includes four CNC lathes; two with mill turn, two machining centres with fourth axis, five auto lathes, an NC Digi bender for square and round section bending as well as various presses and general engineering workshop machinery, along with mig and tig welding. Myriad Engineering was founded in 1972 and is currently under its third ownership and continues to thrive. Mark Wilson purchased the business seven years ago and since then Myriad Engineering has gone ahead in large strides. When Mark took over, Myriads had old CNC lathes and no machine centre capability. He has invested heavily in technology and updated machinery. The first major purchase was a Puma 240M mill turn which provided more capability and reduced the amount of second and third operation work that was being done. This machine was key in the company growing and keeping pace with that growth and the addition of two Doosan machining centres with fourth axis has kept

pace with that growth. In 2010 Myriad Engineering added an additional 350 square metres to their floor space. “We were fast outgrowing our existing capacity and this gave us space to expand and created a workspace of approximately 1000 square metres.” Myriad Engineering is run as a contract engineering business based around the CNC capability. They also carry out fabrication and assembly work as well as welding and

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maintenance work for other manufacturers. To quote Mark, “a lot of time is spent understanding our customers, from their purchasing, warehousing and factory requirements; as we don’t have our own product we rely on our ability to satisfy and exceed customers needs to ensure we get the next order and continue growing our business.” Go to www.demm.co.nz/enquiry quote:

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D111128

CAD/CAM/CNC

Novamech invests in new laser scanning technology For the past two years Nova Mechanical Design (Novamech) has been providing a terrestrial 3D laser scanning service, using a Leica HSD instrument. The company has been focusing on mechanical plants and systems such as piping and structures. This service can be used in the construction phase or to conduct current status surveys of mechanical structures. The data gained is then processed with a number of high-end 3D CAD packages to provide users with meaningful and concise information on their plant, structure or asset. This service has an accuracy of ±2mm within a range up to 300m. “During this time Novamech has had a goal of offering a higher level of accuracy to our laser scanning engineering service, thereby providing a comprehensive one stop shop for mechanical laser scanning,” says Novamech’s Director Nick Bush. Recently, the company has purchased a Romer SI PCMM arm with integrated laser scanning and its engineers have undergone training to provide reverse engineering, part inspection and Nurb surface 3D modeling using PolyWorks v12 software. Some of the major manufactures using this software include Boeing, NASA, Bell Helicopters, Ford, Toyota, Audi, and VW. “So, we are in good company and Novamech is excited about being able to offer this cutting edge technology to companies

here in New Zealand,” says Nick Bush. According to Nick the accuracy that the Romer PCMM arm is 0.05mm when using the cmm probe function and 0.1mm when laser scanning. The measurement data is then processed with PolyWorks v12 and 3D models are produced that can be used by almost all current CAD packages. It is also easily possible to produce component inspection reports. “In the future we hope to offer an even higher level of accuracy directly to New Zealand’s industry. However, at present we can only access higher accuracy though our product support network,” says Nick. Typical applications for this sophisticated technology are reverse engineering of parts no longer available and mould tool profile capture in cases where no 3D CAM model is available. “We can accurately measure anything within a 1.25m radius, which opens up many measuring jobs that were previously placed in the too-hard basket. The instrument is fully portable so we can come to our customers if required or the components can be shipped to our South Auckland facility.” Novamech is an Auckland-based mechanical design service and design consultancy business with “an enviable reputation for delivering high quality mechanical design services and offering some of the cutting edge technological services that

only a specialist can effectively provide,” “From minor drawing changes to major 3D design projects Novamech’s team of engineers share a passion for sound design practice.” The company works with tools such as SolidWorks Premium, PolyWorks v12, Leica HDS, Romer and Hexagon metrology. “For now and the foreseeable future Novamech will endeavors to provide services to the engineering community that would otherwise not be available in New Zealand.” Go to www.demm.co.nz/enquiry quote: D111129

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CAD/CAM/CNC

Software lifecycle approach to the structural supply chain Building Information Modelling (BIM) is transforming the way we work in the building and construction industry. In most small and large scale construction projects, steel provides an important deliverable to project completion. Use of technology throughout the project to the construction site, is though variable across the contract. Indeed, the AEC market is competitive with engineering companies tending to be risk-averse when awarding contracts, with tight controls through fixed-price subcontracts with structural detailers and steel fabricators. This characteristic is as much as about historical contracting, operating and technical strategies, as it is about sharing risk/reward. One key aspect to a successful BIM project that has not been considered in full to date is the fabrication knowledge needed to enable effective design implementation, tight project controls and on-time construction. In effect, there is much to be gained from increased collaboration between engineers, suppliers and contractors to enable increased traceability and material cost savings through the supply chain. For collaboration to work effectively, technology is an important enabler. There is therefore a dichotomy in project execution. Pass the risk to contractor or utilise open reimbursable contracts, where architects, engineering, fabricators and construction teams can harness the data and information through the project to the benefit of all â&#x20AC;&#x201C; to reduce cost, risk and schedule. When multiple contractors are used, the project controls further increase the complexity of controlling communication, delivery to site and construction management within what are always very demanding project schedules.

Important questions to consider So how can the complex structural supply chain be organised to benefit all, bring the competitive advantages throughout contracting, while delivering complete project management to the engineering teams involved in delivering structural assets? How can steel material costs be reduced? How and what can detailing and fabricating companies deliver value into engineering, and also content into construction? How is the impact of change reconciled more effectively? How can site rework be reduced? The answers of course are not simple, without changes to both business practice and integration into the supply chain to maximising the opportunity for cost savings. By looking at each stage in turn, in design, fabrication and construction, we can start to see what the projects of tomorrow can offer. By first looking at the structural design cycle workflow, the value characteristics can be first seen through design model interoperability; from design systems to analysis, and detailing with joint/ connection design. Here standards such as IFC, CIS-2 and SDNF formats enable good levels of interoperability, but workflows without a common methodology and collaborative work sharing still give rise to design fragmentation. This is further

November 2011

Integrating fabrication work processes

complicated with the issue of the structure, to one or more detailing companies. Here manual issue of drawings prevail; electronically sharing of the structural design model is not as common. As a result, increased man-hours for model re-entry into the detailing system of choice, error and a loss of accuracy reflect in estimation inaccuracies, production and construction planning â&#x20AC;&#x201C; causing avoidable and costly rework. However, while engineering companies are increasingly looking for more detail and clash-free resolution in the multi-discipline BIM model, it is only the detailing/fabricating companies that have the experience and knowledge to provide this. With more detail comes more accuracy of information and quality of design to enable realisation of cost savings through procurement into construction. For example, faster and more accurate steel estimates much earlier in the project, and improved knowledge base to support project planning, such as constructability and sequencing reviews. Secondly, when the structure is contracted to the fabricator, the engineering company relies on information from the fabricator to support project plans. This information ranges from material estimates, status, completion, dispatch, delivery to site etc., but tends to be static and document receipt based. But what if a change happens? What is the impact of change? How best to communicate change? Does the fabricator have the capacity or agility to accept change to a new timeframe? Access to real-time fabrication information in these and many other instances could be invaluable for project managers to assess the impact of change, work with the fabricators to align to site requirements and manage the cost of change. Finally, as the structure goes to site, many questions need to be formulated to enable timely construction

by the planners and erection crews. Questions like: Is the structure on site? Where is the structure on site? What are the sub-structures that make up field erection or workface plans? How is the structure assembled and erected? How is impact of change reconciled on site? The knowledge base for each stage comes from the work processes that go into fabrication. Today, there is an opportunity for change, if the workflows can be harnessed. In the field of steelwork detailing and fabrication management, AceCad Software has been at the forefront of technological innovation for over 25 years. In 2008, AceCad decided it needed to take a close look at its business and its position within the structural steel software sector. It re-evaluated the technology at the heart of its products, but also examined what the steel fabrication industry needed to drive it forward. AceCad worked with its customers to identify where bottlenecks were occurring and drew on the vast experience of its in-house StruServices detailing team, which has worked on a wide range of worldwide contracts.

Unique lifecycle approach to the steel project The result was a unique lifecycle approach to the steel project through its StruAEC solution. StruAEC is positioned to enable engineering, fabrication and construction companies to collaborate much more effectively than traditional methods to reduce steelwork design, fabrication and construction schedules, and costs. With its latest evolution series release of software, on a modern, open .NET platform, AceCad Software provides the products and the work tools that enable project teams to fully implement BIM projects across the steelwork lifecycle. Implemented in full through the project, the environment provides a fully managed and collaborative workflow approach to release data and information to the

CAD/CAM/CNC AceCad’s lifecycle approach to the Structural Supply Chain

project – on demand. With StruEngineer evolution, the engineer’s gateway to the 3D structural model, the conceptual design stage can effectively be realised with greater accuracy, much earlier in the project. At its heart is an integration platform that provides BIM interoperability and managed issue through change variations, between the design, analysis, detailed and fabrication content workflows. For complete interoperability an open approach is needed. The integration platform naturally supports advanced implementations of the IFC, CIS-2, SDNF standards, in addition to dedicated and enriched data exchange with other leading

software product file formats. Furthermore, all BIM disciplines can collaborate with the use of a global multi-user system to gain instant progress of the detailed model, simply for visualisation and enquiry purposes, or for active mark-up and RFI (Request For Information) management. Importantly, control of the structural model is back with the engineer to enable controlled issue and distribution to multiple detailers/fabricators of each work package. Once detailed, the completed model with deliverables, in part or in full, can be checked back in project server for final review and signoff. 3D modelling in either StruEngineer or StruCad evolution could not be simpler, with all the advanced parametric modelling tools you would imagine. With automatic connection modelling facilities, moment connection design and estimating capabilities, projects can be designed and costed much earlier, all with the impact of design variations fully managed. All deliverables, including general arrangements, fabrication

drawings, CNC data and bill of materials reports are generated automatically from the 3D model. For project engineers and managers, project status enquiries can be achieved by contract from the fabricator, enabling full decision support. Through online login to the fabricator using StruM.I.S evolution, AceCad’s fabrication management system, real-time updates of the 3D structural model can be utilised, for example to reflect production status, undertake impact analysis of design changes, priority changes, and steel order verifications etc. Such capability enables true traceability and transparency for all contract data. Communication across the project enterprise is provided for with StruWalker evolution: a free downloadable BIM multi-model collaboration tool. StruWalker enables review teams to visualise, verify and contribute to the model. Any mark-ups or data changes can be synchronised bi-directionally to/from the StruCad model. With multiple standard format imports support and clash checking tools, StruWalker enables construction teams to truly benefit from the data within the model. Together with construction planning tools and the ability to create sequences and videos, StruWalker provides is a must for construction teams that use BIM. Article by Paul Daynes, Head of Engineering and Global Business Partners, AceCad Software Limited Go to www.demm.co.nz/enquiry quote:

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D111131

Engineering Ltd

ed ! "I'm programm

my set " h is n fi I y ll a r tu So na Integrators of specialised robot systems Phone: (64) 9 826 0580 Web: www.carbines.co.nz

CAD/CAM/CNC

New xPC Target 5.0 now available MathWorks announced the availability of xPC Target 5.0, which provides support for FPGAs, extending the rapid prototyping workflow for Model-Based Design. Now engineers can leverage automatically generated HDL to program FPGA boards from Simulink models for execution on xPC Target Turnkey systems. As a result, they can prototype and validate their Simulink designs in a highperformance, real-time target system and speed up their development cycle. With xPC Target, computationally intensive algorithms can now run on FPGA boards that provide speed and flexibility. Control systems engineers can program FPGA boards for xPC Target Turnkey systems using code generated by Simulink HDL Coder, accelerating designs to meet higher performance requirements. The new capability offers the ability to reconfigure digital input/output (I/O) modules and to implement high speed algorithms for controls or signal processing within realtime testing and prototyping environments. In addition to FPGA support, other key new product features include: task-level profiling of execution times to help with load balancing, support for cameras based on the Camera Link interface standard, image acquisition from USB webcams and ability to send and receive UDP packets in real time. Go to www.demm.co.nz/enquiry quote: D111132

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Programming FPGA boards for xPC Target Turnkey real-time target machines using Simulink HDL Coder Workflow Advisor.

PC-based control: The scalable CNC package

The CNC solution from Beckhoff is fully scalable, from machine tool operating panels to safe drive technology.

A new comprehensive package of scalable CNC control solutions for machine tools comes from Beckhoff. The CNC solution is based on the Beckhoff PC Control technology, which integrates all machine functions on a single hardware and software platform. The CNC package is modular and finely scalable and offers an efficient control solution for any task, from compact dental processing centres to complex plasma cutting machines. Frank Saueressig, Product Manager CNC at Beckhoff Automation, comments: “Our CNC solution is now complete. By expanding our drive technology and integrating safety technology into the I/O and motion layer we are now able to offer individually tailored, complete solution packages for the whole range of machine tools.”

November 2011

CNC control systems from Beckhoff have been tried and tested in many sectors, including woodworking and cutting/welding machines. “Our next objective is to conquer the machine tool market by positioning our flexible, PC-based solution as an alternative to conventional CNC providers: PC-based control from Beckhoff offers the basis for integrating visualisation, safety technology, measurement technology, condition monitoring and robotics into machine controllers, in addition to PLC, motion and CNC control.” The scalability of the Beckhoff CNC solution covers the entire control system: 1. Software TwinCAT offers a modular software

architecture for PLC, motion and CNC functions. 2. PC hardware Scalable performance for any application: from compact embedded PCs with integrated I/O interface to industrial PCs with multi-core processors. 3. Operating panel A wide range of control panels is available for operation and monitoring: from basic touch panels to CNC-specific panels for machine tools. 4. Communication The EtherCAT high-speed fieldbus integrates all areas of operation: I/O, motion and safety. Conventional fieldbus or industrial Ethernet systems such as Profibus or Profinet can be integrated via EtherCAT Terminals. 5. Drive technology Performance-related drive solutions: from servo and stepper motor connection in the format of a standard bus terminal to the AX5000 EtherCAT drive series for the medium and upper power range (up to 118 kW), with associated servomotors. 6. Safety technology The scalable safety solution TwinSafe: from safety I/O terminals to complex PC-based safety controllers. TwinCAT 3, the latest software generation from Beckhoff, offers users a modular, multi-core-capable

control architecture with a high degree of integration for PLC, motion and CNC functionalities. The multichannel architecture of TwinCAT CNC – with the option of flexible exchange of axes and spindles – offers the required flexibility for realising different functions on the same machine. The CNC was expanded with highspeed cutting (HSC) functionality for optimised milling cutting of free-form surfaces. The TwinCAT Kinematic Transformation library enables robot kinematic systems to be mapped in software for seamless integration into the control system. The engineering platform of TwinCAT 3 is fully integrated in Visual Studio from Microsoft. Using this familiar framework as a basis opens up extended programming options: In addition to the object-oriented extensions of IEC 61131-3, TwinCAT 3 now also offers the languages of the IT world, i.e. C and C++, so that C code can be integrated in the CNC, for example. Through the integration of Matlab/Simulink, TwinCAT 3 is now also suitable for application in scientific fields, such as digital simulation of complex technical systems. Go to www.demm.co.nz/enquiry quote: D111132a

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MAINTENANCE MATTERS

“YOU ARE NOT ALONE.” The Manukau Institute of Technology and the Christchurch Polytechnic Institute of Technology have scheduled a free seminar for Christchurch’s industry in November. Stefan Richter talked to Larry Wiechern about how this initiative can set up the city's businesses for the future. DEMM: Who had the initial idea to set up the seminar? LW: We had a general discussion here at the Manukau Institute of Technology about how this year’s one day seminars were going within the maintenance and reliability centre. Suddenly Peter Quigg, Director, Academic Operations, asked, “Why shouldn’t we run a free seminar for the people of Christchurch?” After some thought of what topics would be relevant to helping out, we came up with an agenda called “Preparing your Business for the Future”. DEMM: What are the main goals of your seminar? How do you want to help? LW: We intend to introduce topics that are relevant to the industry of Christchurch, topics which can make an immediate impact on the local industry if the offered support and information is taken on board. The final topic on our agenda, getting to the root cause of any problem, is a very nice way to wrap up the seminar before moving on to a networking opportunity. Here guest speakers from throughout NZ and Australia will be available to the attending engineers from Christchurch to expand on certain topics and answer upcoming questions in more depth. DEMM: Where do you see the main problems businesses and engineering companies are facing in Christchurch? LW: When companies are in a position of having to resite plants and machines, they need to be aware of all the pitfalls before the actual move is carried out, to prevent ongoing problems with ground movement causing machines to move out of alignment. When that happens, the rejection rate in production is sure to increase, which of course will raise the cost of the overall product. The other area of misalignment of rotating equipment, such as coupling misalignment, can affect the business through higher power costs if not taken into consideration during installation or scheduled inspection. Often companies have no idea they have an air leak and are unaware of the high hidden cost of that leak to their industry, so the topic of ultrasonics

is going to be extremely valuable to bring to the attention of the seminar attendees. Ground movement to poorly supported pipe work can lead to these sorts of problems going undetected. Infrared is another very useful technology for identifying problems unseen by our eyes, especially in electrical applications and applications involving insulation. But this technology also supports other techniques when it comes to looking at the efficient use of plants and equipment. Vibration is well understood by the engineers of Christchurch, but it is also the language of machines and how they communicate to us their state of health. Once you break down all the various frequencies from the rotating components such as bearings, couplings, gears and other associated parts within that machine you will have a very good idea of its current state of health, especially when these life signs are trended over time. DEMM: Do you know of other sources available to help the engineering companies in this area? LW: I would strongly suggest they make contact and support the various training opportunities offered by CPIT, the Christchurch Polytechnic Institute of Technology. They can also get involved with organisations such as VANZ, the Vibration Association of NZ, and the Maintenance Society of NZ, MESNZ. These organisations freely provide support information and help. DEMM: What is your message to Christchurch? LW: You are not alone, all people throughout NZ strongly feel for you, and if we can help in any way we will endeavour to do so. All the guest speakers have given up their time and produced a paper that is going to be relevant and useful to all attendees. What is more, the attendance of the seminar is free of charge, because all related costs are paid by the speakers or their companies. I think that contribution speaks for itself and shows how we feel for the people of Christchurch at this time.

“If we can help Christchurch in any way we will endeavour to do so.” Larry Wiechern, Lecturer - Modern Apprenticeships, School of Mechanical Engineering and Trades, Manukau Institute of Technology.

Preparing your business for the future – Free seminar for Christchurch Date: Tuesday, 29 November 2011 Venue: Christchurch Polytechnic Institute of Technology Time: 8.30am – 4.10pm The agenda of the seminar: • Alignment and installation of plant and machinery. • Alignment of rotating equipment, cost of power usage and equipment through misalignment. • Ultrasonics – cost of leaks and associated problems. How do I know I have a leak and how much is it costing me? • Infrared – installation of electrical equipment. Is it safe and not likely to cause further problems? • Vibration Analysis – Now I have installed or re-sited my machines, how do I know all is functioning as it should? • Industry alerts. • RCA – Getting to the root cause to prevent problems occurring again. Presenters include: Allan Paterson – Calibration Centre Glen Pepper – Sirf RT – Industrial Maintenance Round Table NZ Dr James Neal – University of Waikato Dr Ken Jackson – Science Directions Kevern Rump – Commtest Larry Wiechern – Manukau Institute of Technology Melissa Cameron – Sirf RT Australia Contact: Cheryl McLeod on cheryl.mcleod@manukau.ac.nz or phone 09 968 8654.

MAINTENANCE MATTERS

Lubricant line-up for industrial applications Penrite is expanding the range of lubricants to suit commercial and industrial applications such

as agriculture, mining and machining. Among the Penrite fluids used in industrial applications are hydraulic oils. The primary application of hydraulic oil is to transmit force applied at one point in a system to another. As well as this, it must also protect seals, lubricate and transfer heat. The viscosity of the oil is important, to ensure efficient power transfer. If too heavy, high-pressure drops may occur, the system becomes sluggish and power usage increases. If too light, then wear can be a problem, efficiency decreases and leaks may occur. Penrite’s hydraulic oils are designed for use in a wide range of hydraulic systems under various ambient temperatures and are available in ISO grades of 32, 46, 68 and 100. Industrial gear oils, typically API GL-3 oils,

use low doses of conventional sulphur-phosphorus additives. They tend to be straight grade oils. Penrite produce premium, extreme pressure industrial gear oils, from ISO 150 to 680. Compressors may use a multitude of products, depending on the type of compressor and its service; this includes motor oils, hydraulic oils, ATFs and other specialised fluids. Penrite stock many oils suitable for compressors, but they vary widely depending on the application. Cutting fluids are straight petroleum oils with specialised additives or ‘soluble oils’ which are designed for use in water. They are used for many different machining applications and come in a wide range of viscosities and additive types. Penrite manufacture honing oil and soluble oil for various cutting applications. The use of the wrong industrial oil in machinery can cause wear, failure, carbon deposits and other undesirable chemical reactions, so great care must be taken when selecting fluids Go to www.demm.co.nz/enquiry quote:

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D111134

Large range of standard seals available online Sealnet, a Division of Oz Seals Australia, announce they have the widest range of “standard” hydraulic and pneumatics seals, packings, mechanical seals, seal kits and customised special seals available from any manufacturer in the world. The extensive range of seals is now available via the new online OzStore at www.sealnet.com.au. The Sealnet OzStore is user-friendly and makes for a simple, practical and economic way to order standard seal lines for any application. The company manufacture seals and sealing systems for hydraulic

applications, heavy duty hydraulics, pneumatic applications, forklift trucks, road construction machinery, injection moulding machines, presses, diesel engines, propelling shafts, mining props, valve and pump seals. All seal types, in all sizes and materials that are shown on the website are available off the shelf and can be shipped to anywhere around the world. For special orders, the manufacturer is able to manufacture any item to suit specific requirements and hold them in-store for agreed repeat orders. The company even offers a one hour service if required.

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November 2011

INDUSTRIAL AIR SYSTEMS NZ

Material quality is vital to the capability, performance and life of a seal and, so the manufacturer says, an OzSeals seal will generally outlast the equipment it is purchased for. The company also develop their own, state-of-the-art seal manufacturing

systems, and these manufacturing systems and specific CNC software are available to be purchased or leased depending on the user’s location. Go to www.demm.co.nz/ enquiry quote: D111134a

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Pumping up efficiency Anyone involved in manufacturing knows how crucial reliable, wellfunctioning pumps are for keeping production on track and on schedule. However, fewer are aware of the massive energy-saving opportunities often present in pumping systems. Of all the economic electricity saving opportunities in New Zealand industry, around 40 percent are in liquid pumping systems. Given this, it makes sense for EECA to help industry improve its bottom line and productivity by improving pumping systems efficiency. The pump unit may be operating reliably and to specification, but is it sized correctly for the application? Is the drive system between the motor and pump efficient? Is the pump pushing liquids at higher than necessary flow rates? Is cavitation occurring in the system?

Programme partners We’ve recently approved a number of engineers and energy auditors with experience in pumping systems, to work with industry under EECA’s (subsidised) auditing and project implementation programmes. By choosing an EECA Programme Partner you’ll be engaging someone who knows how to improve the performance of a range of different pumping systems, and is also au fait with how EECA can assist. EECA offers several funding options that can help reduce the risk for businesses wanting to invest in pumping system efficiency. Provided certain criteria are met, we can help fund a base-level system audit, a more in-depth system audit, a feasibility study on a system improvement, or project implementation.

Examples throughout industry

TOTALLY SAFE NO WORRIES

One company that has profited from investing in pumping efficiency is Rohm and Haas NZ Limited. An energy audit highlighted that significant electricity savings could be achieved through more efficient control of the cooling water pump at its Auckland plant. The pumping system was using 27kW to 35kW of power to pump water through its cooling system. But between batches when no cooling was needed, the pump still used 19kW of energy. A variable speed drive (VSD) was fitted to the circulation pump to allow the running speed to match the cooling requirements. The project reduced electricity usage on the pumping system by 28 percent and had a simple payback period of 1.7 years. A project we ran with the Aggregate and Quarry Association led to several profitable projects in quarries. In one instance we found that eliminating double pumping brought energy savings worth $25,000 a year (with a payback of 1.2 years). Another quarry found that fitting a VSD control system on its process water pond pump (and a level sensor), brought annual energy savings worth $25,000, and a payback of just over a year.

Our Nevastane range of food grade lubricants are guaranteed safe which eliminates any worries for you and your business. Nevastane products are guaranteed NSF H1 registered, they contain no compound of animal origin, GMO and Allergen Free. But what really sets us apart from our competitors is our exceptional service, distribution network, turnaround times and local technical support.

Improve your pumping system expertise

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Helping improve capability – among both managers in industry and energy service providers – continues to be a major focus for EECA’s industrial programme. If you’re a plant or engineering manager and want to learn more about pump efficiency, check out the University of Waikato’s Best Practice in Industrial Pump Systems one-day workshop on 18 Nov 2011. Following the “programme partner” model that EECA has adopted for compressed air and now pumping systems, we’ll be looking soon at fan systems in industry. If you’re a service provider and would like to become an EECA Programme Partner to improve fan efficiency, a great way to upskill yourself is via the Best Practice in Industrial Fan Systems course run also by the University of Waikato. This course is for people who want an in-depth knowledge of fan systems and includes a four-day lecture and laboratory component on 14 – 17 November. See www.eecabusiness. govt.nz/training to find out more about upcoming courses. For more information on EECA programmes for motorised systems, see www.eecabusiness.govt.nz/motorsystems. Article by Rod Treder, Industrial Programme Manager, Energy Efficiency and Conservation Authority

MAINTENANCE MATTERS

Maintenance on the go MEX has released an asset management application for the Apple iPad to significantly enhance operational efficiency for businesses by allowing mobile workers to access the MEX platform on the go. The new iPad app provides a convenient asset management tool that cuts downtime and streamlines the resource management process to allow for instant updates to the client’s MEX platform. Company CEO and founder Stephen Ninnes says, “Asset managers lose approximately ten hours each week travelling to worksites and back, this equates to 592 hours in lost productivity each year per employee. The MEX iPad application brings our asset management platform to workers wherever they may be, so they can access information and record critical data on-site and whilst on the move.” The MEX iPad application links in with a client’s existing MEX system allowing for paperless work to be done. Any updates to the iPad app will

inform tradesmen or field workers of all new work immediately. With new application, workers will have far greater control over maintenance operations, including: assets, work orders, purchasing and reporting. Stephen Ninnes adds, “One of the biggest contributors for causing errors in the workplace is not recording the correct details of a task, which has a knock-on impact onto subsequent actions. By allowing workers to revise data directly from their location, downtime is cut and the risk of inaccurate recording or even forgetting vital information is reduced. Other staff members can also immediately perform action on any new updates. The introduction of a mobile maintenance management system to businesses will reduce counter productivity by allowing real-time updates to the asset management platform.” MEX has been providing computerised maintenance management solutions to businesses across a range of industries for over 15 years and has evolved with the

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November 2011

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changing needs of these industries. The MEX iPad application is the next step in this evolution. “The iPad is fantastic as an entertainment device but there are also many opportunities for businesses to make use of this tool. However, many business apps are just enlarged copies of the iPhone version. What MEX has done is to complement the high functionality of the iPad and adapted our maintenance software to work specifically on this platform,” says Stephen Ninnes. Medical Equipment Management CEO Trevor Riessen has been beta testing the new application for about six months and summarises his experience. “This one is a winner. Our company MEM have been beta testing MEX for iPad in the field for some time and we are very impressed. Once fully rolled out in our company, MEX for the iPad will be used in the field by our Biomed Technicians and will greatly increase our efficiency, quality and customer service.”

Overview of the benefits of MEX for the iPad: • Elimination of information double-handling. • Improved quality of communication. • Paperless system for work orders, forms and reports. • Increased time efficiency; there is no longer a need to wait until you get back at your desk to enter or receive data. For example; you can inform tradesmen of new work immediately. • Convenience, especially for MEX users who don’t regularly sit at a desk or use a desktop computer. • Increased data integrity, allows users to enter data while it is fresh in their minds. To download the application for free, simply search for “MEX” in the App Store or check www.mex.com.au for more details. Go to www.demm.co.nz/ enquiry quote: D111136

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Looking for staff? Phone or email Frank Atkinson 09 477 0362 or frank@adrenalin.co.nz

MAINTENANCE MATTERS

How is your grease doing? Grease operating life is the decisive factor in maintenance. A new grease sensor incorporating an electronic evaluation system enables the condition of grease in bearings to be analysed during operation. Users now have the ability to precisely plan the schedule for replacing grease and to detect any changes in the condition of the grease long before any damage to the rolling bearing occurs. Grease will be replaced while taking actual requirements into consideration and not according to defined time periods. This reduces outlay and costs and is also beneficial to the environment and resources. Downtimes that are attributed to operational disturbances are reduced as well as the cost for lubricants, maintenance and replacement parts. At the same time, the degree of utilisation and efficiency of machinery increases.

usually re-lubricated halfway through the so-called grease operating life. The great disadvantage of this procedure is that absolutely nothing is known about the condition of the grease. Up to now, users could only receive information about the grease in bearings by taking samples and undertaking costly and time-consuming analyses of these samples in a laboratory. The grease sensor now enables the condition of the lubricant to be analysed immediately during bearing operation. The optical near-infrared reflection method is used here. The process, developed in conjunction with the Fraunhofer Institut for Electronic Nano Systems (ENAS) in

in rolling bearings. The know-how involved is not only in the setup of the sensor, rather in particular in the evaluation of the measured signals.

This measurement method can be used for around 95 percent of greases available on the market. The new sensor was developed

Reliability and Maintenance

The output analog signal quickly informs about the condition of the grease.

The grease undergoes rotationally symmetrical irradiation with certain wavelengths from the sensor. The sensor head is embedded in the lubricant during this procedure. The reflected light is measured perpendicular to the grease. This enables shadow effects and surface inhomogeneities to be completely excluded. The reflected light is evaluated in terms of the quality of the grease. Power is supplied and signals transmitted from the sensor to the evaluation cable by means of a cable. A wireless solution can also be provided. Four grease parameters can be detected using the sensor: Water content, cloudiness, wear (thermal or mechanical wear) and temperature. An analog signal (4-20 mA) is The grease sensor and electronic evaluation system enable changes in the condition generated from these parameters in of the grease to be detected long before damage occurs to the rolling bearing. the electronic evaluation system, which displays the condition of the grease The grease operating life is the Chemnitz, Germany, is based on the quickly and simply. A digital signal decisive value during preventive infrared process used in laboratories can be generated that indicates poor/ maintenance if it is shorter than the to measure grease qualityThe and wasknowledge good grease quality pathby setting for a trigger bearing life. In this case, bearings are adapted for online measurements threshold (limit value).

by Schaeffler Group Industrial in conjunction with Freudenberg Dichtungs- und Schwingungstechnik and Klüber Lubrication München. These companies have validated the method for a wide variety of greases. The online evaluation of the condition of the grease enables users to draw conclusions about any changes that may suddenly occur and, due to the digital signal, quickly react to them. Options for optimising the design and selection of the rolling bearing also quickly become apparent by using the method. Go to www.demm.co.nz/ enquiry quote: D111137

training courses

•

ask our U us about PSK Mem ILL - VI ber Principle setup of the optical sensor head. staff in their work environment Prog ship ram! Training Needs Analysis: skills improvement for your staff today

The knowledge path for staff in their work environment

Needs Analysis (TNA) starts with a good initial understanding of Training Needs Analysis: skills improvement for yourTraining staff today

where your staff is today by assessing their training needs through a progressive structured approach to competency skillby assessment and where they need to Training Needs Analysis (TNA) starts with a good initialand understanding of where your staff isand today be tostructured attain optimum planttoperformance. assessing their training needs through a progressive and approach competency and skill

assessment and where they need to be to attain optimum plant performance. The TNA enables this crucial understanding by combining SKF Reliability Systems experiThe TNA enables this crucial understanding by combining SKF Reliability Systems ence in training and our knowledge of maintenance and reliability. experience in training and our knowledge of maintenance and reliability. • Classroom and onsite courses with hands-on applications directly • Classroom andtraining onsite training courses with hands-on applications directly transferable to the transferable toworkplace the workplace • Selflearning paced learning and computer courses • Self paced throughthrough online online and computer basedbased courses • Customised courses specific to your industry and application • Customised courses specific to your industry and application • Comprehensive courses that cover all aspects of machine reliability from asset • Comprehensive courses that cover all aspects of machine reliability from asset management to basic maintenance skills management to basic maintenance skills • Nationally and internationally accredited courses • Nationally internationally accredited courses • 20and expert instructors who have 25+ years teaching experience • 20 expert instructors have 25+ yearsproven teaching • Quality processwho developed through leanexperience 6 Sigma and ISA 9001 techniques • Quality process developed through proven lean 6 Sigma and ISA 9001 techniques For further information on Public Course or to organise an Onsite Course:

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For further information to organise course Phone 03 9269or0763 or Emaila rs.marketing@skf.com Phone 0800 753 872 or email marketing.skfnz@skf.com

MAINTENANCE MATTERS

Infrared thermometers with Bluetooth connectivity Land Instruments International, a unit of Ametek, has announced efficiency and accuracy improvements to its Cyclops portable infrared thermometers for non-contact industrial temperature measurement in the 200°C to 3000°C range. All models now include Bluetooth connectivity as a standard feature. This eliminates the need for cable connection to a recording device, making them easier and safer to use. Two new models, 160B+ and 100B+, have the stability to resolve temperatures in 0.1°C increments, improving capabilities as transfer standard instruments in calibration laboratories. Any New Cyclops Models 100B+ (shown) and 160B+ have enhanced firmmodel can be supplied with full calibration ware to improve use as transfer standard instruments. certification, traceable to National Standards, from Land Instruments’ accredited laboratory. The reliable, battery-powered thermometers are used in a wide range of industries including primary and secondary metals, glass, petrochemical, plastics and laboratory/research and development. They have precision, narrow field of view continuously focusable optics with through-the-lens sighting for accurate sample point selection. Long-term drift-free measurement assures confidence in the readings. The six thermometers in the range include special purpose units for molten metals and in-furnace measurements. Advanced spectral filtering eliminates the distorting effects of water vapor in the atmosphere. Their rugged casings are designed to withstand harsh environments. Go to www.demm.co.nz/enquiry quote: D111138

•

Model 055B Meltmaster is specially designed for accurate measurement of liquid metal temperatures.

Metalworking applications include precise temperature monitoring for induction bolt heating to reduce cost and relieve pre-load stress.

Chain hoists for industrial applications Stratalign Limited is the sole New Zealand agent for both the Nitchi and Balken electric chain hoists. Nitchi hoists have a well-proven record in all areas of industrial applications. One of the main explanations for the quiet long dependable life of the EC 4 series, are the helical gears in the first stage of the reduction gear system which reduces gear tooth impact and operating vibration. The over-lifting and over-lowering limit switches are one of the most important safety devices on an electric chain hoist. These comprise of three parts – the buffer springs located at both ends of the load chain, the limit lever that positively activates the limit switch system and the limit switches that instantly stops the hoists when over lifting or over lowering. Nitchi and Balken hoists are fitted with all these safety devices. The 4-1 speed ratio of the hoists dual speed models are ideal for a large variety of lifting applications with the slow speed working accurately when spotting the load to a desired position. By using the fast speed, the load can be quickly and efficiently handled. Available in single speed, dual speed, single phase and three phase, there is a hoist suited for all industrial applications. All models are also available direct coupled to motorised, geared or plain trolleys with mechanical devices. Stratalign Limited also stock the San-Ei range of Air Hoists. These hoists are inherently flame and explosion-proof in design. They have many applications in manufacturing, foundries, refineries, mining and paint booth areas where operating loads are near capacity or there is a need for high duty cycles. That is, where a hoist is required to be active almost constantly. Aluminum gantry systems, both the moveable and the collapsible units, are promoted by Stratalign Limited. Ideal units for both permanent or temporary applications, they can be moved into confined spaces and fully erected ready to lift loads up to 1500kg within five minutes. Stratalign’s comprehensive range of lifting and hoisting equipment includes magnetic lifters, chain blocks, lever hoists, crane scales, beam clamps, spring balancers and trolleys. Go to www.demm.co.nz/enquiry quote: D111138a

• 38

November 2011

MAINTENANCE MATTERS

Mounting bearings: Do it once, do it properly How you mount your bearings will determine the life and performance of the bearings in the long term. Proper bearing handling and mounting methods will prevent you from unplanned shutdowns and bearing failure that would cost you thousands of dollars.

Cleanliness: The first rule Cleanliness is the first rule of proper bearing handling. Whenever possible, keep the working environment clear of sand, sawdust, cement, corrosive substances, and high humidity. Prior to bearing installation, thoroughly clean and dry the shaft and housing. Cover exposed areas with plastic sheeting or lint-free cloth when you are not working with the bearing. New bearings should be kept in their packaging until mounting. Do not wash new bearings or remove the rust-inhibiting compound (except from the bore and the outer ring’s surface). Thoroughly inspect and clean used bearings prior to installation. Lubricants should be clean and fresh. Keep lubricant containers closed until the lubricant is needed. Use the right type and quantity of lubricants, as contaminated lubricants, or incorrect lubricant amounts, can cause early bearing failure.

Check shaft preparation Ensure the shaft size is within its specified tolerances before you mount a bearing. The bearing seat should be perfectly round, and the shaft should be clean and free from nicks and burrs. Inspect the shaft for damage that may have occurred when the previous bearing was dismounted. There are four basic methods for mounting bearings: mechanical, heating, hydraulic and oil injection. The correct method depends on bearing type and size.

Mechanical mounting Mechanical mounting is generally suitable for small (4” or less O.D.) bearings. Place a fitting tool sleeve against the inner ring and use a press or hammer to

advance the bearing to its proper location. Do not apply a sleeve to the outer raceway when mounting on a shaft, or to the inner raceway when mounting in a housing. Never mount a bearing by striking the bearing directly with a hammer. A spanner wrench, or impact spanner and lock nut, can be used to cold-mount small and mediumsize bearings with tapered seats.

dismounting from engineers, using the correct fitting and removal tools and techniques. This course is directly aligned with the NZQA Unit Standard 19873, Demonstrate knowledge of bearings used in machines and equipment and Unit Standard 19874, Service and replace bearings in machines and

equipment. SKF delivers the course under the auspice of Manukau Institute of Technology. Article by Rob Bertz, SKF @ ptitude Exchange. Go to www.demm.co.nz/ enquiry quote: D111139

•

Heat mounting Heat mounting is suitable for medium and large bearings, and for small bearings with cylindrical seating arrangements. A bearing temperature of 65.6 degrees C (150 degrees F) above shaft temperature (not to exceed 121.1 degrees C or 250 degrees F) should provide sufficient expansion for mounting. As the bearing cools, it contracts and tightly grips the shaft. It is important to regulate heat accurately, as excess heat destroys a bearing’s metallurgical properties. Heat mounting tools include induction heaters, ovens, heating rings and electric plates. Never use an open flame to heat a bearing.

Hydraulic mounting Hydraulic mounting uses hydraulic pressure rather than mechanical force to mount bearings. A hydraulic ram mounts small bearings with straight and tapered bores. A hydraulic nut is recommended for bearings with bore diameters over 50 mm (1.97 in.).

Oil injection The oil injection method (which is sometimes used in conjunction with hydraulic bearing mounting tools) is suitable for all bearings with tapered seating arrangements and for large bearings with withdrawal or adapter sleeves. Oil injection forces high pressure oil through a passage between the shaft and the bearing’s inner ring. This minimises friction between the two parts.

SKF training The SKF Bearing Technology and Maintenance course showcases the worlds best practice in bearings, principles of mounting and

Looking for an offsite training and seminar facility? Vause can help. The Vause Training Centre is a multi-purpose training and seminar facility that can be tailored to suit your needs. Our facilities include a main seminar room that can comfortably sit 30, and a 100 sq metre workshop area for hands-on training. Also available; a smaller break-out room, a kitchenette and lounge area for relaxing between training sessions. For information and bookings, please visit us at

www.vausetraining.co.nz 7 De Havilland Drive (West) Bell Block, New Plymouth, NZ 4312 P. 06 755 0752 F. 06 755 1666

MAINTENANCE MATTERS

Higher level training for maintenance apprentices In response to industry demand for more in-depth training for apprentices, Skills4Work has launched the Apprenticeship Plus programme for maintenance apprentices. This programme runs alongside the national level 4 qualification for mechanical and electrical apprentices with focus on giving the students the additional knowledge needed to become more pro-active in their approach to maintenance. There has been a lot of talk lately about the looming skills shortage and about the way the apprenticeship programme is structured. While I believe the current ITO system of training apprentices is a good vehicle for teaching specific disciplines such as hydraulics, welding or pneumatics at the workplace, it fails to teach the concept of maintenance and its

benefits. The new Apprenticeship Plus programme will address this by introducing subjects such as reliability engineering and how to take a structured approach to maintenance. It will also offer an understanding of lean maintenance. I believe this has huge advantages for industry and for future tradesmen. Employers will see increased reliability, less downtime and greater productivity through a better skilled workforce. Students will not only have a full understanding of good maintenance but also a recognition of that with 30 NZQA credits towards their level 5 advanced trade qualification should they wish to pursue that as their career progresses. It’s a win-win situation. The Apprenticeship Plus programme has been designed

to supplement the mainly workplace based mechanical and electrical apprenticeships for future maintenance technicians with four one-week block courses spread over a three year period. As with all Skills4Work maintenance programmes there are relevant unit standard outcomes, with the first course leading to level 4 unit standards. The final three courses lead to level 5 unit standards that can be used towards the electrical and mechanical level 5 advanced trade qualifications. The first intake for the programme will commence March 2012. Skills4Work has been successfully running high level maintenance training courses for several years. These skills learned during the formative years of an aspiring tradesman will embed an approach

Looking for financial assistance to up skill? Entering into training is a huge commitment, not only of money – but also time of time and effort. The financial pain can be eased however, with the help of the 2012 Competenz Scholarship. Competenz, the industry training organisation for the engineering and manufacturing industries, is calling for scholarship applications. Competenz has $1000 each to award to six ambitious individuals. This is the perfect opportunity for anyone with a Level 4 or 5 qualification, wanting to progress their career and up-skill to Level 5 or 6. Competenz also wants to give financial assistance to those who are skilled and experienced in their trade but missed out on qualifying when they were younger. • The scholarships are for those enrolled in any of the following courses between the 1st of October 2011 and the 1st of March 2012: • Level 5 National Certificate in Mechanical Engineering Level 6 NZ Diploma in Engineering in Engineering Practice • Assessment of prior learning – to achieve a Level 4 Mechanical Engineering related qualification. And to be eligible to apply, applicants must

November July 2011 2011

meet the following criteria: They are skilled and experienced in their trade, but missed out on gaining a qualification when they were younger. Or they have completed, or are due to complete, one of the following qualifications: • Level 4 or Level 5 National Certificate in Mechanical Engineering • Level 4 National Certificate in Fabrication • Level 4 National Certificate in Refrigeration and Air Conditioning • Level 4 National Certificate in Heating, Ventilation and Air Conditioning • Level 4 National Certificate in Locksmithing • Level 4 Fire Protection Sound like you or someone you know? For an application form, check out www.competenz.org.nz or call 0800 526 1800. Applications must be submitted by the January 23rd 2012, and successful applicants will be notified by the February 3rd 2012. Competenz is committed to supporting education and wants to ensure New Zealand’s engineering and manufacturing workers have the skills to lead rewarding careers.

to maintenance that will lead to greater professionalism and hence greater reliability. More details can be found on the Skills4Work web site www.skills4work.org.nz. Phil Hurford is Programme Manager of the Skills4Work Maintenance Excellence programme. p.hurford@skills4work.org.nz

MAINTENANCE MATTERS

It’s conference and committee time By Craig Carlyle

education, qualification setting, apprentices, advisory committees, lobbying, website, networking forums and of course our own national conference. We continue to develop and deliver our support and resources for maintenance engineers and have some great ideas for 2012. The need to refresh the roles with new blood is ongoing and the committee has established a healthy basis for encouraging individuals to step up without risk or fear of the unknown (from both sides). More representation from tradesmen and different engineering disciplines (electrical, electronic, hydraulics, pneumatics, PLC) is healthy for the society growth, but regardless of your background, if you think you have something to offer, you wish to put something back into industry, or if you see involvement as contributing to your own self-growth, go on, put your hand up. A variety of roles exist both within and outside of the committee and we would love to hear from you. Non executive roles can be co-opted at any time, so today’s good!

Craig Carlyle is secretary of MESNZ

By the time you read this, the focus of maintenance engineers, society members and attendees will be the National Maintenance Engineering Conference in Rotorua. The response to the annual event has again grown from previous years, exceeding expectations and validating the desire of engineers to “lift their game”. Let’s hope that tomorrow’s engineers lock into the desire for continuous improvement. This year’s MESNZ scholarship winners, Ben Vollebregt and Sanjeev Kumar, are two such candidates for future glory who richly deserve their joint 2011 scholarships. Look forward to next month’s magazine to hear more about these lads and the presentation of their awards at the National Conference. The National Conference is also AGM time for the society, which is a TIG (technical Interest Group) of IPENZ. The committee is a dynamic and practical group who work year-around on the society goals and the ongoing representation of engineers.

The committee is passionate about NOT falling into committee-think mentality and has built structures and processes to make committee membership attractive, fulfilling and worthwhile, while protecting the society’s aims and responsibilities. The committee is run along business lines with clear strategies, with roles assigned to individuals and individuals given the mandate to make decisions. Committee meetings are about summaries, not decisions. The roles are transferrable depending on requirements and documented for the benefit of newcomers. The roles range from the traditional elected executive positions (Chairman, Secretary, Treasurer), to committee roles, (newsletter, website, marketing, conference, education) and even non-committee where required. While the committee is relatively small, it has achieved a lot in 2011, representing maintenance engineers in other organisations (OHSIG, VANZ, IPENZ),

IS 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

INDUSTRY WATCH

Driving around the world on solar power

Electric motors turn the cogs of industry – but these days they are turning other wheels as well. Global issues with fossil fuel effect-andsupply are finally beginning to power up a serious electric car movement. SEW-Eurodrive NZ is a company that takes electric motors very seriously, providing NZ customers with a comprehensive range of modular electric motor and controller, power, size and drive configurations backed by around-the-clock technical support. SEW-Eurodrive NZ is proud to assist with the Bochum University team’s attempt to make the first ever circumnavigation of the globe in an autonomously solar-powered car. The NZ section of this journey will begin on 24th November from Auckland and, accompanied by electric car expert Mike Duke and a small team of students from Waikato University with their own experimental electric car, they will proceed down SH1, hopefully arriving at Bluff around 9th December. On reaching Christchurch the ensemble will be joined by the “made in Christchurch” Team SolarFern vehicle. At Bluff the Bochum car will be packed up for shipment to the USA and the next part of its year-

long adventure, meanwhile Team SolarFern will turn back northbound for Cape Reinga – an estimated journey of six days. They will attempt the Wellington-to-Auckland section in a single day – theoretically possible given good weather. This unprecedented flurry of solar/ electric activity on SH1 should provide the NZ motoring public with some food for thought. SolarFern was created by a small group of private enthusiasts and raced in the 2007 World Solar challenge with the distinction of sporting the oldest solar array in the event, having borrowed solar panels from the Hamilton-built 1993 Solar Kiwi car. This was their “plan B” solution, activated when anticipated sponsorship funding for a state-of-the-art commercial silicon array being specially built for them was withdrawn at the last minute. In true Kiwi fashion, even with this handicap, they out performed many well-financed teams using who were using much more powerful new solar arrays. Bochum University of Applied Sciences has a history of building and racing solar cars dating back to 1999, beginning with a combined student project undertaken with

www.nz.sew-eurodrive.com

Southbank University in London. At this point a future connection to NZ was formed as Mike Duke, then working on the project for Southbank, later moved to Waikato University in Hamilton bringing with him a wealth of talent, international experience and passion for the topic. In 2001 the first German solar car Mad Dog III was solely constructed by German students in London and participated in the epic World Solar Challenge (WSC) event run across the Australian continent from Darwin to Adelaide. Between 2001 and 2003 Bochum developed a new car called Hans Go! that placed fifth in the 2003 WSC, also winning the Technical Innovation Award presented by Australia’s Commonwealth Scientific and Industrial Research Organisation for their implemented telemetry system. They placed eighth in the 2005 WSC. Next came what they like to call “The Most Beautiful Solar Car in the World” – Solarworld-1, which was planned and built from 2005 to 2007. They placed fourth in the 2007 WSC and were awarded Best Design. In 2008 they came third in the North American Solar Challenge and received award for innovation and excellence in the fields of mechanics and electrical engineering. When not on the road in Australia or America, the most beautiful car in the world resides at the University of Applied Sciences Bochum, on display as a proud inspiration to others. In 2009 a new vehicle, the BOcruiser was made for the World Solar Challenge. Built with typical street-car dimensions and not designed as a race car, though still employing fibre-reinforced

Innovation arrives in NZ

Geared motors Industrial gear units Drive electronics Drive automation November 2011

EM5of5-Nov11

INDUSTRIAL DRIVE TECHNOLOGY

• • • •

composites, high-strength aluminium with newly developed wheel-hub motors, this “sun chariot” brought practical solar transport a step closer to everyday life. Now Bochum’s latest, even more ambitious, more conventionallooking two door, two seater, publicfriendly and solar-powered vehicle will soon be seen on NZ highways as part of its journey around the globe starting from Darwin with the 2011 WSC fleet on the 16th of October. Named SolarWorld Gran Turismo (SolarWorld GT) the car is facing a road journey of some 34,000km and two equatorial crossings to fulfil the official circumnavigation requirements for a place in the Guinness Book of World Records and gain a significant place in transport history. They hope that their example will transform the prevailing public perception of solar/electric cars from merely a motorsport oddity into a vision of achievable, potentially affordable and environmentally preferable personal transport reality. Essential factors of success in the Bochum project are the integrated interdisciplinary team work approach within the University, a great passion for what they are working on, and the continued support of their international sponsors such as SEW-Eurodrive.

SEW-Eurodrive are proud to be sponsors of the Solar Powered Car round the world challenge. The New Zealand leg starts November 24th Auckland to Invercargill.

INDUSTRY WATCH

Marketing: Where to start? Most businesses think of marketing as advertising, brochures or a website. While all these are great tools if used correctly within a broader marketing strategy, they are actually the final stage of delivery for your marketing activities. These tools are effectively where the marketing process ends and your sales process begins. They are the grey area, commonly known as “sales-andmarketing” (more on that later!). Implementing these tools without doing the real marketing work that needs to come first is a bit like turning on the lathe and expecting a product to magically appear. So just like any good engineering or manufacturing process, marketing needs to start with plenty of careful design and planning. Target Marketing Let’s just jump straight in here and say you’re all set to work on some

telling them what they want to know or what you want them to hear?

new marketing strategies to grow your business. There are a lot of different factors within your proposed marketing environment that need evaluating. Taking the time to accurately assess and define your target market is a great place to start. Now the tricky thing with engineering and manufacturing businesses is that you are not normally selling to people in the street (ie. retailing). Your customers are generally other businesses who use your product or service to improve what they are doing. That means you have to think a bit more carefully about who you are talking to and why – is your product going to help my business be more profitable? In a nutshell, target marketing is the art of standing in your ideal customer’s shoes and thinking about what they want from your business. Are you

Who is your ideal customer, really? Sometimes it’s easier to define your target market if you start by asking who you don’t want as a customer – bad debtors, low skilled, slow growing? Another approach is to think about your best customer, and define that person or business. What are they like? How do they operate? What do they like about your business? What do they want from you? Case study: But my product is perfect for everyone! That may be so but it is extremely difficult (and expensive) to market to everyone unless you have the budget and sales team of Nike or Coke. As SMEs, we need to be smarter and more targeted with our marketing strategies.

LOOKING FOR NEW BUSINESS AND SALES ENQUIRIES?

Before embarking on a strategic marketing programme, Prolan NZ, manufacturer of environmentally friendly lanolin lubricants, anti-seizes and corrosion inhibitors, correctly identified that their product is viable in virtually every industry you could name – boating, engineering, farming, home maintenance. However, the team at Prolan were wearing themselves thin and getting no real momentum for all their efforts. Through a strategic marketing approach we identified that engineers and farmers were their primary target markets. As a result they created a brochure and display material talking directly to engineers, in support of sales activities targeted at getting Prolan in front of their preferred engineering customers. They also created a brochure and display material talking directly to farmers, in support of sales activities targeted at presenting the Prolan range at farming industry events and to nationwide farming retailers. This target marketing approach enabled them to focus their effort and resources to get the “best bang for the buck” and increase their sales.

Contact Frank Atkinson Email / frank@adrenalin.co.nz DDI / (09) 477 0362

Article by Chantelle Laurent, Marketing Strategist, Formula One Results

JANUARY ISSUE: Water Treatment & Wastewater Systems • Pumps & Valves • Materials Handling • Industrial Coatings

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FROM THE MAIL BAG in association with

TelstraClear Pacific Bearings

17 November 2011 Manukau Institute of Technology, Auckland Content: Identification, Installation, Disassembly, Counterfeit bearings – it may be happening to you, Troubleshooting and failures. For more information or to register, contact Cheryl McLeod, phone 09 968 8654, Cheryl.mcleod@manukau.ac.nz

18th International Corrosion Congress

20-24 November 2011 Perth Convention Exhibition Centre, Australia The congress provides the latest information about corrosion and its mitigation. Go to www.18iccperth2011.com to find out more.

Dairy Innovation Summit

28-29 November 2011 Crowne Plaza, Auckland The theme of this year’s summit is “staying competitive in the functional dairy arena”. Visit www.conferenz.co.nz for more information.

The National Asset Performance Improvement Conference 2011

28-29 November 2011 Crowne Plaza Melbourne, Australia Liquid Learning present a case study driven conference focusing on the pursuit of business improvement initiatives through better management and maintenance of assets. www.liquidlearning.com.au

Pacific 2012 International Maritime Conference

31 January-02 February 2012 Sydney Convention & Exhibition Centre, Darling Harbour, Australia The conference provides an opportunity to discuss the latest developments in design, naval architecture, engineering, science and technology. Visit www.pacific2012imc.com for details.

Cleantech Forum 2012

27-29 February 2012 Park Hyatt, Melbourne, Australia The 8th Annual Australasian Cleantech Forum brings together clean tech companies, investors and energy users to discuss issues impacting cleantech investment. Go to www.terrapinn.com/2012/clean-tech-forum to find out more.

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. For more information: email: info@emex.co.nz, http://emex.co.nz/

www.pacific.org.nz

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

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

The article What’s happening with our trades? paints a gloomy picture of apprentices’ education and their experience with Technology education at school. But does it match the reality? Students in 2011 think differently, learn differently and have expectations of a career which are unlike those of generations before them. They are technically savvy, independent, and want jobs that suit their interests, offer security and that they can be proud of. If we want to get these students involved in engineering perhaps we should consider their needs and expectations rather than suggesting we educate them like their grandparents? There is no denying that while we are near the top of the OECD tables for average achievement at age 15, 40percent of young New Zealanders leave formal schooling without gaining even a NCEA Level 2 qualification. Amongst the OECD nations we have one of the lowest rates of participation in education and training for those aged 15-20. Achievement and participation are significantly lower for some groups, notably Māori and Pasifika boys. These significant concerns are recognised by the education sector. There is growing flexibility in the schooling system which can accommodate vocational pathways. Many schools already offer their students the opportunity to work towards industry qualifications through links with external providers, fitted within the school timetable. Technology teachers are making links with local industry both to reinforce what is required in a particular field and these experiences help to show students the relevance of their learning and offer glimpses of a possible future. The Ministry of Education has developed the Youth Guarantee initiative to address the loss of young people from the education system. The Ministry’s vision is focused on a clear and simple framework of vocational pathways to supplement existing academic routes. A number of industry groups offer cadetships to enable students to earn while they learn and over 350 companies support careers promotion by releasing upwards of 650 staff to support the curriculum and talk with students about what they do. This is a 21st century issue and I would encourage your readers to find ways to contribute to the work currently being undertaken to persuade our young people to consider a career in engineering at trade, technician and professional levels.

Email:_____________________________________________________________________

Yours sincerely

Postal ______________________________________________________________________

Angela Christie Director – Schools The Institution of Professional Engineers New Zealand Wellington

_______________________________________________________________________

Re: What’s happening with our trades – published September/October

November 2011

2011

ENGINEERS, MAINTENANCE MANAGERS, TRADESMEN, LINE MANAGERS, ASSET MANAGERS

Twenty eleven Lifting the Game of Maintenance Engineers in New Zealand Presentations from peers and experts on Lifting YOUR Game in Maintenance Management; Preventative Maintenance, Staff Management, Health and Safety Management, Training, Apprentices, as well as Technical innovations, practical applications and case studies. Trade Expo representing: engineering suppliers, careers and employment, hydraulics, pneumatics, electrical, bearings, software, preventative maintenance, condition monitoring, electric motors.

November 9/10

@ The Distinction Hotel, Rotorua PRICE: $680 + gst pp (accommodation not included) Bring extra colleagues for ONLY $400+gst pp

FREE PUBLIC ENTRY TO TRADE EXPO: Tuesday 8 November EXHIBITORS: participation from only from $550+GST (small business table top)

Contact Leanne Powley - Admin on Call P: 09 296 1333 | M: 021 134 6315 E: info@adminoncall.co.nz Proudly Supporting MESNZ

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SAVE 1,000

2500mm x 4mm

HYDRAULIC NC GUILLOTINES • Ezy-Set NC-89 Go-To back gauge with ﬁne adjustment • Rapid blade gap adjustment • Individual hydraulic hold downs • Swing away back gauge for long sheets • Shadow line lighting • 4 edge 9Crsi blade for stainless steel • Stroke counter & short stroke adjustment • 250mm throat shearing longer material • Three photo electric rear guarding

SAVE 2,000

HG-860B (S932) 2500mm x 6mm

16,800

SAVE 2,000

HG-2504 (S934)

HG-3204 (S935)

HG-3206 (S940)

3200 x 4mm

2500 x 4mm

23,500

17,500

SAVE 1,950

3200 x 6mm

28,000

HYDRAULIC PRESS BRAKE

HYDRAULIC NC PRESS BRAKE

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

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

PB-135B (S908G)

PB-160A (S910G)

SAVE 1,450

PB-820Y (S583A) 2500mm x 2mm

SAVE 1,450

9,500

PB-830A (S584A)

PB-1030 (S585)

2500 x 4mm

3050 x 3.2mm

17,500

19,950

SAVE 2,000

135T x 4000mm

SAVE 2,000

42,950

176T x 4000mm

62,900

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www.machineryhouse.co.nz MILLING MACHINES • 2 axis digital readout • 3hp, 240V motor (M603D) • 3hp, 415V motor (M604D) • 1270 x 254mm work table • NT30 spindle SAVE • X axis power feed $ 450 • Includes: halogen light, 150mm vice, coolant system, clamp kit, swarf tray • Travels: (X) 760mm (Y) 360mm (Z) 430mm

• 3 axis digital readout • 3hp 415V motor • 1370 x 254mm worktable • NT30 spindle • Variable 70-3500rpm • X axis power feed • Includes: halogen light, 150mm vice, coolant system, clamp kit, swarf tray • Travels: (X) 860mm (Y) 360mm (Z) 430mm

SAVE $ 950

SAVE 1,000

BM-30 BM-30A 240V (M603D) 415V (M604D)

9,500

BM-40V (M607D) $

10,950

SAVE 1,450

BM-65VE (M629D)

BM-70VE (M630D)

18,000

19,500

BAND SAWS • 305 x 178mm rectangle capacity • 0.75kW / 1hp 240V motor • Adjustable 4-speed pulley drive system enabling 26-50-73-95mpm cutting speeds • 750W/240V fully enclosed fan-cooled motor

• 3 axis digital readout • 5hp 415V motor • 1500 x 305mm work table • NT40 spindle taper with 105mm chrome & ground quill • Z-Axis powered elevating motor • X & Y-Axis inverter power-feed • Includes: light, pneumatic draw bar system & coolant system • Travels: (X) 1050mm (Y) 420mm (Z) 500mm

• 3 axis digital readout • 5hp 415V motor • 1500 x 300mm worktable • NT40 spindle • Variable 60-3600rpm • Includes: halogen light, coolant system, clamp kit, swarf tray • Travels: (X) 925mm (Y) 420mm (Z) 480mm

SWIVEL HEAD METAL CUTTING BAND SAWS • 406 x 125mm rectangle capacity • 1.1kW / 1.5hp 240V motor • Adjustable 4-speed pulley drive system enabling 25-40-52-72mpm cutting speeds • 750W/240V fully enclosed fan-cooled motor

• 310 x 205mm rectangle capacity • 2hp 415V • Swivel head double mitre cut to 45º right & left, 60º right • 2-speed motor enabling blade speeds of 35 & 70mpm

• 315 x 230mm rectangular capacity • 2hp 415V motor • Swivel head double mitre cut to 45º right & left, 60º right • Coolant system • Quick action lock / release lever • Adjustable hydraulic cylinder • Electronic variable blade speed 20 - 75mpm

SAVE $ 160 SAVE $ 300

BS-912

(B014)

1,920

BS-916A $

3,160

(B015)

SAVE $ 200

EB-320DS

5,050

SAVE $ 200 (B067)

EB-320DSV (B067D)

6,050

Unit D/38 Highbrook Dr, East Tamaki Ph: (09) 2717 234 Specifications & Prices are subject to change without notification. All prices exclude GST and valid until 30-12-11

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