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CONTENTS

Volume 23 Number 06 December/January 2024 ISSN 1832-6080

FEATURES

AUTOMOTIVE & TRANSPORT Triple Eight Race Engineering Getac Cadpro

32 38 40

AGRICULTURE, FOOD & BEVERAGES Number8Bio RMIT spikes superbugs HRS Heat Exchangers

42 44 48

ONE ON ONE Caroline Wilkie, ARA CEO

54

PLASTICS, COMPOSITES & ADVANCED MATERIALS Uluu in WA Corrosion Solutions Dolphin Products ACS Australia

56 58 60 64

ROBOTICS & AUTOMATION TACCA Industries Motopal Gripper Richmond Rolling Robots

66 71 72

BUSINESS MANAGEMENT Sevaan Group Infor on AWS City of Whittlesea

75 77 80

STATE SPOTLIGHT: NSW PCW Commercial Windows Swisslog

82 83

CUTTING TOOLS Tempus Tools Zertivo 2.0 coating

86 88

COMPANY PROFILE Think Fencing

90

ENERGY & SUSTAINABILITY AEMO & CSIRO AXT & Lightning Machines

92 96

FORMING & FABRICATION Victor Precision Teschner Cycles Astroworx

98 99 102

MATERIAL REMOVAL TISCO big shot blast Grade GC4405

REGULARS

From the Editor From the CEO From the Ministry From the Industry From the Union Government News Industry News Voicebox Tech News Product News AMTIL Forums AMTIL Inside Industry Calendar Manufacturing History – A look back in time

AMT DEC/JAN 2024

32

Cover Photo: Mark Horsburgh – Edge Photographics'

TRIPLE EIGHT RACE ENGINEERING Triple Eight Race Engineering adopts the latest fabrication technology to win their races, one meet at a time.

42 NUMBER8BIO Animal agriculture and the resultant methane, is a huge problem to solve, and one bioengineering start-up thinks it has the answer.

54 ONE ON ONE

104 106

8 10 12 14 16 18 20 24 28 30 108 110 116 118

The CEO of Australian Railway Association, Caroline Wilkie

90 THINK FENCING Jack Fitzgerald has changed the rules on building fences with recycled PVC.

008

FROM THE EDITOR PAUL HELLARD

Railroading our supply chain The Australian Rail Supply Chain report came out recently, outlining a clear state of play, recommending various moves, and illuminating many challenges for the future logistics sector.

The Australian rail industry contributes nearly $30bn per annum to the Australian economy and is responsible for generating over 165,000 jobs. Over the last three years alone, the rail industry’s economic contribution has risen by 16%, adding 20,000 jobs to the national economy.

However, the future health and long term sustainability of the Australian rail supply chain is at a critical juncture. The combination of a record $155bn rail investment pipeline over the next fifteen years, a wave of replacement investment for ageing technologies, systems and rollingstock, and a fundamental rethinking and reorganisation of global supply chains in the wake of the COVID-19 pandemic provides an unparalleled growth opportunity for the local rail industry and the broader Australian economy. Severe threats and challenges remain but meeting these challenges has the potential to yield tremendous business and employment growth, as well as broader social and economic benefits, in coming years.

Action is required now if Australia is to maximise these benefits. Industry and governments urgently need a better understanding of the current capabilities and capacity of the Australian rail supply chain, the challenges they face which stymie growth and jobs creation, where opportunities for reform exist and recommended actions which will maximise benefits for all Australia. This is the purpose of the rail supply chain report, which has been informed through mapping hundreds of organisations linked to the Australian rail industry, direct industry consultation from surveys and interviews, and reviews of existing practices and policies.

From this analysis, this report provides recommendations which are designed to inform a blueprint for a stronger, more sustainable local Australian rail supply chain which, in turn, will support Australian economic growth and the generation of skilled jobs well into the future.

Key messages According to BIS Oxford Economics which prepared the report here, the rail supply chain is a major contributor to economic and social well-being in Australia and also provides valuable export dollars, but its economic and social contribution and capability is often underrated. While parts of the supply chain are more concentrated in some states than others, all states and territories have supply chain businesses that can benefit from policies which seek to raise participation from the Australian rail industry. However, current industry policies tend to place state priorities above the broader national interest.

Editor Paul Hellard phellard@amtil.com.au Contributors Paul Hellard Dr Cameron Tsai Drew Turney Sales Manager Nicholas Raftopoulos nraftopoulos@amtil.com.au Publications Co-ordinator Caroline Robinson publications@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia under ISO140001 Environmental Certification using FSC® Mix certified paper sourced using sustainable tree farming practices.

Contact Details AMT Magazine AMTIL Suite 10, 5 Corporate Boulevard Bayswater VIC 3153 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright

While rising investment has improved the health of the local supply chain in recent years, challenges and threats to its longer term sustainability remain. In particular, the domestic rail industry has numerous well-known legacy issues which impact its ability to scale up, innovate, increase efficiency and effectively compete against international rivals.

© Australian Manufacturing Technology (AMT).

All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher.

Contained specifications and claims are those supplied by the manufacturer (contributor).

COVID-19 is providing short term challenges to the local supply chain but is also providing an unparalleled opportunity. The local supply chain has been resilient in the face of disruptions to global manufacturing and production and the closure of international and state borders which has constrained the movement of vital rail skills. On the upside, local firms have accelerated their uptake of productivity-enhancing technologies and data analytics, while more flexible working arrangements are making the industry more attractive to a more diverse range of employees. But most of all, the pandemic is leading to a fundamental rethink of where all rail components, products and services are sourced, providing an unparalleled opportunity for local firms to position themselves into more diversified local and international supply chains.

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes.

AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published bi-monthly.

Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $190.00 (ex GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

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FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

AMTIL appoints President and new Directors AMTIL recently held it’s Annual General Meeting and as a result has appointed two new Directors and reappointed Brigitte Stavar as President for the coming twelve months.

Brigitte Stavar, Managing Director of Sheetmetal Machinery Australia, has held the position of President of AMTIL since October 2019 and has helped guide the Association through some interesting times.

COVID caused the postponement and subsequent cancellation of our flagship exhibition, Austech, along with many other events we run. This provided many challenges to us in not only meeting the needs of our members but also the financial implications of not running a show. We also purchased new offices with a fit-out and move in September 2021 followed by the announcement that Austech and the Reed Exhibition-owned National Manufacturing Week would evolve into one new show, Australian Manufacturing Week, owned and organised solely by AMTIL. Our thanks go to Brigitte and our current Board for the direction and guidance they gave our body during those times. We are pleased to say we have come through it with flying colours and are in a strong position to move forward.

Along with Brigitte, our existing Board comprises Annaliese Kloe – Group Managing Director of Headland Technology; Mark Dobrich – General Manager Machine Tools at John Hart Pty Ltd; Pat Green – Manager Director of Automated Solutions Australia; Paul Philips, Managing Director at Benson Machines Pty Ltd and Peter Sutton, Managing Director of Sutton Tools Pty Ltd. At the AMTIL Annual General Meeting in October we also appointed two new Directors and I take the opportunity to welcome them here and introduce them to our readership.

Phil Bowles is currently Chief Operating Officer (COO) at SPEE3D Pty. Ltd., a leading innovator in metal cold spray additive manufacturing machines, revolutionising the field of 3D metal printing.

Phil's journey in the manufacturing industry began in 1981 with a fouryear apprenticeship as a Fitter and Machinist at Repco Clutch Company in Bentleigh East, Victoria. Over the years, he honed his expertise, becoming a qualified toolmaker and working within the metallurgy department where he remained for an additional two years after his apprenticeship. With over four decades of experience in manufacturing, 31 of which were dedicated to ANCA Pty Ltd, Phil made significant contributions to the company. His journey at ANCA began in

AMT DEC/JAN 2024

Phil Bowles

Johanna Boland

the role of a Machine Tool designer, where he played an instrumental role in creating numerous cutting-edge ANCA machine tools. As his career progressed, Phil's dedication and skill propelled him into executive leadership, eventually holding the position of Global Engineering Manager.

In this capacity, he led a team of over 120 engineering professionals worldwide as well as spearheading the growth of ANCA's business in Thailand where he worked for three years. His experience living and working in Thailand broadened his global perspective, fostering his passion for diverse cultures and exploring new destinations.

Johanna Boland is the Group Strategy and Communications Manager at ANCA and came to manufacturing and the family business, after working for entities including large multinationals, Melbourne City Council, PR firms in London and not-forprofits. ANCA specialises in designing and manufacturing high precision CNC machine tools primarily for international markets.

Phil's professional journey extends beyond his operational roles. He possesses extensive skills and experience in strategy, management, leadership, and operations, and has completed the Director's course at the Australian Institute of Company Directors, attaining the GAICD nominal.

This experience further enriched his understanding of corporate governance, finance, strategy, and risk from a strategic perspective.

Phil's love for old motorcycles drives his passion for restoration, and his dedication to health, fitness, and good nutrition underscores his balanced approach to life.

“Phil is married with two adult children and resides on Philip Island, Victoria, alongside their delightful companion Basil the pug.”

Johanna is a public relations, brands, marketing and communications 'all rounder' with over twenty years’ international experience in-house and agency side across multiple sectors. Curious by nature she thrives in a dynamic environment to develop and drive ideas. Specialties include: Branding, social media, media relations, B2B, internal communications, crisis management, change communications, written communication and collateral development, social marketing, stakeholder relationship management, marketing, campaigns, strategic integrated campaign management, web management and budgeting.

Phil and Johanna bring unique skill sets to the existing Board and will be great additions as we progress through the next few years of business. I am sure you will all join me in welcoming them both to the AMTIL Board. amtil.com.au

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012

FROM THE MINISTRY THE HON Ed Husic MP – Minister for Industry and Science

National Reconstruction Fund Australian ingenuity has led to many world-changing medical breakthroughs, from the world’s first antibiotic, penicillin, to the ultrasound scanner and spray-on skin.

Innovations like these have allowed us to live longer and healthier lives – and there are plenty more being developed in our universities and medical research labs. The Albanese Government is continuing to invest heavily in our bioengineering, MedTech and biotech sectors so Australians can access the latest therapies and medical devices.

But we also want to retain more of the economic value of Aussie medical ingenuity – avoiding a repetition of opportunities lost in past because we lacked sophisticated manufacturing capabilities.

When the Human Papilloma Virus (HPV) vaccine was developed

by Professor Ian Frazer and Dr Jian Zhou at the University of Queensland in the 1990s, it was obvious this would be a gamechanger in combatting cervical cancer. UQ licensed the compound to the blood therapeutics business CSL. At that time, however, CSL lacked the fermentation facilities to manufacture the vaccine and licensed the science to pharmaceutical giant Merck.

The result was an important Australian-developed vaccine now administered world-wide, ended up being manufactured in Pennsylvania, in the US. Our goal is to ensure Australia’s next medical breakthrough, whether it is a vaccine or a medical device, is manufactured here. Which means overcoming the challenge of industrial translation and scale-up – as well as expanding our sovereign manufacturing capability. The newly established National Reconstruction Fund Corporation is at the centrepiece of the Albanese Government’s commitment to diversify and transform Australia’s industry and economy.

Medical science is one of seven priority funding areas for the NRFC, reflecting our strong R&D expertise in BioTech, RNA, and synthetic biology. Up to $1.5bn of the NRFC’s funding budget of $15bn has been allocated to support MedTech and related manufacturing projects. Having an arm of government as the equivalent of a cornerstone investor will help create the right environment for other commercial money to crowd in and support promising new industry projects. Through our Cooperative Research Centres Projects grants program, we are also enabling SMEs like OncoRes Medical to transition their breakthroughs through to commercial manufacture in Australia.

OncoRes Medical has created a hand-held probe that surgeons can use to identify cancerous breast tissue while operating. This device will not only improve outcomes from the surgical removal of cancers but create new export opportunities.

The requirement for regulatory approvals means getting diagnostic tools – as well as medicines, drugs and vaccines – to the point of manufacture can be long and arduous. In 2018, OncoRes Medical received a three-year, $3m CRC-P Grant that allowed it to iterate the initial design of the handheld probe to a point where it could be used inside a patient. Last year, OncoRes Medical was awarded a second $3m CRC-P Grant that will advance the imaging probe through to approval by the Therapeutic Goods Administration . This CRC Project support will help OncoRes attract local investors and allow it to manufacture the probe in Australia, creating jobs for skilled workers and export income for Australia.

We’re also supporting Vaxxas, a Brisbane technology firm, to scale up manufacturing of its high-density microarray patch (HDMAP) device – a skin patch able to deliver vaccines to the body.

In September, we took a significant step forward in our efforts to expand Australia’s sovereign medicines manufacturing capability when I announced ANSTO would build a new nuclear medicines

AMT DEC/JAN 2024

facility in Sydney. ANSTO makes around 80% of the radio isotopes used in nuclear medicine in Australia. Overseas hospitals and medical clinics also use the nuclear medicines produced at ANSTO’s Lucas Heights campus. However, the current facility is ageing, and a more modern manufacturing and distribution chain is needed to keep up with evolving needs of the radiopharmaceuticals market.

For example, new radiopharmaceuticals are being developed which can deliver radiation therapy directly and specifically to cancer cells.

Targeting radiation therapy at the cellular level can potentially reduce the side effects of treatment while at the same time enabling even tiny deposits of cancer cells to be killed throughout the body. The new state-of-the-art ­ nuclear medicine manufacturing facility at Lucas Heights will ensure ANSTO can increase manufacturing to meet growing cancer and other illness diagnosis rates.

And it will enable the introduction of cutting-edge new cancer treatments like targeted radiopharmaceutical therapy. Upscaling sovereign medicines manufacturing is not without its challenges.

Existing resources and infrastructure can be tested by the need for complex and technical regulatory oversight – as well as intellectual property requirements – for manufacturing vaccines or medical devices. The advent of advanced manufacturing in Australia is helping overcome many of these challenges. For example, Melbournebased 3DMEDiTech used 3D printing to address shortages in nasal swabs for COVID-19 testing – and in a comparatively short space of time.

The company had a nasopharyngeal swab designed, to market, and in use 172 days. Manufacturing of its kits rose from 5,000 a week in the early stages of the pandemic to 80,000 in mid-2021 – testament to the company’s agility and its use of advanced manufacturing techniques. There are over 1342 medical technology, biotechnology and pharmaceutical companies, including 152 listed on the ASX .

Australian-based operations of organisations in the MedTech sector generated revenues of $11.4bn in 2021-22 – an annual growth rate of 6.2% over the previous two years. About a third of MedTech manufacturing output was exported.

By supporting biomedical start-ups and providing them with the means to successfully scale up, we need never again new products like Gardasil end up being made elsewhere. industry.gov.au

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FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Australian industry steps up to cyber challenge The national debate on cyber often focuses on the risk of consumer data being exposed on the dark web.

But as Australian industry digitises, a new and important front in our cyber defences is opening.

Many Australian businesses – more than you would think – have experienced first-hand the impacts of even minor cyber-attacks on their data, workforce, suppliers, and customers, impacting their operations and reputation. We saw this most recently with the cyber-attack on DP World’s Australian operations, which impacted the flow of around 40 per cent of goods through our ports.

The digital revolution in industry – often known as “Industry 4.0” – is transforming Australia’s tech horizons. Using digital technologies and data analytics to improve industrial operations is bringing a potentially stepwise change in productivity that will secure our competitiveness in global markets.

One potential risk of this transformation is cyber. As industry digitises, the amount of commercial data we collect – and the risk of its damage, loss or theft – also grows exponentially. Digitised industries are becoming an increasingly attractive target for cyber criminals. Cyber-attacks can cripple a business, shutting down entire production lines for weeks or months and locking a business out from access to customer details and invoicing. The cyber criminals then may demand a ransom to unlock systems and to allow management to regain control and restart operations. Such attacks could be an extinction event for some businesses.

We need to balance the benefits of industrial digitisation with appropriate management of cyber risks. To understand how businesses are adapting, Ai Group has released new research into the cyber readiness of Australian industry. The findings reveal that industry leaders are conscious, concerned, and moderately confident regarding their cyber preparedness. But there remain some significant gaps in our national cyber defences we still need to fill.

Here are the main take outs from feedback from over 200 large and small Australian businesses from across the economy. First, cyber security is now a major operational challenge for industry.

We estimate there are around a quarter of a million cyber incidents affecting Australian businesses annually – meaning one-in-five deal with an incident each year. The rate rises to one-in-three for businesses in industrial sectors like manufacturing, transport and utilities.

Second, cyber security is now mainstreamed as an investment decision. We found that it is the fifth highest investment priority for businesses today – not far behind conventional capex, and roughly equal to R&D. Interestingly, cyber-related IT investments ranked higher than general IT investments – showing how dominant cyber concerns have become for Chief Technology Officers.

Businesses also treat cyber just like any other investment. Fortyeight percent of Australian companies say the main factor shaping their cyber investments is a return on investment, and 34% say it is cost of technology.

Third, few businesses ‘go-it-alone’ on cyber security. Our research reveals that 82% of Australian businesses bring in help from external vendors, often to augment their in-house IT teams. This is extremely valuable in ensuring business leaders have access to the expertise, knowledge and technology that keeps pace with quickly evolving threats. In fact, we have identified a cyber maturation process.

Small startups rely mostly on external vendors for cyber security.

But as they grow to medium size, they start building up their own capabilities. And those that grow to become large businesses see their in-house IT teams take control.

AMT DEC/JAN 2024

Fourth, size matters when it comes to cyber security. Large businesses have a greater risk profile due to their rich data and deep supply chain linkages, and are twice as likely to suffer a cyberattack. But large businesses also have greater capacity to protect against these threats with defensive systems.

Our findings show it is medium businesses – those with between 20 and 200 employees – that face the greatest cyber risk. They have a similar risk profile to large businesses, but not the same resources to dedicate to cyber defence. We therefore need to think carefully about designing appropriately scaled cyber solutions. “One size fits all” cyber approaches will end up fitting none.

Fifth, good cyber security requires technology and people.

Fifty-three per cent of Australian industrials tell us they make investment cyber security training – for all employees, not just the IT team – a component of their cyber investments. The reason is the technological literacy of the entire workforce matters, particularly in the technical and trades roles that are frontline users of digital technology.

However, we need to see this number substantially increase. Cyber experts will tell you the biggest security risk lies in human error, not technology failures. A holistic approach to cyber security needs to blend investments in technology and people for best effect.

The digitisation of industry is of course not simply a source of cyber risk. It also provides rich opportunities to increase our innovation, productivity and international competitiveness. But to do it securely, we need to embed good cyber security practices into every step of business operations.

With carefully calibrated efforts, we can keep our digital investments well ahead of the cyber curve and sleep a little better at night. aigroup.com.au

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016

FROM THE UNION STEVE MURPHY – National Secretary Australian Manufacturing Workers Union

Industrial Transformation Watching overseas taking the economics of future jobs seriously, Australia needs to start engines.

A little over a year ago, an ambitious piece of legislation with an uninspiring name caused shockwaves in global manufacturing and kickstarted a race to invest in green manufacturing.

I’m referring to the US Inflation Reduction Act. Between this and the European Green Deal, governments are transforming their economies from dependent on fossil fuels to manufacturing their renewable energy future – and providing Australia with a blueprint of how to do the same.

Passed in August 2022, the Inflation Reduction Act pours US$783bn into renewable energy investment – about $1.2Tn in Australian dollars. The legislation created a “green bank” to underwrite renewables projects, put billions towards modernising America’s advanced manufacturing sector and requires supply chains to be local.

It’s already having an enormous impact.

Millions of American homes now have heat pumps instead of old gas boilers, new buildings are installing more efficient appliances, including heating, ventilation and air conditioning systems, and more than 170,000 new jobs have been created in green manufacturing.

Instead of shipping jobs overseas, major employers are now building factories to make wind turbines, car batteries and solar panels in the US, and bringing their supply chains back onshore.

Before global events once again reminded us of the criticality of manufacturing self-sufficiency, the AMWU campaign to Support Aussie made called for a significant investment in our local manufacturing industry for the green jobs of tomorrow. Workers

AMT DEC/JAN 2024

in Collie, Wollongong, the Hunter, Gippsland and other traditional manufacturing communities have championed the kind of response from government that we’re now seeing elsewhere: support our local industries to invest and grow so we can make things here.

It requires vision, collaboration and long-term commitment.

That’s why the AMWU has been working with big manufacturers, environmental groups and local communities to convince the Albanese government to support a big agenda to reindustrialise Australia.

It will involve creating incentives to encourage the local production of wind towers, solar panels, hydrogen and batteries; rewriting our federal anti-dumping laws to stop exploitation and inferior standards; using the expertise and experience of manufacturing workers to inform the process; and investing in our local industries and supply chains.

The Inflation Reduction Act has opened the eyes of policymakers around the world to what’s possible when government plays a fundamental role in decarbonisation and green manufacturing policy. We are at the precipice of the most significant industrial transformation in generations. It presents unprecedented opportunities for local industry and local workers, but our governments must back up their lofty words with the investment needed to realise them.

We cannot afford to miss the global race for the jobs of the future. amwu.org.au

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GOVERNMENT NEWS

University partnerships Taking research out of the lab and into the market with Breakthrough Victoria.

The Andrews Labor Government is backing the commercialisation of world-class research and innovation so more home-grown ideas are developed and manufactured in the state through new partnerships with five Victorian universities.

Victorian Minister for Industry and Innovation Ben Carroll recently announced new co-investment partnerships with five Victorian universities as part of the $100m Breakthrough Victoria – University Innovation Platform. The announcement was part of his speech at the opening of the Global Entrepreneurship Congress, attended by 4,000 investors and entrepreneurs from around the world and hosted in Victoria for the first time.

The new partnerships totalling $87m with Deakin University, La Trobe University, Monash University, RMIT University and Swinburne University will help commercialise critical research and unlock its market potential.

Each university will contribute up to $9m in funding matched

by Breakthrough Victoria to invest in startup and early-stage companies spun out of their own research, with typical pre-seed investments of around $500,000 each. Investing in startups at this critical early stage will help fund product concepts, prototypes, and trials to support research with strong commercial potential

move beyond the research and development phase. “We are backing the translation of unique research and development from our world class universities into commercial opportunities locally and globally,” said Minister for Industry and Innovation Ben Carroll. “This partnership between Victorian universities and Breakthrough Victoria will ensure our brightest ideas grow locally.”

The partnerships will boost the development of local innovations and sovereign manufacturing capabilities, while building a pipeline of Victorian products and startup companies to invest in and help scale up globally. There are now six university partnerships established under the Breakthrough Victoria – University Innovation Platform, with the University of Melbourne Genesis Pre-Seed Fund announced last year.

In addition to the $2bn Breakthrough Victoria Fund, the Labor Government is providing targeted industry investments to drive innovation through LaunchVic’s $15m Alice Anderson Fund to support more women-led startups and the $15m Industry R&D Infrastructure Fund to incentivise local business to increase their R&D activity. premier.vic.gov.au

Securing the North Australia-US multibillion-dollar defence partnership will spell $6bn in the Northern Territory.

The Billion Dollar Partnership, the report produced by ACIL Allen and commissioned by Master Builders NT shows that $6.23bn will be invested in the Territory by the Australian and US military over the next five years resulting in 7,500 extra jobs and boosting economic growth in the NT by nearly five per cent.

of businesses and other economy-wide benefits that will extend across the whole Top End.”

Billion Dollar Partnership models the economic impact of 25 defence projects in the Territory with data provided by the Department of Defence as part of its continuing partnership with Master Builders NT.

“The report also confirms the capacity of the construction sector in the Top End to deliver these projects,” Carter added. “The DSR amplified the vital strategic importance of northern Australia and strengthening and expanding bases and facilities in the Northern Territory. It’s great news that such substantial progress is being made toward the achievement of that objective.”

“This is a multibillion-dollar partnership between the Australian and US Defence Departments and the construction sector,” Chief Executive of Master Builders Northern Territory Ben Carter said.

“It’s going to create a surge in jobs, opportunities for thousands

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The report highlights the progress that the Federal Government and the Department of Defence are making in response to the Defence Strategic Review (DSR).

mbnt.com.au

GOVERNMENT NEWS

SmartSat CRC increases investment to support Canberra’s new space agenda SmartSat CRC-backed academics in ACT are spearheading research in system autonomy and intelligence, cybersecurity, and precision measurement in space.

Australia’s leading space research centre, SmartSat Cooperative Research Centre (CRC), has announced a suite of new R&D projects and university appointments in support of the ACT Space Update 2023 unveiled in Canberra today, bringing its joint investment in the ACT to over $7m.

With the launch of the ACT Space Update 2023, SmartSat is amplifying this commitment by injecting new funds into research in space technologies addressing bushfire resilience, spacecraft system autonomy, space objects surveillance and cybersecurity.

One of two new research projects co-funded by SmartSat and ACT Government brings together the Australian National University (ANU) and EOS Space Systems to deliver advanced manufacturing technologies for the OzFuel instrument. This is a key payload of an Earth Observation Resilience satellite mission that aims to improve continental scale fire management and environmental monitoring tailored specifically to Australian Eucalypt forests.

The second project brings together Infinity Avionics, UNSW Canberra and Nominal Systems to develop capabilities in SpaceBased Space Surveillance (SBSS), a vital tool for both defence and commercial space operations contending with the risks of navigating increasing debris and space objects in Low Earth Orbit (LEO). SmartSat has also recently approved funding research capabilities in cybersecurity and resilient artificial intelligence for space systems at UNSW Canberra. This is in addition to two

SmartSat-backed Professorial Chairs at ANU: Professor Hanna Kurniawati, Professorial Chair for System Autonomy, Intelligence and Decision Making; and Professor Kirk McKenzie, Professorial Chair of Precision Measurement in Space.

SmartSat CEO Professor Andy Koronios, says that the $7m joint research investment in ACT demonstrates SmartSat’s commitment to supporting the national space sector.

“Since 2020, SmartSat has demonstrated its commitment to building the ACT’s space R&D capabilities, funding over ten projects at ANU and UNSW Canberra. We are excited to support this proactive agenda laid out by the ACT government.

“This fresh round of research investment by SmartSat delivers a rapid injection to the ACT Space Update. We believe it will have a force-multiplier effect on the development of space R&D capability in the ACT and provide direct support to the ANU’s broader Earth Observation Resilience Mission with critical technology.”

“SmartSat is building the foundation for a strong and successful national space sector. Through strategic investments that bring together prime industry players such as EOS Space Systems and emerging companies like Infinity Avionics with Australia’s leading universities, we are developing the specialist capability needed to grow a robust commercial space industry,” he added. smartsatcrc.com

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INDUSTRY NEWS

iLAuNCH Trailblazer Trailblazing new energy sources to sustain lunar spacecraft.

In the deepest of space, in a lunar nightfall, spacecraft need reliable and consistent power for the duration of the mission to be able to operate in the most extreme of environments. In a new partnership between iLAuNCH Trailblazer universities, the University of South Australia (UniSA) and the University of Southern Queensland (UniSQ), Adelaide-based clean energy technology company entX is set to change the landscape of sustainable energy solutions that will power space missions of the future.

The sustainable energy project is twofold for iLAuNCH. The first project will see UniSA and entX focus on the flow of thermal energy to ensure spacecraft can survive multiple nights in temperatures that can reach down to -180°C on the dark side of the lunar surface. The second project with UniSQ will look to commercialise long-term power sources to spacecraft where solar energy cannot be relied upon.

“We are thrilled to announce entX as another Trailblazer partner and program for the space industry,” said iLAuNCH Trailblazer Executive Director, Darin Lovett.

“Together we are working to commercialise two truly disruptive space energy technologies that will pave the way for global exports and give Australia a sovereign capability to excel on the world stage.”

As Australia is becoming a global participant in lunar-based payload missions, there is an emerging need for sovereign capability to support applications that will need to survive a lunar night cycle of 14 days at temperatures approaching -180°C. In the first project with UniSA, entX will prototype a Radioisotope Heater Unit (RHU) supported technology platform, to provide thermal management for multiple lunar night survival. The RHU will possess a half-life that is more sustainable, and ideal for shorter duration missions (1-5 years) such as small payloads that will fly to the Moon on the emerging series of commercial landers.

RHUs have been used in the global space industry for many years to provide internal heat to keep electronics warm in extreme environments such as lunar night and deep space, but they typically use plutonium which has significant safety concerns as well as a

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difficult regulatory pathway to launch. This project will utilise entX’s safer, more environmentally friendly beta-emitting radioisotope which will have a significantly simpler regulatory pathway to launch.

In the second project, entX will develop high-performance thermoelectric materials and components for advanced, high efficiency Radioisotope Thermoelectric Generator (RTG) technology.

This development will allow for more reliable and consistent electrical power for deep space probes, contributing to scientific knowledge and advancing our understanding of thermoelectric performance.

RTGs are often the only viable option for providing long-term power to probes and spacecraft, and further development will have significant benefits for space exploration and related industries.

“Embarking on an exciting journey towards lunar occupation in the upcoming decades, securing a reliable source of thermal energy solutions is paramount,” said entX General Manager Defence and Space, Scott Edwards.

“Robust RHUs and RTGs will play a pivotal role in ensuring the safety and effectiveness of lunar surface exploration, including the enigmatic dark side of the moon and the depths of lunar craters.

Moreover, extending asset availability during lunar nights by leveraging advanced energy technologies creates a step change in the amounts of data collected, processed, and transmitted, leading to a maximized mission ROI.” Together, iLAuNCH universities and industry partners will build Australia’s sovereign space capability that will enable a wide range of new lunar exploration and science missions, driving further innovation and development in the Australian space sector.

The Australian Government is building new research capabilities, driving commercialisation outcomes and investing in new industry engagement opportunities through the Department of Education’s Trailblazer Universities Program. Through this federal program, iLAuNCH will receive $50m of investment over four years, alongside a further $130m from universities, industry partners, and CSIRO. The net economic benefit of the $180m investment is expected to be $3.6bn by 2040. USQ.edu.au

INDUSTRY NEWS

VEEM props Launch of the SHARROW by VEEM series of propellers represents a historic moment for marine propulsion technology and manufacturing.

US-based Sharrow Marine, a subsidiary of Sharrow Engineering LLC, a leading manufacturer of revolutionary propellers for boats and ships, has announced an exclusive worldwide licensing agreement with Australia-based VEEM Ltd, a designer and manufacturer of disruptive, high-technology marine propulsion and stabilization systems. Under the partnership, VEEM™ has secured the exclusive global rights to manufacture and commercialise the innovative Sharrow Propeller for inboard propellers up to five metres in diameter. The companies will work together to produce a groundbreaking, state-of-the-art series of SHARROW by VEEM propellers that are dramatically quieter and more fuel-efficient than any inboard propeller currently on the market.

The partnership unites the two leaders of innovation and excellence in marine propulsion and manufacturing, marking a significant moment for the industry. Combining Sharrow’s revolutionary propeller technology with VEEM's proven history of manufacturing excellence and innovation across marine propulsion, the SHARROW

by VEEM propellers will initially be produced for superyacht and commercial vessels in the 10 – 30m range. The SHARROW by VEEM propellers will deliver significant fuel savings and a superior onboard experience, with reduced noise and vibration, and improved handling, due to a drastic reduction of tip vortices and cavitation.

“Bringing Sharrow Propellers to the inboard market has long been a strategic priority, and VEEM is the perfect partner for us to do so quickly, at scale, and with uncompromised manufacturing quality,” said Greg Sharrow, Founder and CEO of Sharrow Engineering, and inventor of the Sharrow™ Propeller. “The SHARROW by VEEM propellers will provide a superior experience for larger yachts and commercial vessels, representing a true leap ahead of traditional marine propeller design.”

“This agreement with Sharrow Engineering is further testament to VEEM’s commitment to pushing the boundaries of what’s possible in marine technology,” said Brad Miocevich, Chairman of VEEM Ltd. “We are thrilled to embark on this journey together to set a new standard for performance and sustainability. We believe this will be nothing less than transformative for the inboard market.”

The new SHARROW by VEEM propeller series represents the beginning of what Sharrow™ and VEEM™ plan to achieve together, in partnership around the world. The SHARROW by VEEM range of propellers will become available to purchase through 2024 and can be ordered directly through the SHARROW by VEEM website or through a growing network of agents around the world. sharrowbyveem.com sharrowmarine.com veem.com.au

Spotlight on VAILO VAILO awarded for innovative manufacturing manufacturing ultra-high-performance LED sports lighting.

Advanced lighting technology company VAILO has been named by the AFR as one of Australia and New Zealand’s most innovative Manufacturing & Consumer Goods companies.

The award was in recognition of VAILO’s development of the innovative Zenith Gen-V LED sports light, now one of the best-in-class LED sports lights internationally, and was designed and manufactured in Australia.

With more than 230,000 source lumens, the 1,500-watt Zenith Gen-V LED luminaire has been designed for sports stadia and fields but is also suitable for applications such as airports, seaports and mining operations.

VAILO was ranked sixth in the AFR BOSS Most Innovative Companies (Manufacturing & Consumer Goods), having been selected from more than 700 nominated companies across Australia and New Zealand.

Now in its twelfth year, the 2023 AFR BOSS Most Innovative Companies List assesses the innovation prowess of Australian and New Zealand organisations. It is judged and compiled by behaviour change consultancy Inventium.

The award comes after a year in which VAILO continued to expand its presence into the eastern states from its South Australian base. VAILO CEO and Founder Aaron Hickmann said being named on the AFR’s list of most innovative companies recognised the hard work and ingenuity of the VAILO team.

“VAILO has created a culture and our own unique innovation processes where the team are supported to push themselves every day, be brave and back their ideas,” said Mr Hickmann. “This accolade follows the AFR BOSS Best Places to Work awards in April where we placed fourth in the Manufacturing & Consumer Goods list, which I believe shows a direct correlation between a happy and innovative team.

“Our approach isreflected in the design, production and continual refinement of the Zenith Gen-V LED and its growing acceptance into fiercely competitive global markets.”

Founded in 2012, VAILO is an Australian advanced technology company specialising in manufacturing ultra-high-performance LED sports lighting and as a premier solutions provider of LED digital displays tailored to sporting venues and major outdoor events. vailo.com

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INDUSTRY NEWS

Science and manufacturing Strong collaboration between scientists and manufacturing industry key to our economic recovery.

With business spending in manufacturing research and development (R&D) falling over the past decade, a new focus on science and R&D in the Government’s manufacturing strategy has been welcomed by Australia’s leading science body.

The Australian Academy of Science says the strategy’s focus on increased collaboration between manufacturing and Australian scientists is important and plays to our nation’s strengths.

The Academy’s Secretary for Science Policy, Professor David Day FAA, says as a nation we have to look to where we have a comparative advantage, not just a competitive advantage, and the Government’s manufacturing strategy promises to do that.

“Resources technology and critical minerals are key priority areas announced in today’s manufacturing strategy and today in his Press Club speech the Prime Minister highlighted the increasing international demand for critical minerals,” Professor Day says.

“The Academy’s 10 year plan for Australian Geoscience, launched in 2018, highlighted the need to ensure the right infrastructure is in place to know how and where to explore for the critical resources needed for Australia’s future.”

One of the proposals in the Academy plan is to develop a ‘downward-looking telescope’ that could look at least 300 km beneath Earth’s surface to unlock Australia’s hidden mineral wealth.

Professor Day says manufacturing is a major funder of R&D in Australia. “However, business investment in manufacturing R&D has been declining in the last decade from almost $5.5bn to $4.6bn, so this new investment into revitalising Australian manufacturing, supported by Australian science and technology, cannot come soon enough.

Professor Day says the current and looming job losses from universities and other research institutes are of great concern and it is imperative that opportunities are created within the manufacturing sector to redeploy the early- and mid-career researchers losing their

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current positions. "We have invested heavily in these people and they represent an opportunity to turbo-charge the manufacturing sector with fresh people, ideas and innovation.

“As a nation we invest more than $1bn a year training PhD graduates so we should grasp this opportunity to enrich and develop a new high-tech industrial workforce,” Professor Day says.

The Academy’s Federal Budget submission includes a number measures to take advantage of and complement the Government’s new manufacturing strategy including: initiatives to encourage researchers to move into industry, such as internships or investment incentives for the private sector to hire people with PhDs. This could involve implementing a recommendation of the 2016 Review of the R&D Tax Incentive, which argued that incentive should also apply to the cost of employing new STEM PhD or equivalent graduates in their first three years of employment.

• initiatives to encourage researchers to start up their own companies.

• reforms of intellectual property laws to reduce barriers for researchers starting their own companies and capitalising on their research discoveries and inventions.

“If this strategy is to succeed, as an economy we will need to deepen our investment in STEM skills and research collaboration to provide the scientifically literate workforce and ideas to succeed and prosper in a post pandemic world,” Professor Day says.

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“A modern, growing, manufacturing sector working hand in hand with Australian science promises to be key to our economic recovery from the recession.”

The Academy looks forward to seeing more detail on the Government’s manufacturing strategy and working with it to ensure it is underpinned and informed by science. science.org.au

INDUSTRY NEWS

Marand with Kongsberg Marand announces extension to KONGSBERG Naval Strike Missile (NSM) collaboration.

Marand has announced an additional contract from Kongsberg Defence Australia to produce structural Launcher Frames and Rails for the KONGSBERG Naval Strike Missile (NSM) Launcher Canisters being delivered under Project SEA 1300. These are key components for the NSM Launcher Missile Module (LMM) which constitutes the All Up Round. This follows on from Marand’s announcement in February that they had been contracted by Kongsberg Defence Australia to manufacture NSM Launcher Ramp Systems.

Last year, the Commonwealth of Australia announced the selection of the NSM to replace the Harpoon Anti-Ship Missile capability on the Royal Australian Navy’s ANZAC Class Frigates and HOBART Class Destroyers. The NSM is a fifth generation, highly capable, long-range, precision strike weapon that will provide an advanced maritime strike capability to the Royal Australian Navy.

“We have been working closely with Marand and are delighted to award this additional contract to them, further expanding our existing relationship,” John Fry, General Manager, Kongsberg Defence Australia said. “Marand is a very capable Australian manufacturer and we see them as an important local partner on this project where KONGSBERG is maximising local manufacturing content within an accelerated delivery schedule. These launcher components are significant elements of the Naval Strike Missile and the local production of these systems demonstrate our commitment to furthering Australian manufacturing in support of the Sovereign Guided Weapon Explosive Ordnance (GWEO) Enterprise.”

“We are very pleased to be awarded this contract,” added Marand CEO Rohan Stocker. “As well as the Project Management, procurement and assembly processes at Marand we have leveraged the broader group to bring best of breed in detail component machining and surface treatment processes. We have the capabilities and capacity required for GWEO, where size and production rate are key drivers, so we are pleased that has been recognised. Finally, we have appreciated the technical rigour from KONGSBERG in Norway and Australia, and the excellent teamwork we have seen.”

Production of the Launch Ramp Systems is already underway, and under this additional contract, production of the Launcher Frame and Rails will commence immediately. marand.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Fuel tax credits The fuel tax credit scheme refunds fuel tax to users of heavy vehicles, machinery, plant and equipment and light vehicles used off public roads. This article provides an overview of the fuel tax credit scheme, including when an entitlement to a credit arises, and which fuels and activities attract fuel tax credits.

Who is entitled to a fuel tax credit?

The scheme provides businesses with a credit for the fuel tax that is included in the price of fuel. Fuel tax credits may be claimed where the following conditions are met: 1. you acquire, manufacture or import ‘taxable fuel’ - this is fuel that is liable for duty under excise or customs legislation (e.g. diesel and petrol), with certain minor exceptions; 2. you acquire, manufacture or import this fuel for use in carrying on your enterprise; and 3. you are registered for GST, or required to be registered.

The fuels must also constitute ‘eligible fuels’, and you must undertake ‘eligible activities’.

What are the ‘eligible fuels’ that attract fuel tax credits?

To claim fuel tax credits, the fuel must be ‘taxable fuel’, on which excise or customs duty has been paid.

Eligible liquid fuels include petrol (e.g. unleaded, premium unleaded, and high octane), diesel, fuel oil, kerosene, mineral turpentine, white spirits, toluene and heating oil.

Blended fuels The rate of fuel tax credit you can claim for fuel blends depends on the amount of biodiesel or ethanol in each blend.

Blended fuels are blends of two or more liquid fuels. Petrol/ethanol blends are treated as entirely petrol (i.e. taxable fuel and eligible for credits) if the ethanol component does not exceed 10%. Diesel/ biodiesel blends are treated as entirely diesel (i.e. taxable fuel) if the biodiesel component does not exceed 20%.

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diesel vehicles acquired before 1 July 2006 with a GVM of at least 4.5 tonnes.

The ATO considers the term ‘vehicle travelling on a public road’ includes any vehicle that can be authorised to travel on a public road by the relevant road traffic authority, and may include plant, equipment or machinery that is capable of locomotion.

Non-eligible activities

Transport gaseous fuels (duty paid)

Fuel tax credits do not apply to:

You can claim credits on transport gaseous fuels, which include:

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liquified petroleum gas (LPG) or liquified natural gas (LNG) intended for use in an internal combustion engine of a motor vehicle or vessel; compressed natural gas (CNG) that is imported or compressed for use in a motor vehicle; and all gaseous fuels for mixed use (that is, both transport and non-transport use) or when the end-use is unknown.

Non-transport gaseous fuels (not duty paid) Non-transport gaseous fuels that are not duty paid are not eligible for fuel tax credits. Such fuels include: • • • •

LPG and LNG delivered only for use other than in an internal combustion engine of a motor vehicle or vessel; LPG delivered for use in forklifts; CNG imported or compressed only for use in forklifts; and CNG compressed at a residential premises using equipment capable of compression at a rate not more than 10kg of natural gas per hour and not for sale.

What are the ‘eligible activities’ for fuel tax credits?

Road Transport Businesses can claim credits for fuel used in road transport activities for vehicles travelling on public roads, using: •

vehicles with a gross vehicle mass (GVM) greater than 4.5 tonnes; and

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fuel used in light vehicles, i.e. vehicles with a GVM of 4.5 tonnes or less travelling on a public road (e.g. a car or small van); and fuel used in pre-1996 heavy vehicles, i.e. vehicles with a GVM of more than 4.5 tonnes, travelling on public roads, that do not meet specified environmental criteria.

How are fuel tax credits calculated?

Fuel tax credit rates are indexed twice a year. For fuel acquired from 1 August 2023 to 4 February 2024, the rates for liquid fuels and most blended fuels are 20 cents per litre for heavy vehicles, and 48.8 cents per litre for off-road activities.

The credit rate for fuel used in heavy vehicles for travelling on public roads is reduced by the road user charge, which is currently 28.8 cents per litre.

How are fuel tax credits claimed?

Fuel tax credits are claimed by business taxpayers on their business activity statement (BAS) in a similar manner to GST input tax credits, and are attributed to the same tax period as the GST input tax credit for the fuel.

Entitlement to a fuel tax credit ceases to the extent that the credit has not been taken into account in an assessment within the fouryear entitlement period.

If you would like to discuss your entitlement to fuel tax credits, please contact Tamara Cardan, Tax Counsel at Rigby Cooke, on 03 9321 7862. rigbycooke.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

RBA’s monetary policy efforts bearing fruit CreditorWatch’s Chief Economist, Anneke Thompson talks about what’s topical in Australia’s economy and business landscape including the retail trade and employment figures, inflation data, as well as business and consumer sentiment.

September saw the continuance of fuel inflation, with petrol and diesel prices rising substantially due to reduced production by key oil states like Saudi Arabia. The increase in fuel prices, alongside continued price gains in insurance and residential rents, resulted in a small increase in monthly inflation. While many commentators argue this could result in the Reserve Bank of Australia (RBA) increasing the cash rate at its October meeting, this is unlikely given the key drivers of inflation are not interest rate sensitive. Consumer demand is still very flat, with retail trade growing by a modest 0.2% over the month. This is well below inflation, and means that on a volume basis, Australian consumers continue to pull back on their spending.

Overall, the economy continues to track along well, especially given how weak consumer demand is. Business sentiment and conditions are still reasonably positive, and while job vacancies are falling, they are still well above 2019 levels.

Fuel prices driving inflation Residential rents, fuel and insurance pricing continue to gain momentum. For the business community, rising insurance will have a big impact and add to already significant cost pressures many businesses are facing. The construction sector, in particular, is very reliant on insurance, and while price growth momentum in building materials is slowing, rising insurance premiums will be the next headache the industry will face. It is likely that we will start to see business consolidations in this sector, as smaller operators find the cost of maintaining insurance too great, and look to join larger businesses.

Unemployment rate steady While the August 2023 unemployment rate remained steady at 3.7% on a seasonally adjusted basis, there was a strong gain in employed persons overall, at 64,900, or a 0.5 percentage point increase. The increase in the participation rate from 66.9 to 67.0% was the reason this jobs growth wasn’t enough to lower the unemployment rate again. While this is good news for the economy overall, coupled with still very subdued consumer confidence, it is unlikely to be enough to warrant an increase to the cash rate after the October meeting.

Underemployment continues to rise, from 6.4% in July to 6.6% in August, meaning a larger proportion of workers are looking for more hours. And despite the large surge in employment over August, monthly hours worked in all jobs actually declined by nine million hours, or 0.5% on a monthly basis. Quarterly Job Vacancy data was released this month, and showed that job vacancies continue to fall at an accelerating rate. Job vacancies were down 8.9% over the three months to August, and 15.2% over the year. This is taking some pressure off wage price increases, however job vacancies still sit well above pre-COVID levels.

Retail activity subdued Retail Trade continues to grow very modestly, with a 0.2% seasonally adjusted monthly increase recorded over August. This equates to an increase in spending of 1.5% over the year, and is well below inflation rates.

The one bright spot for retail trade was clothing, footwear and personal accessories, which was given an unexpected boost over the month by the FIFA Women’s World Cup and associated merchandise purchasing. Spending in this category grew by 1.5% over the month.

Food retailing continues to fall, and was down by 0.3% over the month. This is likely due to falling prices in some major food categories, such as fruit and vegetables. Strong population growth and a weakening economy usually results in food retailing being one of the strongest categories, so this is quite an unusual dynamic.

It is also likely reflective of consumers trading down to cheaper alternatives of commonly purchased grocery items.

The one consistent area of increased spending is café, restaurant and takeaway food services, which grew by 0.7% over the month.

It seems Australians are still keen to eat out and not give up their takeaway coffees. However, despite still good demand in the sector, increased spending could also be attributed to many businesses being forced to increase prices. Moderating fresh food prices will be welcome relief for café and restaurant operators, however, energy, transport and insurance bills are all still rising considerably, and continue to impact the viability of many of these businesses.

Business and consumer sentiment Consumer confidence remains incredibly weak - down 1.5% in September. Consumers are still fearful of an additional rate rise, but also appear to have accepted the contention that interest rates will stay high for some time. This means that higher rates are going to be a drag on discretionary spending for at least another year.

Global conditions Inflation in the UK fell to 6.7% over the year to August, which was further than most commentators expected. In response, The Bank of England nominated to maintain the cash rate at 5.25%, which was the first pause after 14 consecutive rate rises. The US Federal Reserve also held rates steady at its latest meeting, with the target rate sitting at 5.25 – 5.50%.

Most central banks appear to be at the ‘wait and see’ section of the monetary policy tightening cycle. Consumers in the US in particular appear to still be reasonably confident, as home borrowers in that market are less impacted by cash rate rises given most are on fixed rate loans. Job markets also remain tight around the world. While it is appearing more likely that cash rate rises have finished, it is also the case that most central banks will hold them at this level for much longer than previous tightening cycles given inflation is moving down to target bands at a slow pace. creditorwatch.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Everyone is responsible for a Mentally Healthy Workplace Workplaces are talking more about Mental Health, but do you have the skills to comfortably be a part of the conversations? Nat Wild has some sage advice.

If a part stops functioning properly, productivity is threatened. In a healthy workplace the team brings their learned and instinctive skills together, creating a best outcome for the challenge. If a job is not being done properly, we talk and improve protocols. If a mechanical or technical component falters, we prevent things from getting worse, then call a person trained in more permanent solutions. We work to improve systems. If we turn a blind eye to any of these parts, production tends to falter.

Now think about this. Regarding health in the workplace, we rely on: • each other to be OK; • every team member to be on point in their role, and; • each person to do their part for the system to work well.

If a person stops functioning properly, productivity is threatened. In a healthy workplace the team brings their learned and instinctive skills together, creating a best outcome despite the challenge. If a job is not being done properly, we talk and get clarification around the changes we are observing. If a member of the team is not focused or is distracted, we minimise damage with the skills that we have, eg: check in, help ease any immediate concerns, then call a person trained to work with improving mental health. If we turn a blind eye to changes in a coworker’s demeanor, production tends to falter.

Noticing physical illness is more straight forward as you can often see it. A burn, a broken limb, or favouring a body part, or illness such as a cough, wincing at pain, looking pale, runny nose etc. When physical symptoms are less obvious, we tend to be more critical of the person, or we may minimise their reality. Physical illness or injury can be fleeting, situational, prolonged or chronic, and have degrees of severity, from an annoying distraction, to permanently crippling.

Most of us are comfortable with physical unwellness because we can ‘see’ it, and as a culture, have given ourselves permission to talk about it and encourage support seeking behaviours.

Mental health challenges are a bit trickier, as although they are very similar in nature to physical issues. No one asks for it to happen, it can be fleeting, situational, prolonged, or chronic, have degrees of severity, and range from an annoying distraction to permanently crippling, at first glance it is harder to see.

In recent years we have started talking more about Mental Health, but like all good things, it is taking its time to become second nature. Some people are comfortable discussing mental health issues, and others are still dipping their toe in the water. Overall however, we are giving ourselves permission to talk about it, and encouraging support seeking behaviours. This is a great step in the right direction. Another step is knowing when to approach, how to approach, understanding the spectrum of issues, and the best support options available to fit the presenting mental health challenge.

When to approach Noticing change in a person’s behaviour is a sign that something has shifted for them. When a focused person becomes distracted, a motivated person becomes disengaged, changes in food habits, decrease in productivity; these are some telling mental unwellness ‘visuals’. Basically, any obvious difference from the norm for a person can be a mental unwellness flag.

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Best approaches Minimal judgement. As with physical challenges, the same mental challenge can present differently in each person. Try not to assume what is going on for a person. A statement such as “I noticed you have been distracted lately, is everything ok” opens a door to talk.

“You don’t seem yourself, I’m here if you want to vent…if not I will check in again later”. It is common for someone not to talk on the spot, but that can change. Important note: if you say you will check in, make sure you do.

Be you. If you are not comfortable with Mental Health yourself, find a way to show acceptance. Carry some support numbers in your phone, and offer them.

Know your limits. You are not expected to know everything. Put a list of support options up in a place that staff frequently use, creating accessibility to services. Without saying a word, you are showing unconditional support.

Spectrum of issues and support needs Know your limits: No one expects you to be an expert. Think of it like this. First aid training teaches you how to step in and keep a person safe until the professionals arrive. The mental health equivalent would be to keep the person safe and promote accessing help.

I hope you have found this helpful, and I wish you the best in your ever-growing healthy workplace cultures.

Nat Wild is a Registered Counsellor and Counselling Supervisor.

Founder of Low Cost Counselling Program at ReDefine Life redefinelife.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Survey results on inventory Avoiding inventory management pitfalls in the manufacturing sector, by Liam Merrick, Sales Engineer at ECI Solutions.

Inventory management is critical for small to mid-sized businesses (SMBs) because it directly influences both production efficiency and profitability. However, despite this, it's often an area that needs the greatest improvement.

Effective inventory management involves complex and interrelated tasks, from forecasting demand and maintaining optimal stock levels, to ensuring swift and accurate delivery, managing storage, and reducing waste or obsolete models. These require detailed analysis, accurate data, and the use of advanced technology or inventory management systems. Without these, manufacturers may struggle with issues like low inventory turns, lack of visibility across departments, overstocking, stockouts, and high holding costs, which can significantly impact their operational efficiency, customer satisfaction, and bottom line.

Manual processes cost time and money Results from a recent ECI Software Solutions' customer "Warehouse Management Woes" survey shows that 53% of SMBs conduct manual inventory counts approximately once a quarter and 50% of respondents have challenges counting or reconciling inventory.

This is because many SMBs do not have inventory recordkeeping policies and processes in place, including regular inventory counts, maintenance, and documentation.

A lack of inventory processes creates ad hoc warehouse management, but the fact that so many SMBs rely on manual processes creates a bigger problem. When you have physical counts conducted across multiple spreadsheets and data systems, it's difficult to trust the data or track the flow of inventory.

For manufacturing companies, inventory is their business. Yet often there is limited visibility into inventory, from raw materials to manufactured goods, and what is dispatched. They also have little insight into where there could be losses, inefficiencies, and even theft.

On the other hand, accurate inventory recordkeeping lets SMBs effectively balance inventory levels to ensure the proper stock is on hand. This delivers more streamlined manufacturing production, less waste, less time spent on shelf and over (or under) stocking, reduced operating costs, lower labour costs, and more consistent on-time orders delivered.

Visibility is crucial to manufacturing competitiveness One of the biggest competitive challenges that SMBs face compared to their much larger counterparts is limited time, personnel, and financial resources. The result is that inefficient storage, display, and receipt processes are common.

When a business does not have a firm handle on its inventory, from raw material to final product, there can be a cascading effect that leads to other costly mistakes, including over-ordering, missing stock, and ordering incorrect materials.

To resolve this challenge, manufacturers must have a documented process that holds personnel accountable for oversight and the implementation of an automated and integrated process. One prime resolution to this challenge is by ensuring that employees have clear instructions to follow regarding interaction with inventory, the ordering and storage of materials and finished products, material and merchandise handling, and the reporting of data. Ultimately, the business has full visibility into its entire manufacturing process without requiring more people on the ground.

Unlock working cash for growth If cash is tied up in raw materials or excess inventory that have not been moved, the business can't invest in other areas that provide return on investment (ROI). This lack of liquidity also prevents the company from freeing up capital to purchase more raw materials or invest in updated technology or manufacturing equipment.

Accurate inventory and sales information, particularly around fastmoving products versus slower moving products, is essential to an accurate purchasing process, as well as understanding the best opportunity for future growth. Successful marketing and advertising initiatives, as well as flash sales, are based on accurate inventory levels as well.

Streamline inventory management and reduce costs with automation On a positive note, SMBs understand the importance of scheduled inventory counts. Unfortunately, due to a lack of automation, these counts tend to be physical. The ECI ‘Warehouse Management Woes’ survey found that 82% of SMBs complete scheduled physical inventory counts, and 46% supplement these with unscheduled.

In addition, 22% perform cyclical counting of specific products on a rotating basis, and 19% do full physical counts only when an issue is discovered. The common thread here is that these counts are physical, which is both time-consuming and prone to errors.

This might be why almost half of the respondents also conduct unscheduled spot checks.

Integrated inventory management software streamlines this process, reducing costs and offering a more accurate understanding of actual inventory levels. This provides multiple benefits such as: optimal inventory levels; predictive purchasing; process streamlining; and increased productivity.

Dynamic markets, fluctuating needs, supply chain issues, and the importance of being competitive make it crucial for SMBs to have visibility into the business and inventory management. Integrated inventory management software also gives insights into trend and market identification and variable inventory management due to fluctuating demands, empowering SMBs to stay ahead of the game. ecisolutions.com/en-au/

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TECH NEWS

Australia: Surgery could be less stressful for patients following a virtual reality experience Giving a patient a virtual reality tour of the operating theatre before surgery could make the process less anxiety-inducing, according to Australian and international researchers. The researchers say anxiety before elective surgery is common and associated with negative outcomes. They recruited 74 people scheduled for their first surgery under general anaesthesia and randomly gave them either standard pre-surgery care or an eight minute tour of the operating theatre using a VR headset. The researchers say compared to standard care, the VR group showed less pre-surgery anxiety and lower stress levels both immediately after the VR tour and before the surgery. However, they say there was no difference in pain and the amount of time they stayed in hospital after the surgery between the two groups.

La Trobe University, Chinese University of Hong Kong

Australia: Titanium micro-spikes skewer resistant superbugs A new study suggests rough surfaces inspired by the bacteria-killing spikes on insect wings may be more effective at combatting drugresistant superbugs, including fungus, than previously understood.

The increasing rates of drug-resistant infection has health experts globally concerned.

To avoid infection around implants – such as titanium hips or dental prosthesis – doctors use a range of antimicrobial coatings, chemicals and antibiotics, but these fail to stop antibiotic-resistant strains and can even increase resistance. To address these challenges, RMIT University scientists have designed a pattern of microscale spikes that can be etched onto titanium implants or other surfaces to provide effective, drug-free protection from both bacteria and fungus.

The team’s study published in Advanced Materials Interfaces tested the effectiveness of the altered titanium surface in killing multi drugresistant Candida – a potentially deadly fungus responsible for one in 10 hospital-acquired medical device infections.

The specially designed spikes, each of a similar height to a bacteria cell, destroyed about half the cells soon after contact. Significantly, the other half not immediately destroyed were rendered unviable from the injuries sustained, unable to reproduce or cause infection.

Lead Postdoctoral researcher, Dr Denver Linklater, said metabolic analysis of protein activity revealed both the Candida albicans and multi-drug resistant Candida auris fungi cells sitting injured on the surface were as good as dead.

“The Candida cells that were injured underwent extensive metabolic stress, preventing the process where they reproduce to create a deadly fungal biofilm, even after seven days,” said Linklater, from RMIT’s School of Science.

Advanced Materials Interfaces, RMIT

AMT DEC/JAN 2024

Australia: Drug-resistant bacteria taking over A new study has warned common infections in babies and children are increasingly untreatable with antibiotics, with more Australian children contracting antibiotic-resistant bugs than a decade ago.

The University of Sydney-led study showed some antibiotics recommended by the World Health Organisation for children had less than 50% effectiveness in treating infections such as sepsis, pneumonia and meningitis.

Data from 11 South-East Asian and Pacific countries found one particular drug, ceftriaxone, was only likely to treat one in three cases of sepsis or meningitis in newborns. Lead author Phoebe Williams said overuse of antibiotics in humans was not the only factor, but that medication used in veterinary practices and agriculture can lead to resistant bacteria also entering food and water supply chains.

Medical Xpress

Australia: AI bias against women in leadership New research from the Tasmanian School of Business and Economics at the University of Tasmania has revealed that AIgenerated content can perpetuate harmful gender biases. Through analysing AI-generated content about what makes a ‘good’ and ‘bad’ leader, Dr Toby Newstead and Dr Bronwyn Eager found that men were consistently depicted as strong, courageous, and competent, while women were often portrayed as emotional and ineffective.

“By exploring how AI tools generate responses to questions around good and bad leadership, we were able to show that AI reflects and perpetuates known gender biases,” Dr Newstead said.

“Any mention of women leaders was completely omitted in the initial data generated about leadership, with the AI tool providing zero examples of women leaders until it was specifically asked to generate content about women in leadership.” “Concerningly, when it did provide examples of women leaders, they were proportionally far more likely than male leaders to be offered as examples of bad leaders, falsely suggesting that women are more likely than men to be bad leaders.” Generative AI technologies, which use machine learning processes to understand and create content, are trained by processing vast amounts of data from the Internet as well as human input designed to reduce harmful or biased information being generated. Dr Eager says that the findings of this research highlight the need for further oversight and investigation into AI tools as they become part of daily life. “Biases in AI models have farreaching implications beyond just shaping the future of leadership.

With the rapid adoption of AI across all sectors, we must ensure that potentially harmful biases relating to gender, race, ethnicity, age, disability, and sexuality aren’t preserved,” she said.

"Our research highlights the need for ongoing monitoring and evaluation of AI-generated content to ensure that it is not perpetuating harmful biases. We hope that our research will contribute to a broader conversation about the responsible

TECH HEADING NEWS use of AI in the workplace.” Dr Toby Newstead and Dr Bronwyn Eager are internationally recognised academics in leadership, entrepreneurship, and AI education at the Tasmanian School of Business and Economics at the University of Tasmania.

Massey University

Australia: Tau-ting the importance of protein mapping For the first time, University of Queensland (UQ) researchers have shown how the tau protein, known for its role in dementias, behaves where communication in the brain takes place. The study led by Dr Ramón Martínez-Mármol and PhD student Shanley Longfield from UQ’s Queensland Brain Institute used super-resolution microscopy to visualise individual tau proteins in motion while neurons are “talking” to each other. Dr Martínez-Mármol explained that the team’s discovery is a big step towards understanding what triggers tau aggregation in disease states like Alzheimer’s disease.

“We discovered that tau in a healthy brain controls an important population of vesicles at the presynapse critical for neuronal communication,” Dr Martínez-Mármol said. “These vesicles are like the words that neurons use to transmit information to other neurons. For the very first time, we’ve shed light on the mechanism by which tau acts in our nerve cells. By understanding tau’s role in a healthy context, we begin to fully understand what leads to the abnormal accumulation of tau in disease.”

Ms Longfield said that observing tau’s behaviour in healthy states provides clues to how these toxic aggregates start to form.

“Studying tau in a healthy brain is more challenging than studying it in a diseased brain, where changes in its molecular behaviour are far more prominent and obvious,” Ms Longfield said. “But by visualising tau at the nanoscale and in this context, we can identify the molecular behaviours that precede the formation of toxic protein aggregates in disease.”

Nature Communications

USA: Wearable tech could help prevent astronauts from getting lost in space In space, astronauts are at risk of becoming disoriented without the usual cues that tell them what's up and what's down, and in the wrong circumstance this can be deadly. While astronauts are given intensive training to manage this risk, international researchers have developed wearable sensors called vibrotactors - which they say could help the learning process and assist out in space. The sensors were tested by recruiting 30 people; 10 of whom were given training, 10 given the vibrotactors and 10 receiving both. The participants were then given a challenge of keeping a multi-axis rotation device steady while undergoing sensory deprivation. While all participants were initially disoriented by the challenge, the researchers say those with the vibrotactors eventually began performing better, with the group with both the sensors and the training performing the best.

Losing your sense of where you are can be fatal enough for aircraft pilots: spatial disorientation is a leading cause of fatal aircraft accidents. But losing your orientation in space itself is even more dangerous. Scientists have now developed wearable devices called vibrotactors that, combined with specialized training, improve people’s ability to fight spatial disorientation and could help astronauts correct themselves when their perceptions can no longer be relied upon.

The sky is no longer the limit — but taking flight is dangerous. In leaving the Earth’s surface, we lose many of the cues we need to orient ourselves, and that spatial disorientation can be deadly.

Astronauts normally need intensive training to protect against it. But scientists have now found that wearable devices which vibrate to give

orientation cues may boost the efficacy of this training significantly, making spaceflight slightly safer. “Long duration spaceflight will cause many physiological and psychological stressors which will make astronauts very susceptible to spatial disorientation,” said Dr Vivekanand P. Vimal of Brandeis University in the United States, lead author of the article in Frontiers in Physiology. “When disoriented, an astronaut will no longer be able to rely on their own internal sensors which they have depended on for their whole lives.”

Frontiers in Physiology

Australia: Underworld marketplace exposed: Fake IDs for sale on the dark web Counterfeit Australian identity documents, especially driver’s licences, rank among some of the most frequently listed and sold identity documents on anonymous dark web marketplaces, according to new research from the Centre of Forensic Science at the University of Technology Sydney (UTS). These documents are used by crime rings, terrorist organisations and other criminals for a wide range of illicit activities, including identity crime, money laundering, human and drug trafficking, illegal immigration, scams and espionage. UTS Centre for Forensic Science PhD candidate Ciara Devlin shared her research on fake Australian identity documents and how they are sold through cryptomarkets at the International Association of Forensic Sciences (IAFS) conference, held in Sydney in late November.

“The manufacture and distribution of fraudulent identity documents is a pervasive and prolific crime problem, so much so that Europol has said that fraudulent identity documents are a threat that enables and facilitates most, if not all, other types of serious and organised crime,” Ms Devlin said. “Despite this, most instances of document fraud are treated on a case-by-case basis, meaning the individuals holding the document are charged, with no real attempt to identify the source of the documents, resulting in very limited impact on the overall crime rate.” “Internationally it has been found that the fraudulent document market is very organised, with prolific offenders operating at the core of the market, but in Australia, very little is known about the document fraud criminal environment,” she said. Ms Devlin has been working to fill these gaps in knowledge, approaching the problem from two angles. First, she has profiled the visual characteristics of fake Australian driver’s licences, to see if they share a common source. Second, she is investigating the extent of the fraudulent document market on the dark web, particularly for Australian identity documents.

Australian Journal of Forensic Science

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PRODUCT NEWS

ANCA FX7 ULTRA Unleash the power of precision: ANCA's FX7 ULTRA guarantees perfection for small tools down to 0.1mm.

Designed for small tools, the new FX7 ULTRA is the latest gamechanging innovation in ANCA’s premium ULTRA machine range.

New software, hardware and design features significantly improve surface finish, accuracy, and controlled runout, ensuring batch consistency from the first ground tool to the last. These advancements ensure that the FX7 ULTRA is the go-to solution for precision grinding in industries that rely on small tools, including electronics, telecommunications, medical devices, aerospace, automotive, diemold, and general machining.

“The FX7 ULTRA introduces cutting-edge technologies that revolutionise precision grinding for small tools down to 0.1mm diameter. If you produce tools such as ballnose, corner radius endmills, and complex or intricate profile tools, then this machine is for you,” says Darren Fox, ANCA Product Manager.

The FX7 ULTRA not only grinds tools faster than other machines, but also produces tools with both finer surface finishes and greater accuracy — which means superior tool performance and quality.

The ULTRA technology has enabled production of high-quality small tools with the capability to grind down to a size as small as 0.1mm. The nanometer control enables micro-adjustments for smoother axis movement resulting in optimal tool geometry, ensuring superior cutting performance and surface finish. These advancements will have a significant impact across the entire tool range, enabling precise and efficient grinding operations for a variety of applications,” Darren concludes.

“Our customers who supply to industries where intricate and precise machining operations are paramount are always striving for the best quality tools,” Pat Boland, ANCA co-founder says, “and now they can stay ahead of the game with the FX7 ULTRA. After years of dedicated research and development, the FX7 ULTRA is set to revolutionise the way we manufacture small tools.”

A technical look at the FX7 ULTRA: Greater control for the velocity and acceleration or deceleration along with machine jerk limits: To increase the stiffness of the C-axis, the FX7 ULTRA combines developments to the nanometre or micro degree resolution in the linear and rotary axis, tuning parameters, several system enhancements, and major mechanical changes.

ULTRA-fast response to internal or external disturbances: ANCA’s newly designed servo control algorithm allows silky smooth motion of an axis with the use of a unique algorithm and nanometre measurement in the control system. This will create finer cutting edges and eliminating micro-chips making it more efficient while used in actual machining of materials.

Better cycle time and higher productivity of high-quality cutting tools: The unique algorithm is key to the performance of the machine and ensures outstanding tracking performance. It also allows ULTRA-performance of the servo system without using a complex, complicated, or expensive mechanical system.

Reduces setup times and scrap: Cutting-edge software has been developed by ANCA to ensure batch consistency in large volumes. LaserUltra will maintain consistency and accuracy of the grinding process which includes in-process measurement and compensation to accommodate wheel wear and other external variations during large batch grinding.

Increased wheel life and better-quality tools: Tool and wheel performance can be further optimised by the iBalance software, which guides a user to the optimal grinding position and RPM for vibration monitoring and balancing the wheelpack inside the machine.

AMT DEC/JAN 2024

Consistency in finished tool quality: The total tool runout measurement and compensation operation is available in the iGrind software. When an endmill is in rotation it is important that each tooth hits at the exact same spot along the workpiece for longer tool life and efficient cutting. Every tool in the batch can be measured and compensated for runout to make sure the entire batch is within a tolerance of 0.002mm.

Consistent spindle thermal stability: Motor Temperature Control (MTC) is a patent pending innovation built into the motor spindle drive firmware. Smart control algorithm actively manages and maintains the temperature of motorised spindles in the FX7 ULTRA. Dramatically reduced machine warmup time means production can start sooner, once the machine has reached thermal stability. This improves productivity and machine use.

Post grinding processes: The smoother, finer cutting edge and surface finish as a result of the combination of all the above including the nanometre control will assist in all post grinding applications like edge preparation and coating. A finer edge that has been properly prepared has greater stability, which reduces the likelihood of it chipping, while also decreasing surface roughness which can cause increased friction between the tool and the workpiece. anca.com/FX7Ultra

PRODUCT NEWS

Flexicon food conveyor Mobile high-capacity bulk bag discharger and flexible screw conveyor.

A new Mobile Frame-Mounted Bulk Bag Discharger with Flexible Screw Conveyor from Flexicon allows rapid, dust-free discharging and conveying of bulk solid materials at multiple plant locations.

The BULK-OUT BFF Series discharger allows forklift-loading of bulk bags from 914 to 2134mm tall. A removable bag-lifting cradle with Z-CLIP strap holders permits bulk bags to be attached securely at floor level from an ergonomic standing height, and then forklifted into cradle cups atop the discharger's upright posts.

The bag spout is pulled through a 305mm diameter iris valve which is then closed around the spout, preventing material flow. The spout can then be untied, the snap-action access door closed, and the valve released slowly, allowing controlled flow into the enclosed hopper through the bulk bag interface chute.

Complete discharge is aided by FLOW-FLEXER bag activators that press against op-posite bottom sides of the bag at timed intervals to form a steep "V" shape, and top-mounted POP-TOP extension devices that raise the uprights as the bulk bag empties, promoting the flow of material from the corners of the bag through the bag spout.

The hopper is vented to a BAG-VAC dust collector that creates negative pressure with-in the sealed system to contain displaced air and dust, and vacuum any particles trapped in bag creases during disconnect. Reverse pulse air jets on a timed cycle dis-lodge material accumulated on the filters, returning it to the material stream.

The enclosed 156L hopper measures 762mm square by 1067mm high and is equipped with proximity level sensors, and a pneumatic vibrator assembly to promote flow of material to the conveyor.

The outlet of the hopper charges the inlet of a BEV-CON Flexible Screw Conveyor that propels free- and non-free-flowing bulk materials at a 45-degree incline in user-specified distances for discharging directly into processing equipment or storage ves-sels through 254mm diameter down spouting.

Specialised geometry of the internal screw allows handling of materials that pack, cake, smear, seize or fluidise, with no separation of blends. The screw is the only mov-ing part contacting material, and is driven beyond the point of discharge, preventing material contact with seals or bearings, and allowing rapid cleaning.

Mounted on a mobile base with support mast, the self-contained unit can be rolled to feed various locations or to a cleaning station.

A lower clean-out cap on the conveyor tube can be removed to flush the smooth interi-or surfaces with steam, water, or cleaning solutions, or to fully remove the flexible screw for cleaning and inspection. The system is available in carbon steel with durable industrial coating, with stainless steel material contact surfaces, or in all-stainless steel finished to industrial, food, dairy or pharmaceutical standards. Its NEMA 4 control panel with PLC allows manual and automatic start/stop and speed adjustment.

Flexicon also manufacture other configurations of mobile and stationary bulk bag dis-chargers, as well as flexible screw conveyors, tubular cable conveyors, pneumatic conveying systems, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, bag dump stations, drum/box/container tippers, drum fillers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. flexicon.com.au

Flexicon Mobile Bulk Bag Discharger with Flexible Screw Conveyor allows rapid, dust-free transfer of abrasive and high-density bulk solid materials to process equipment and storage vessels at multiple plant locations.

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AUTOMOTIVE & TRANSPORT

DRIVING AROUND IN CIRCLES Triple Eight Race Engineering adopts the latest fabrication technology to win their races, one meet at a time. AMT Editor Paul Hellard takes a ride around the tracks.

AMT DEC/JAN 2024

AUTOMOTIVE & TRANSPORT

Photos credit: Mark Horsburgh – Edge Photographics

Jamie Whincup has been a part of Triple Eight Race Engineering as a driver since he joined the team in 2006. “My father bought me a go-kart when I was seven years old, so racing was originally a hobby,” Whincup tells me. “Fast forward, and the whole thing just got out of control and has become my profession for 20 years. I was very happy to join what I regarded as the best team in the country in 2006. And they've gone from strength to strength. And we've won many races, but it must be stated that we are an engineering company that showcases our talents on the racetrack.”

Now Managing Director, Whincup is straight-forward with his descriptions of what Triple Eight does. “Motorsport has always been about getting a team of people together, to build a race car, take it to the track and race our mates, try to go around in circles quicker than them and get to the finish line before everybody else,” he adds. “It's pretty simple.”

Whincup also says there are two parts to the equation. It's about trying to engineer the unfair advantage. Trying to engineer a car that's faster than anybody else’s. And then of course going to the racetrack and trying to outperform everybody else with their setup and strategy and driving faster or quicker pitstops.

“Our technical director is Jeremy Moore. He's been with Triple Eight Racing right from the very start, about 20 years,” explains Whincup. “He did go over to Germany to design the RSR for Porsche for five years. And then he returned to Triple Eight.”

“Engineering R&D is massively important to a race team,” says Whincup. “Motor racing involves a sophisticated race car to go around the track very, very fast. But it has to be very reliable as well. We're constantly balancing between making a component or a car go as fast as possible. But the biggest cost in motorsport is a DNF. That’s a Did Not Finish. We very much have to finish the race. We cannot afford to have a DNF, but we need to get there as quick as possible. That's the big challenge. Plus our deadlines are critical. When we have a race meeting, that date is set. We can't change that. If a part isn’t ready, we can't just push it out a week. We have to hit the deadlines.

That's all part of the challenge to get the best engineered car to the track at that race meeting deadline, to go out there, compete and then come back and improve it for the next time.

Triple Eight Race Engineering produces parts for their own two cars as well as supplying parts for the entire Supercar Championship field. But there have been those times when there was no public race meets. When COVID hit, a team of talented engineers turned their creative minds to help the wider community. “This was when Triple Eight pivoted their designer minds to create three iterations of medical ventilators. In about three months, we were ready to go. In the end the project wasn’t required, but it was a great example of how quickly we could re-kit and prepare to build, which is pretty much anything.

We have inhouse designers, manufacturers, with electronics experience, all in one building. In the end though, we went back to concentrate on building even better race cars.”

Continued next page

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AUTOMOTIVE & TRANSPORT

Continued from previous page

Gen3 Supercars have just debuted their brand-new race car, called Gen3. The complete redesign of the chassis, suspension, the entire car was redesigned and is also run by every competitor in the field. A lot of the car now is ‘Controlled Design’. The only part of the ‘Car of the Future’ Supercar to come across to Gen3 was the transaxle, which is like a gearbox and differential system all-inone, set up in the back of the car. In the chassis, is tubular chrome alloy. Whincup says there is 300M grade steel in the spindles, and a little bit of stainless. “But as far as exotic materials go,” he says, “they’re strategically ruled out in the rule book to help keep the costs under control.”

“Triple Eight Race Engineering has now built infrastructure to design and manufacture a brand-new race car, which was debuted at the start of the year,” says Whincup. “We are nine months in, and there are a few parts needing to be redesigned and improved during the year. But we're sitting here with design and manufacturing capability of the category's biggest Motorsport brand looking for a new challenge.”

The last time AMT magazine spoke with Triple Eight Race Engineering, in 2012, the latest race car weighed in at 1,500kgs.

The spec of the Gen3 has massively changed mainly through design and the use of material as well. “The cars now come in around 1,350kgs,” explains Whincup. “That as you can appreciate, is a massive reduction in weight. Over a hundred kgs lighter than the previous car. The ceiling is also one hundred millimetres lower, so the roof can fit the modern Mustang and Camaro. The build is 100mm wider as well. So has a much wider stance, which helps with road grip around the corners.”

Mindset and culture The team at Triple Eight Race Engineering strive for a culture of playing their part to make sure their cars succeed. “All of the roles here at Triple Eight are unbelievably important pieces of the chain to be successful on the track. The great thing about sport is you can perform at your absolute best and ‘smash it out of the park’, but your opposition can go one better and you come home deflated.”

“There’s no set budget, so to speak, but we must keep improving, staying in front of the opposition who are also moving forward very fast. It's a very motivating world to be in and it creates great drive, passion and purpose for the 70-odd people we have here at Triple Eight.”

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The safety of these vehicles has also come a long way. While we are just trying to go fast and trying to be as light as possible, we're all for forever improving safety in the vehicle as well with window nets, firebombs and crumple zones. The list goes on and on.”

Partnerships Triple Eight Race Engineering is very proud of the fact they represent some of the biggest listed brands in the world. “We represent Red Bull and Ampol as our co-naming rights partners, and then we have companies like Supercheap Auto, National Storage, Chevrolet, Harvey Norman, HP, as part of our corporate partner lineup. That's a reflection of our quality assurance. So, we absolutely have to make sure that we represent brands in the best possible light.”

Jamie Whincup visited AMTIL’s Australian Manufacturing Week trade show this year, and has been interested to work with the Australian manufacturing community on new ventures.

“We've geared up to design and manufacture this new Gen3 car, and we've stocked the shelves,” he says. “We'd love to collaborate with other designers and manufacturers, to be able to utilise our highly skilled team. Some people might think we'd be too expensive, but this is not necessarily the case. The focus of this new Gen3 car is to reduce the costs, while still be able to manufacture highquality componentry that can be manufactured efficiently with our expertise, high performance, attention to detail and quality control.”

The Gen3 development focused on a lower cost vehicle, compared to the ‘Car of the Future’ which was superseded in 2023.

“Our focus is on being able to design something that's quicker, cheaper, and more efficient to manufacture,” says Whincup.

Triple Eight’s manufacturing capability begins with their five CNC machines, a big fabrication area. They also have an ABB robot with a welding head attached.

Fabrication Mark Dutton is Triple Eight’s Team Manager, AMT spoke to him about the range of fabrication machines on hand in the garage. Triple Eight currently has five Haas CNC machines in the machineshop, two 5-axis and one 4-axis mill, alongside two CNC lathes with living tooling. “With our highly skilled machinists, we have been able to consistently produce high precision components for ourselves, every Supercars’ team in pitlane and non-motorsport customers including Qantas.”

AUTOMOTIVE & TRANSPORT

“Alongside our incredibly talented manual fabricators, we have our CNC fabrication capabilities with a 5-axis tube laser cutter,” says Dutton, “and a flat bed laser cutter being programmed by our laser cutting specialist with over 20 years experience.”

Their 5-axis multi-stack CNC mandrel bender has produced the exhaust system for every racing Camaro competing in Supercars, along with a range of other components used throughout the race cars.

Triple Eight’s large dual station robotic cell houses the ABB robot equipped with top-of-the-line Fornius CMT welding technology, big enough to have two current Supercar chassis on jigs simultaneously if needed. “The single robot tracks between the two high-capacity rotary stations so that it can safely weld in one cell while a technician is unloading or preparing the next job to maximise productivity,” explains Dutton. “The ability for the robot to utilise the track and rotator simultaneously makes it an 8-axis system.”

six and a half hours, driving over 1,000kms to get to the finish.

It’s a very hard race to win and a very easy race to lose. Triple Eight Race Engineering is very proud of the fact that we've won 50% of the times we've taken up the challenge. We've won ten out of 20.

And we want to make sure we keep that record up.”

The next race on the agenda for the Triple Eight Race Engineering team is the Adelaide 500, which really is the grand final, the final race for the year. Although at the time of writing, the race is yet to be run, AMTIL wishes them all the best. This is the Team Championship.

The Driver’s Championship. And it is also the Manufacturing Engineer’s Championship. redbullampolracing.com.au

“At Triple Eight, we are constantly looking to increase our capacity and capabilities so we have a Trumpf Robotic Welding Cell joining the team early in the new year. This will be perfect for rapid production of smaller components,” says Dutton. “With its teach learning programming a real time saver, the quality of Trumpf means it is built for getting the job done with precision and speed, a perfect match for Triple Eight.”

“This Trumpf robotic weld cell is our newest fabrication tool,” adds Whincup. This unit is designed to fabricate small quantities at a high precision capability. “This is perfect for our racing components because we have thousands of different parts but we only need quantities of say, 30. The ability to quickly switch to fabricated multiple items in a single day is important.”

Bathurst 1000 The Bathurst 1000 is by far the biggest event of the year. “It's like our Grand Final, although it's not the last race of the season,” he says. “It's the Melbourne Cup of Motorsport, really. It's the one event that, there'll be millions of people that don't watch motorsport all year, but they certainly tune in to see the Bathurst results, similar to the Melbourne Cup.” To Whincup, there are three things that make up Bathurst. “The 60-year history of the Bathurst 1000 race is fantastic. The circuit itself is magnificent. It’s in the top five circuits in the world. We're very lucky to have a circuit of that quality here in country New South Wales.”

“And then there's the race itself, at 1000kms. We've got these highperformance race cars that we are absolutely ringing the neck for

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AUTOMOTIVE & TRANSPORT

World best practice digitisation in transport/freight: And Australia?

A final report for our country’s Digitisation in transport and freight: Lessons for Australia project, run with the Department of Infrastructure, Transport, Regional Development and Communications and Swinburne University of Technology.

The aim of the project was to undertake a comprehensive systematic literature review of international best practice in digitisation in the transport and freight sectors. Key case studies demonstrating the benefits and impacts in terms of enhancing network performance, efficiency and productivity will be identified and analysed.

A number of measures available in the literature indicate that Australia’s transport sector falls behind on digitisation trends compared to many other Organisation for Economic Co-operation and Development (OECD) countries, particularly in terms of the role of information and communications technologies (ICT) in enhancing the performance and efficiency of the transport and freight sectors.

Background This research undertook a comprehensive review of international best practice in the area of transport and freight digitisation, with a view to understanding how digitisation might enhance these sectors’ performance. The research identified learnings from the experience of countries with higher levels of transport and freight digitisation, and how these could be adapted to help Australian decision-makers shape the future directions of innovations in these sectors. Key case studies demonstrating the benefits and impacts in terms of enhancing performance and productivity were analysed.

The research also included stakeholder consultations to ensure the findings reflected industry and government experiences of the barriers, opportunities and benefits of digitisation.

Evaluation framework This study considered all users and transport modes that are part of the transport and freight sectors. These include road, public transport, freight and supply chain management, rail transport, maritime and shipping, active transport and aviation. Within each sector, a number of functional areas that are amenable to digitisation and technology solutions were identified. A total of 40 functional areas were analysed that included road safety, adaptive traffic signal control, managed motorways, public transport management, video

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surveillance and monitoring, electronic ticketing payment systems, asset and cargo management, train signalling, airport safety and security, predictive asset management, port operations and safety of cyclists and e-scooters. The study also identified key emerging technologies that offer promise in addressing the key challenges facing the transport and freight sectors such as artificial intelligence (AI), CAVs, Internet of Things (IoT) and blockchain. Digitisation best practices in each of the 40 functional areas were evaluated taking into consideration the numerous benefits of tech-enabled smart mobility solutions such as improving safety, productivity, efficiency and user experience. The evaluations showed high benefit-costratios (BCRs) for digitisation solutions compared to expanding physical transport infrastructure. On average, traditional transport capacity expansion projects (such as building new roads or tunnels) provided a BCR below 3.0. This is much lower than the benefits of technology and digitisation solutions that were found to exceed a BCR of 5.0 in many cases and reach as high as BCR of 30 in some cases. Digitisation investments were also found to require much lower capital investment compared to infrastructure building projects.

Benchmarking This study also included benchmarking of best practice transport and freight digitisation across OECD countries. Comparative evaluations were undertaken based on 10 international digitisation indicators in addition to 40 new indices developed in this research covering all functional areas. This information was used to develop best practice transport and freight digitisation indices based on three pillars that included productivity, industry and consumer acceptance, and policy and regulations. The benchmarking results showed Australia’s best practice transport and freight digitisation index to range between a score of 59 for the maritime sector up to a score of 81 for the road sector. Australia’s overall index score across all sectors was 72 which ranked Australia at number 13 amongst all OECD countries. imoveaustralia.com

AUTOMOTIVE & TRANSPORT

Mercedes-AMG PETRONAS F1 Team TeamViewer gives fast and reliable access to data to drive performance for the Mercedes-AMG PETRONAS F1 Team.

In Formula 1, where the competition is as fierce off the track in terms of performance as it is on it, nothing is left to chance. The MercedesAMG PETRONAS F1 Team seeks competitive advantage at every stage of its process to get the car across the finish line first and that includes the technology it deploys throughout its operations.

TeamViewer’s software allows the engineers to share this insight with their driver with zero delay, permitting them to talk the driver through the information as it is presented. This ability to discuss run plans and much more information is of high value to the team when preparing for their next track run.

As one of the world’s most highly technical and data-driven sports, the team's engineers trackside and in the Race Support Room (RSR) at the factory in Brackley, play an essential role during pre-season test sessions and during qualifying and practice runs on Grand Prix weekends. Communication between the engineers and the driver is crucial and the ability to provide the driver with instantaneous access to data, videos and telemetry via the drop-down screens in the garage, informs critical decisions about strategy and pit stop.

Results

Challenges With tight turnaround times between runs, when the driver pulls into the garage during qualifying, practice and test sessions, time is of the essence. It’s even more important since the 2021 season, as both Friday practice sessions have been shortened by half an hour each to just 60 minutes. To avoid wasting valuable seconds, two drop-down screens displaying multiple applications allow the driver to scroll through visuals to access crucial information without having to get out of the car. In a sport where every millisecond counts, the data feeds to the drop-down screens need to be one hundred percent accurate and reliable. The team had trialled other software solutions, but reliability issues meant they did not deliver the performance required.

Solution The Mercedes-AMG PETRONAS Formula 1 Team has already been successfully using TeamViewer Tensor as the ultimate remote connectivity platform across its racing operations. In July 2022 the engineering team turned to TeamViewer as its software solution for the dropdown screen data feed. The Tensor platform enables enterprise grade remote connectivity for always-on scenarios. It boasts the best-in-class security, scalability and manageability making it the performance driving solution that the team needed during practice and qualifying runs in the garage.

Using the platform, the team's engineers trackside and in the Race Support Room (RSR) at the factory can provide the drivers with fast and one-hundred-percent reliable access to all the live data they have on the runs while the driver stays in the car. This includes intelligence relating to weather, run plans, strategy, and competitor analysis, as well as live feed TV of the session, playbacks of their run and footage of the competitors on the track – without stepping out of the car and wasting essential seconds. Within the Team garage, two engineers control exactly what information is distributed to the driver on each of the drop-down screens. With a mountain of data available at their fingertips, the engineers are able to disseminate the key information that will aid in the ultimate goal of delivering better performance.

TeamViewer’s secure remote connectivity solution enables the team’s race engineers to provide the driver with instant and consistently reliable access to all the data, stats and live feeds they need when they enter the garage, to inform their strategy for the next and future runs. Having delivered a one hundred percent reliable performance during the trial, the Brackley team counts on TeamViewer as its technical solution for the drop-down screens. And when it comes to performance, it’s not just TeamViewer’s technical prowess that’s been put to the test. The team values TeamViewer’s close collaboration and partnership and is actively working together to identify more use cases around the garage.

“We have a great relationship with the team at TeamViewer and speak to them most weeks about development opportunities and features we’d like to see in the toolset. We can see lots more use cases for our team and we are excited to see what the future brings,” concludes Steve Riley, Head of IT and Service Operations.

About Mercedes-AMG PETRONAS Formula 1 Team Mercedes-AMG PETRONAS Formula One Team is the works team of Mercedes-AMG, competing at the pinnacle of motorsport – the FIA Formula One™ World Championship.

Formula One is a sport like no other. Combining elite teamwork, cutting-edge technologies and innovation, high-performance management and exceptional driving skill, teams develop race cars capable of competing against their rivals in a high-octane environment that spans upwards of 20 races across five continents throughout each season.

The Mercedes-AMG PETRONAS Formula One Team, based across Technology Centres at Brackley and Brixworth in the United Kingdom, brings together over 1,000 dedicated and determined people that design, develop, manufacture, and race the cars driven by seven-time World Champion Lewis Hamilton and Grand Prix winner, George Russell.

Winning seven consecutive double Drivers’ and Constructors’ World Championships from 2014 to 2020 and securing a record-breaking eighth consecutive Constructors’ Championship success in 2021, the Team is one of the most successful in the sport’s history.

Between returning as a Constructor in 2010 and the end of the 2022 season, the Mercedes-AMG works team has scored 116 wins, 264 podium finishes, 128 pole positions, 91 fastest laps and 54 one-two finishes from 259 race starts. teamviewer.com/eu-au

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AUTOMOTIVE & TRANSPORT

Motoring in an AI future Frank Baldrighi, business development manager, Australia and New Zealand at Getac talks about how augmented reality and artificial intelligence are driving change for vehicle repair, which also changes vehicle component requirements.

Electric vehicles and autonomous driving technologies are gaining traction and becoming increasingly common. As vehicles become more technologically advanced and digitally connected, they are transforming the automotive industry, making modern vehicle repair more complex. This is especially true in the industrial sector, where vehicles have grown increasingly intricate, integrating sensors, automation, and digital interfaces.

Many Australian repair shops are now confronted with changing demands that extend beyond their traditional expertise. Technicians are required to handle software diagnostics, electronic calibrations, and intricate digital networks alongside traditional mechanical repairs. A malfunction or breakdown in an industrial setting doesn't just mean a repair cost. Instead, it can lead to significant operational downtimes, jeopardising projects and impacting bottom lines.

The rapid pace of the industrial sector doesn't leave room for prolonged equipment downtime. Stakeholders, from operators to investors, demand quick turnarounds, minimal disruptions, and a guarantee that machinery will operate at peak efficiency.

To meet these stringent demands and keep pace with the industry, repair and maintenance processes must undergo a transformative upgrade. Augmented reality (AR) and artificial intelligence (AI) solutions have emerged as essential tools to help repair shops stay relevant and empower repairers to seamlessly adapt to new vehicle technologies and remain in demand.

There are two key ways AR and AI can empower repairers in the modern operating environment:

1. Virtual diagnostics At its core, AR technology merges the physical and digital worlds.

This lets automotive repairers run remote diagnostics without having the vehicle physically present. This is critical to help industrial operators maintain efficiency even in the event of a breakdown or incident. A vehicle located in a remote operating environment hundreds of kilometres away could connect with a repair shop, giving technicians access to a real-time visual feed of the vehicle’s internal systems. This eliminates the need for long drives and delays for a preliminary diagnosis which adds a layer of convenience for customers and streamlines the repairer’s operations.

Additionally, AR lets technicians tap into remote expert support whenever needed for more complicated repair and maintenance tasks. If a technician on-site faces a challenging repair issue, they can instantly connect with a specialist. Through AR, the expert can view the problem, provide guidance, and even overlay instructions onto the technician’s display if they are using wearable devices like smart glasses.

Field technicians can also use AR and AI tools to access a virtual library of repair manuals, schematics, and expert systems powered

by AI. This on-the-go knowledge repository ensures that they can tackle a wide variety of challenges without the need for back-and-forth trips to vehicles or customers. Bolstered by real-time AR support, even complex tasks like recalibrating advanced sensor systems or troubleshooting hybrid vehicle circuits become more accessible. For example, technicians can overlay digital schematics onto vehicles to ensure precision in every step. AI and AR solutions don’t just benefit technicians in the field, either. With AR, training modules can become immersive experiences, empowering technicians to practice repair scenarios in a virtual environment, letting them learn and make errors without any real-world consequences. AI can be used to customise training modules based on the technician’s proficiency, ensuring a tailored learning experience.

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2. Data-driven insights AI-driven platforms can aggregate data from multiple repairs to identify patterns and offer insights. These can range from predicting common vehicle issues based on make and model to optimising inventory levels based on repair trends. Additionally, it can help determine the recyclability of old vehicle parts, promoting more sustainable practices in the industry and reducing waste by identifying which parts can be refurbished or recycled. Such comprehensive data access ensures that the root cause of any issue is quickly identified and addressed, reducing the likelihood of repeat visits. For example, technicians can use data repositories to instantly access vehicle histories, cross-referencing previous issues with current diagnostics. The analysis of local and global trends can also aid in identifying flaws or areas for improvement, creating a feedback loop that can lead to better vehicle designs in future.

Repairers can also use data to boost their offerings to customers, moving from a solely reactive approach to a proactive one. For optimal service, repairers can use AI to analyse vehicle data and predict potential issues before they become critical problems, including analysing vast amounts of data from vehicles to predict when parts are likely to fail, informing vehicle operators of impending concerns or risks. This lets repairers schedule maintenance sessions in advance to ensure vehicles remain in peak condition and reduce the potential for more costly future repairs. It also means parts can be ordered and replaced proactively, reducing the downtime of vehicles and ensuring that repair shops stock the necessary parts in advance and have the right parts available when needed, reducing wait times for repairs. AI and AR can also be used to effectively integrate operators and repairers more closely with parts suppliers so that, when a part is needed, the best supplier can automatically be identified based on part availability in real-time. The use of AIpowered platforms can also be used for more efficient part-routing and process optimisation for transformation at every touchpoint.

A future rooted in AI and AR-powered repair solutions Differentiation has never been more critical for a crowded market, and it’s clear that repairers armed with AR and AI will be better equipped to handle future challenges by reducing errors, optimising costs, and improving the quality and timeliness of services.

As these technologies mature and businesses fully realise their full potential, the horizon of opportunities will only expand. By staying innovative and open to change, repairers can redefine their trajectories to ensure relevance, growth, and sustainability in an ever-evolving landscape. getac.com

AUTOMOTIVE & TRANSPORT

Electric heavy hauler Wabtec and Roy Hill unveil the first FLXdrive battery locomotive.

Wabtec and its launch customer Roy Hill, a leading iron ore miner majority owned by Hancock Prospecting, have celebrated the debut of the FLXdrive battery locomotive, the world’s first 100% battery-powered, heavy-haul locomotive for mainline service. The ceremony unveiled the unique, striking, pink-coloured locomotive at Wabtec’s design and development centre in the USA state of Pennsylvania in front of employees, customer executives, and other officials.

“This FLXdrive locomotive represents a major step in the journey to a low-to-zero-emission future in the rail industry,” said Rafael Santana, President & CEO of Wabtec. “The FLXdrive is driven from within by our battery technology. Roy Hill is an ideal customer to partner with given their leadership and excellent operational record.”

Roy Hill’s FLXdrive battery-electric locomotive will feature an energy capacity of seven megawatt hours (MWh). Based on the route and company’s rail operations, the FLXdrive is anticipated to provide a double-digit percentage reduction in fuel costs and emissions per train. Once Wabtec completes the final battery installations and track testing, the locomotive will begin its 17,000-kilometre journey in 2024 for delivery to its new home in the Pilbara region of Western Australia, one of the world’s premier mining precincts.

“The foresight of our Executive Chairman, Gina Rinehart AO, has been instrumental in establishing an environment in which we can successfully leverage the ingenuity of our people alongside key partners like Wabtec to transform our rail and mining operations through next-generation technologies,” said Gerhard Veldsman, CEO of Hancock Prospecting Group Operations.

“The FLXdrive locomotive represents not only a first for the Pilbara, but a first for the mining industry. The technological smarts that have gone into the development of the loco make it well-suited for our rail network. By using regenerative braking, it will also charge its

battery on the 344km downhill run from our mine to port facility and use that stored energy to return to the mine, starting the cycle all over again. This will not only enable us to realise energy efficiencies but also lower operating costs.”

Right now, Roy Hill uses four Wabtec ES44ACi “Evolution Series” diesel-electric locomotives to pull trains that are typically 2,700 metres in length carrying more than 33,000 tonnes of iron ore. The addition of the FLXdrive will form a hybrid locomotive ‘consist,’ with Wabtec diesel-electric locomotives. The FLXdrive manages the overall train energy flow and distribution through its state-ofthe-art energy management software. It is also designed with a unique battery thermal management system using liquid cooling to withstand the Pilbara heat, where ambient temperatures can exceed 55°C. Roy Hill’s iconic pink livery symbolises the company’s commitment to assisting research and those suffering from breast cancer. To commemorate the FLXdrive’s premiere, Roy Hill, and Breast Cancer Awareness Month, Wabtec donated nearly A$80,000 to Linked By Pink, a non-profit organisation consisting of Erie area survivors diagnosed with breast cancer before the age of 45.

Roy Hill is a world-class iron ore operation in Western Australia’s mineral rich Pilbara region. Roy Hill is chaired by prominent Australian business leader and current West Australian of the Year, Gina Rinehart AO. Roy Hill incorporates an integrated mine, rail, and port facilities, shipping more than 63 million tonnes per annum.

Roy Hill’s first shipment departed Port Hedland in December 2015 to South Korea and in the years since has established itself as a trusted and reliable producer of iron ore, delivering to steel making markets including Japan, South Korea, India, Malaysia, China, and Vietnam. royhill.com.au wabteccorp.com

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AUTOMOTIVE & TRANSPORT

Custom Plenum Creations Fusion 360 and a Cadpro custom post bridges the gap between 4- and 5-axis.

Ariel Banco of Custom Plenum Creations began hand producing automotive intake manifolds out of his garage in 2003. Fast forward seven years and Banco had evolved his business model and opened shop. He has since acquired three CNC machines and continues to produce intake manifolds for the Australian and international custom car market.

As a small business, Ariel needed to simplify operations and increase efficiency. He required a modelling and CNC software that would allow him to easily model parts and manufacture them. Additionally, his CNC machines were 4-axis, but his parts had features which required machining on the fifth axis.

Project goals

Business outcomes

Banco was looking for CAD/CAM software that was simple to design with and that he could make changes to quickly. He explains, “It’s what I need for a business like mine, it’s not a high production business, it’s a lot of different parts and low volume. I need to make changes quickly and the process needs to be as smooth as possible.”

Fusion 360 has enabled Banco to model and programme on his machine quickly and easily and has driven a streamlined production model in his small business. The custom post-processor has reduced the time and cost it would have previously taken Ariel to produce his manifolds.

To gain 5-axis like machining capability on his 4-axis machines, Ariel required a custom postprocessor that would take advantage of angle milling heads he had previously purchased. To ensure a smooth process, he also needed a seamless and intuitive workflow in Fusion 360 for programming toolpaths with the angle heads.

Solution Banco employed Fusion 360 as the most user-friendly solution for the design and modelling of his intake manifolds. To address the 5-axis requirements, Scott Moyse from Cadpro, supplied Ariel with a custom post–processor. Moyse developed the post to make programming as simple as programming a 5-axis machine in Fusion 360.

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“It removed an operation that I had to do by hand and saved an hour per complete part. In terms of cost, it’s saved 2-3 hours a week, which is two weeks of savings per year. That’s massive for me with a small shop like mine where I’m trying to save every minute.”

Conclusion Fusion 360’s ease of use has allowed Ariel to run his business more efficiently and helped him to avoid costly and time consuming modelling glitches. As he explains, “Fusion 360 is easy to use, easy to learn and I wouldn’t be doing what I’m doing without it,” said Banco. Cadpro’s custom processor has further enabled Banco to run his business less laboriously, saving time in the machining process and cost-effectively bridging the gap between a 4-axis & 5-axis CNC machine. cadpro.io

AUTOMOTIVE & TRANSPORT

WAU picks Stratasys FDM for 3D printing Walkinshaw Andretti United selects Stratasys FDM as its 3D printing technology of choice.

Stratasys Ltd and Australia channel partner TCL Hofmann have announced that motorsports team Walkinshaw Andretti United (WAU) has selected Stratasys FDM® 3D printing technology to anchor its new additive manufacturing hub and has a new Stratasys Fortus® 450mc 3D printer.

“Every second counts not only on the track but also in the workshop,” said Bruce Stewart, Team Principal at Walkinshaw Andretti United. “We use 3D printing to prototype and produce parts much faster than we could through traditional methods.

At the same time, the high- performance standards of Stratasys industrial printers and materials means these parts also perform exceptionally well, despite the extreme heat, dirt, and vibration that go with Supercars racing. As such, Stratasys and TCL Hofmann make great partners for our team.”

WAU’s new Fortus450mc 3D printer is its second FDM printer from Stratasys. The industrial-grade printer accommodates more than two dozen materials, including those with flame-retardant properties, chemical resistance, and strength reinforced by carbon fiber. It provides best-in-class reliability and repeatability, making it ideal for applications such as manufacturing tooling and end use parts. The 3D printers will be located in the new TCL Hofmann | Stratasys

Smart Manufacturing Hub, which is a dedicated, temperaturecontrolled 3D printing hub located next to WAU’s vehicle assembly area. The area is designed to showcase 3D printing capabilities for visitors, including showcasing additively manufactured parts from WAU cars. Stratasys also plans to partner with WAU to use the facility to test innovative new products and materials for the automotive racing industry.

WAU is one of the most successful Supercars Championships teams in the history of the category, with multiple driver and team championships and eight wins at the signature Bathurst 1000.

Stratasys is leading the global shift to additive manufacturing with innovative 3D printing solutions for industries such as aerospace, automotive, consumer products and healthcare. Through smart and connected 3D printers, polymer materials, a software ecosystem, and parts on demand, Stratasys solutions deliver competitive advantages at every stage in the product value chain. The world’s leading organisations turn to Stratasys to transform product design, bring agility to manufacturing and supply chains, and improve patient care. tclhofmann.com.au/products/3d-printing/ stratasys.com

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AGRICULTURE, FOOD & BEVERAGES

Deconstructing methane One of the biggest sources of greenhouse gases – animal agriculture – is a huge problem to solve, and one bioengineering start-up thinks it has the answer. Drew Turney reports from WA. Considering the problems associated with some large scale agribusiness practices like the inhumane treatment of animals, lower quality outputs, high density pollution and staggering water and chemical needs, it's no wonder a return to artisanal subsistence farming seems so attractive.

Dr Alex Carpenter

The bad news; it's impossible. Countries where it still proliferates have stagnant economies, and it doesn't offer the variety of output we need in human diets. A single industrialised world farmer produces more food with higher nutritional quality for more people per labour unit than several subsistence farmers.

There just isn't enough arable land on Earth to feed eight billion people without the scale of factory farming, and if we want to address the negative impacts it can have on the climate and environment, the only thing that might save us is biotechnology.

And one of the biggest problems to solve in growing and processing our food is methane. A third of all the methane we produce is from agriculture, and up to a third of that figure is from enteric methane, produced when farm animals digest food.

That means – at the risk of putting it indelicately – every time a cow or sheep burps or farts, it exacerbates the greenhouse effect. And with meat and dairy animals in the world numbering around three billion, that's enough to make your eyes water for several reasons.

It's also a problem that's only going to grow. According to Dr Tom Williams, a PhD in synthetic biology: “We're going to have to increase food production by as much as 68% by 2050 if the population keeps growing at the current rate.”

Dr Tom Wiliams

It's also urgent because, while carbon dioxide gets most of the rap, methane is considered by climate scientists to be far more serious.

CO2 breaks down over about a century and methane takes only about 20 years, but during those 20 years it's about 80 times more potent. “Anything we do with CO2 emissions we have basically a hundred year lag time because that's how long existing emissions will stay in the atmosphere,” Williams says. “If we mitigate methane emissions now we'll feel the benefits relatively quickly.”

De-methaning agriculture Williams decided to do something about it, and he figured out what he thinks is a ground-breaking method. Along with colleague Dr Alex Carpenter, Williams founded Number 8 Bio. Number 8 Bio takes its name from New Zealand (where Williams is from) farm folklore. Using nothing but home-grown ingenuity and a product called ‘number 8 gauge wire’ that originated in the 1860s, it's said Kiwi farmers can fix anything. In the same way, Number 8 Bio wants to fix the environment, using bioengineering to decarbonise farming. The company has a unique biochemical process to manufacture feed that results in a monumental drop in methane emissions among ruminants – the hoofed herbivores that get nutrients by their digestive systems fermenting food prior to digestion. Williams and his colleagues are working with a compound called bromoform. A colourless liquid in its common form, bromoform is an organohalide, one of several organic compounds that contain a halogen like fluorine, chlorine, bromine or iodine that bonds to a carbon atom. Bromoform is also the most common organohalide produced in the desalination of seawater.

Bromoform is also found in seaweed, specifically a variety called asparogopsis, and the Number 8 Bio team has figured out it’s really good at eliminating methane. When delivered in animal feed containing the correct level of active agents, he says trials have caused methane reductions of up to 50%.

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Number 8 Bio's process has another advantage. Because the animal produces less methane for the food it eats, more of that food is converted into energy, which means it can eat less for the same energy intake – so farms don't need to buy as much feed.

Seaweed in the fields From there, the complex science is theoretically pretty straightforward.

The seaweed contains an enzyme called bromoperoxidase that makes bromoform. Number 8 Bio uses bioengineering to functionally express the bromoperoxidase in yeast, just like the way your genes functionally expressed you to have brown eyes or grow tall in adulthood when you were conceived.

The bromoform-rich yeast is then processed and packaged just like a bag of baker's yeast you'd see at the supermarket, and that's essentially Number 8 Bio's product. It's mixed in with livestock feed that results in far less methane produced by the stomachs of those

AGRICULTURE, FOOD & BEVERAGES

billions of meat and dairy animals. It might seem like the perfect plan because seaweed is so plentiful, but it's not so easy to process in the quantities we'd need to put a serious dent in global ruminant methane emissions. “Seaweed works, but there are some serious challenges in scaling it up,” Williams says. “It grows in the ocean, it grows slowly and it can't be engineered. There's no existing infrastructure for storing or transporting it and it doesn't actually taste very good to cows.”

That's where Williams' and Carpenter's backgrounds came in.

Their day to day studies involved engineering micro-organisms to make chemicals that already exist in nature, molecules with billions of years of practice converting energy, sequestering carbon and breaking methane down.

“If you engineer a micro-organism for yeast, you're using something that's already growing all over the world in million-litre tanks and you can make tons of it in a couple of days. You can dry it, store it, cows love eating it, it's nutritious. It's one of the most well understood organisms on Earth – we can engineer it to do virtually whatever we want easily. That solves the problem of scalability and uptake.”

Selling the future Initially Williams and Carpenter plan to sell the yeast biomass with the active ingredients directly to farmers and nutritionists where it might be combined with alternative feeds that address other animal health or productivity issues.

But they have an eye on the future. As Williams says somewhat dryly about the number of ruminant animals on Earth: 'it's a lot'.

“Servicing even one million animals is pretty good, and the way to do that is probably partner in the places we don't think we'll have sales any time soon,” he says. “In the future we'll look at a mixed model of corporate partnerships or licensing models.”

Then there's the considerable matter of a burgeoning meat alternative market, where sales in meat made of everything from grain to fungus grew by nearly 40% in North America across 2017/18. Haven't we already solved the problem of methane emissions, just waiting for the alt-meat industry to catch up?

“We're very happy for those products to be part of the solution and those companies to succeed, but the reality is we're not taking those synthetic biologies up fast enough to make enough of a difference to climate change,” Williams says.

Not only that, substitute meat might not turn out the silver bullet we hope for. Williams starts our conversation by talking about how culturally ingrained meat is, and how hard it'll be to depose it from the human diet. “It's especially unrealistic to expect it with large parts of the global population coming into the the middle class, which is where consumers demand large amounts of meat and and milk.”

But the other matter that might pose the ultimate hurdle to Number 8 Bio and other companies like it is price. “There has to be some economic benefit to the farmer,” Williams says. “They generally have slim margins and they don't have the luxury of taking on a green technology just because they want to.”

But the value proposition for Number 8 Bio's scientific breakthrough is pretty compelling. Described by Williams as 'feed conversion efficiency', it lets each head of cattle perform more efficiently. As we've seen, animals don't need to eat as much, so even if Number 8 Bio feed is priced a little higher until it takes hold, the economic outlay might still be in its favour.

“We think the company that can lock that in the best will be the one that succeeds in this market,” he says. And with a US presence already set up to capture the North American market and work on perfecting the process continuing apace at home, Number 8 Bio seems on track to do just that. number8.bio

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AGRICULTURE, FOOD & BEVERAGES

Physical daggers win Titanium micro-spikes skewer resistant superbugs.

A new study suggests rough surfaces inspired by the bacteria-killing spikes on insect wings may be more effective at combatting drugresistant superbugs, including fungus, than previously understood.

The increasing rates of drug-resistant infection has health experts globally concerned. To avoid infection around implants – such as titanium hips or dental prosthesis – doctors use a range of antimicrobial coatings, chemicals and antibiotics, but these fail to stop antibiotic-resistant strains and can even increase resistance.

To address these challenges, RMIT University scientists have designed a pattern of microscale spikes that can be etched onto titanium implants or other surfaces to provide effective, drug-free protection from both bacteria and fungus.

The team’s study published in Advanced Materials Interfaces tested the effectiveness of the altered titanium surface in killing multi drugresistant Candida – a potentially deadly fungus responsible for one in ten hospital-acquired medical device infections.

The specially designed spikes, each of a similar height to a bacteria cell, destroyed about half the cells soon after contact.

Significantly, the other half not immediately destroyed were rendered unviable from the injuries sustained, unable to reproduce or cause infection. Lead Postdoctoral researcher, Dr Denver Linklater, said metabolic analysis of protein activity revealed both the Candida albicans and multi-drug resistant Candida auris fungi cells sitting injured on the surface were as good as dead.

“The Candida cells that were injured underwent extensive metabolic stress, preventing the process where they reproduce to create a deadly fungal biofilm, even after seven days,” said Linklater, from RMIT’s School of Science. “They were unable to be revived in a non-stress environment and eventually shut down in a process known as apoptosis, or programmed cell death.”

The surface's effectiveness against common pathogenic bacteria including golden staph was demonstrated in an earlier study published in Materialia.

Group leader, Distinguished Professor Elena Ivanova, said the latest findings shed light on the design of antifungal surfaces to prevent biofilm formation by dangerous, multi-drug resistant yeasts.

“The fact that cells died after initial contact with the surface – some by being ruptured and others by programmed cell death soon after – suggests that resistance to these surfaces will not be developed,” she said.

“This is a significant finding and also suggests that the way we measure the effectiveness of antimicrobial surfaces may need to be rethought.”

“It’s like stretching a latex glove,” Ivanova said. “As it slowly stretches, the weakest point in the latex will become thinner and eventually tear.”

Her team have spent the past decade replicating these insects’ nanopillars in nanopatterns of their own, with this latest advance achieved using a technique called plasma etching to create the antibacterial and antifungal pattern in titanium.

Ivanova said the relatively simple etching technique could be optimised and applied to a wide range of materials and applications.

“This new surface modification technique could have potential applications in medical devices but could also be easily tweaked for dental applications or for other materials like stainless steel benches used in food production and agriculture,” she said.

Industry collaboration

Advances have been made over the past decade in designing surfaces that kill superbugs on contact. However, finding the right types of surface patterns to eliminate 100% of microbes so some don’t survive to become resistant is an ongoing challenge.

Study lead author and joint PhD candidate with RMIT and the ARC Australian Steel Manufacturing Research Hub, Phuc Le, said working closely with industry partner BlueScope Steel helped focus efforts to practical solutions for industry.

“This latest study suggests that it may not be entirely necessary for all surfaces to eliminate all pathogens immediately upon contact if we can show that the surfaces are causing programmed cell death in the surviving cells, meaning they die regardless,” she said.

“Collaborating with industrial partners has been a transformative aspect of my PhD journey,” he said.

Leading the way in bioinspired solutions RMIT’s Multifunctional Mechano-biocidal Materials Research Group has led the world for over a decade in the development of antimicrobial surfaces inspired by the nanopillars covering dragonfly and cicada wings.

Ivanova herself was among the first to observe how when bacteria settle on an insect wing, the pattern of nanopillars pulls the cells apart, fatally rupturing the membranes.

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“Their firsthand insights as manufacturers have provided clarity on the challenges their products face and opened doors for me to research and devise practical solutions. And while our studies are in the preliminary stages, the prospects for product optimisation are promising.”

The research team acknowledge the importance of facilities used in this research including RMIT’s Microscopy and Microanalysis Facility, the Melbourne Centre for Nanofabrication and Bio21 Proteomics Platform, and support from the ARC Australian Steel Manufacturing Research Hub. rmit.edu.au

AGRICULTURE, FOOD & BEVERAGES

Quality air in food The significance of air quality in food and beverage creation.

Air, though seemingly harmless, can carry contaminants that pose significant risks to the integrity of food and beverage products. Traditional ‘lubricated’ air compressors, which inject oil into the compression chamber, have been a standard in many manufacturing facilities. However, these units present a considerable risk in environments where the strictest hygiene standards must be maintained. Oil and its byproducts have the potential to compromise the purity of food and beverage products. Even trace oil contamination an lead to spoilage, off-flavours, or worse, endanger the health of consumers. To address these risks, the industry should incorporate oil-free air compressors as a crucial element of their production process.

The advantages of oil-free air compressors.

Elimination of Contaminants: Oil-free compressors function without compressed air becoming in contact with any lubricating oil, eliminating the risk of potentially harmful substances into the compressed air supply, resulting in a final product of superior quality.

Stringent regulatory compliance: Using oil-free air compressors in the food and beverage industry signifies a dedication to meeting strict regulatory standards. This reassures both regulatory bodies and consumers of the facility's commitment to ensuring food safety.

Maintenance efficiency: Oil-free air compressors require significantly less maintenance compared to lubricated models, reducing downtime and associated maintenance expenses. This leads to a more efficient and streamlined production process.

Environmental responsibility: Oil-free compressors are environmentally friendly because they eliminate the presence of oil in condensate that would otherwise require treatment. This aligns with

the industry's increasing dedication to sustainable and responsible production practices.

In the highly competitive industry of food and beverage production, maintaining high standards of quality and safety is imperative. Utilising oil-free air compressors is a pivotal measure in not only meeting but surpassing these benchmarks. By adopting this technology, manufacturers not only protect the quality of their products but also exhibit an unwavering commitment to the health and well-being of consumers.

As the industry advances, it is crucial that we welcome innovations that enhance our processes. Embracing oil-free air compressors is not just an option; it is a necessity in our quest for excellence in food and beverage production. Let us join together in our dedication to establishing fresh standards for quality, safety, and sustainability in this dynamic field. airpoweredservices.com.au

No-waste bags Biodegradable bags to revolutionise mushroom farming.

University of Queensland researchers are working with industry to develop biodegradable ‘plastic’ bags for use in mushroom farming, which could open lucrative opportunities in packaging and manufacturing.

Dr Nasim Amiralian from UQ’s Australian Institute for Bioengineering and Nanotechnology is collaborating with Queensland producer Scenic Rim Mushrooms to reduce the company’s reliance on plastic ‘grow bags’. “Grow bags are widely used across the fungiculture industry, but most are made from non-biodegradable materials which can only be burned or sent to landfill,” Dr Amiralian said.

"This adds to the 80,000-plus tonnes of plastic waste generated by Australian agriculture each year.

“This 12-month project is about designing a grow bag that provides optimum growing conditions, while also breaking down in soil.”

Dr Amiralian said existing biodegradable plastics made from corn starch, potato starch, or even mycelium – the vegetative part of mushrooms - are often brittle and lack long-term integrity. “But using fibres from agricultural waste like sugarcane is an affordable, high quality and sustainable way to ensure plastic grow bags can withstand high temperatures and humidity,” she said.

Scenic Rim Mushrooms founder Matthew Davis said the company’s farming methods were all sustainable, except for the use of plastics.

“The fungiculture industry has traditionally had to use plastics for mass commercial production, but this project gives us hope,” Davis said. “It’s a problem that needs to be fixed for us to become completely cyclic mushroom growers, and proceed to large volume commercial cultivation.”

Dr Amiralian said the grow bag project could lay the groundwork for the technology to be applied across agriculture, manufacturing, pulping and packaging. “Ultimately we’d like to see the product we develop translated to the global fungiculture and packaging markets,” she said.

The project has been funded with the help of a $30,000 Industry Kickstarter grant from the UQ Agri-Food Innovation Alliance, supported by the Australian Government Department of Education, Skills and Employment under the Strategic University Reform (SURF). uq.edu.au

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Hiringa Energy and Sundown Pastoral decarbonising agriculture Moree region hosts world’s first Good Earth Cotton farm and pioneers the next generation of decarbonised agriculture.

Green hydrogen company, Hiringa Energy and Australian agricultural and pastoral enterprise, Sundown Pastoral Co, have partnered to drive forward the next generation of decarbonised farming and agriculture in the northern NSW region after being awarded $35.8m in funding from the NSW Government. Together, the two industry leaders will enhance the capacity of the world’s first Good Earth Cotton farm to produce climate-positive and traceable cotton.

The Good Earth Green Hydrogen and Ammonia (GEGHA) project involves the construction and operation of a renewable ammonia and green hydrogen production facility near Moree. The project will help farmers reduce the emissions associated with their outputs and enable them to meet consumer demand for low-carbon and sustainable produce in increasingly carbon-conscious domestic and export markets.

The GEGHA project has been awarded $35.8m in funding from the NSW Government’s Hydrogen Hubs Initiative, validating GEGHA’s position in the future of Australia’s thriving green hydrogen industry.

“Our aim is to provide a more resilient, locally produced and lower emissions supply of key inputs — to farm production (fertiliser) and transport to market (fuel). The project will prove the technical and commercial model for decarbonised agricultural systems and sets a precedent for the new frontier of farming and heavy transport industries — where net-zero and commercial viability are inextricably linked,” said Cathy Clennett, Head of Commercial and Corporate Development at Hiringa Energy.

The GEGHA project will see the installation of the 27MW Wathagar Solar Farm, which will produce roughly 45,000MWh of energy per annum — the equivalent to powering over 4,000 homes — and enough hydrogen to displace more than 1.4 million litres of imported diesel.

“As we grow our footprint in Australia, we’re proud of our joint venture which will provide Sundown Pastoral and other regional customers with green ammonia to reduce their emissions related to fertiliser use and hydrogen as a replacement to diesel and LPG, both on-farm and on-road. Not only will GEGHA contribute to the sustainability of the region’s primary business, it will also

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drive employment growth by targeting the use of local staff and contractors,” explains David Heard, Hiringa’s Executive Director Australia. With its dedicated focus on the agricultural fertiliser market, the GEGHA project will simultaneously improve the reliability of fertiliser supply to local agricultural production while also decarbonising it — by manufacturing fertiliser close to the point of use and eliminating the carbon-intensive use of methane feedstock, and using renewable energy to drive the process.

“We’re proud to be leading the industry by example. Our project will contribute to the sustainability of primary production and business in the region, providing a platform for the low-carbon transition, and a foundation for economic stability and opportunity. Australia’s hydrogen industry is at an inflection point, which is forecast to generate $50bn in additional GDP, and create more than 26,000 direct and indirect jobs by 2050,” added Heard.

The GEGHA project will result in direct abatement of over 17,000t CO2 equivalent per annum. This is in addition to substantial indirect abatement and safety benefits associated with reduced shipping and heavy vehicle emissions required to transport fertiliser and diesel.

The project will demonstrate commercial viability of low-carbon fertiliser production based on the world’s first Good Earth Cotton farm in Moree, to be followed by medium-scale expansion across the state’s agricultural sector.

“GEGHA’s production of anhydrous ammonia comes at an important time for the Australian agricultural sector, as global consumers start to demand sustainable food and fibre. Exemplifying how Australia can decouple agriculture from fossil fuel driven fertiliser production, we’ll also provide a credible pathway for heavy trucking to transition to low emission transport using hydrogen and deliver on-farm emissions reduction for the agricultural sector with alternatives to fossil fuels such as LPG and diesel. We’re thrilled to be working with Hiringa to fuel the next generation of agriculture systems in Australia,” concluded David Statham, Owner of Sundown Pastoral Co. goodearthcotton.com

energy.nsw.gov.au

AGRICULTURE, FOOD & BEVERAGES

Seaweed rennet Milk-clotting enzymes found in marine species may help cheesemakers meet our insatiable appetite for cheese.

As global cheese consumption is expected to increase, cheesemakers could face an uphill battle to keep up with our cravings. But if food scientists have anything to say about it, they might one day be able to draw upon a surprising resource to help them ride the wave of demand.

have also indicated proteases from seaweed macroalgae may be chemically suited for the job. “A seaweed-derived milk coagulant would be preferable for industrial-scale cheese-making due to the relative abundance of seaweed available in the world compared to animals,” A/Prof. Zhao said.

Associate Professor Jian Zhao, from the School of Chemical Engineering at UNSW Sydney, says the future of cheese production could be reliant on our oceans. The food microbiologist says the marine ecosystem is a vast untapped resource for obtaining food ingredients. “Considering that over 70% of the world’s surface is covered by oceans, it’s a tremendous untapped resource for food components, including the types of things we need to sustain cheese production as consumption continues to grow,” A/Prof.

Zhao said.

Seaweed-derived milk coagulant

The search for a rennet substitute Milk coagulation, or curdling, is an essential step in cheese production. For many kinds of cheese, this is done using a milkclotting enzyme or ‘proteases’ called rennet, a substance derived from young calf’s stomachs that is in relatively short supply.

Even though some rennet substitutes exist and are used in industrial-scale cheese-making, they can often suffer from various shortcomings and produce inferior quality and lower yields.

“One alternative is to use genetically modified organisms to produce rennet, which chemically speaking is fine, though some consumers have religious and ethical concerns with eating these products,” A/ Prof. Zhao said. “Others, like microbial substitutes, tend to produce cheese with a bitter flavour or poor texture, so the industry is still searching for better alternatives.”

The ocean is home to diverse species representing a vast source of milk-clotting enzymes that might make suitable rennet alternatives in cheese-making.

“One of the potential advantages of using enzymes from marine sources is that they’ve adapted to the harsh ocean environment,” A/Prof. Zhao said. “They may have very different properties from protease from land species, and some may be ideal for milk clotting, due to qualities like higher catalytic activity and ability to operate at wider temperature ranges.”

Some research has shown that when applied as a milk-clotting agent, a marine-derived protease from fish can produce a cheese with comparable characteristics, including flavour and textures, to those made with traditional commercial rennet. Previous studies

A recent study by Dr Zhao and a team of UNSW researchers managed to take this one step further and identified a seaweed species with sufficient caseinolytic activity – milk-clotting ability – to produce cheese. The cheese yield was also comparable to that obtained using traditional rennet.

“We tested seven different seaweed-derived proteases on their milk-clotting potential and found one was able to help make real fresh cheese in a lab environment,” A/Prof. Zhao added. “But this is only a small fraction of the hundreds of different seaweed species in our oceans, so there is a lot more scope to find something out there that could be even more effective.”

But would the cheese be edible? More studies need to be conducted to be certain, but Dr Zhao says it’s likely safe to eat given seaweed coagulant is already widely used as a food gelling agent, and the seaweed is eaten in many diets.

“Safety-wise, we don’t think there are too many concerns, especially as we’re just using the protease as a coagulant,” A/Prof. Zhao said.

“We did need to make an adjustment to the typical temperature used in the purification stage, as the seaweed coagulant is optimum at a higher temperature than the normal rennet, otherwise, the process remained the same.”

If you’re hoping to taste a slice of seaweed-derived cheese, it’s unlikely to happen anytime soon. Between food regulators and appetite from the industry, it will be some time – likely decades – before we see cheese made from seaweed coagulant hit supermarket shelves.

In the meantime, the researchers are hoping to conduct more research into the sensory and textural properties of cheese made using seaweed coagulants and do more biochemical analysis to confirm their suitability as rennet substitutes.

“We’re not getting carried away with the findings, and we consider the work to still be at the pioneering stage,” A/Prof. Zhao said. “But this represents an incremental step forward in the search for an ideal rennet substitute for cheese-making.” unsw.edu.au

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Efficiency key as juice producers squeezed Orange juice remains one of the most popular soft drinks around the world, but supply chain faces record raw material costs after challenging weather conditions in the world’s major production regions of Brazil and Florida. By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers.

The good news is that the demand for orange juice remains high, despite consumers in some markets moving away from fruit juices and related products as they are perceived to be relatively high in sugar and calories. This fall in demand has been compensated for by increasing demand from food processors for the production of smoothies and flavoured water, which are generally perceived as healthier choices. Demand for straight orange juice also received a significant boost from COVID market effects. Overall, most analysts predict level, or slightly increased worldwide demand for the next few years.

Production challenges The trouble for the industry is that despite this buoyant demand, the last couple of years have seen reduced fruit output from the major production areas of Brazil and Florida. Other less important producers are also struggling, with European production also down this year, in line with a longer-term trend.

Brazil, the world’s largest grower of citrus fruit, suffered significant frosts and droughts during the 2021 growing season, but production is projected to bounce back by 20.5% to 317 million boxes for the 2022/23 season. However, the final effects of a warmer winter season, which saw higher than normal levels of fruit drop still have to be assessed. At the same time, lower-than-normal stocks from 2021/22 have kept local prices high (up to 50% higher in July 2022 compared with the previous year).

In contrast, production from Florida (the second largest producer of citrus in the world) is estimated to fall 62% for the 2022/23 season to just 15.7 million boxes. This represents the largest fall in production in 110 years. The reasons for Florida’s reduced production are related not just to weather (orange groves have suffered damage from hurricanes, frosts, and insect damage), but also to citrus greening disease, a bacterium which causes fruit to shrivel and fall from the tree before it is ripe. The number of Valencia orange trees in Florida has also fallen from 36 million in 2006 to just 30 million today as real estate and land prices in the State persuade many growers to cash in the value of their land.

Pasteurisation options Thermal treatment, sometimes known as ‘flash pasteurisation’ is the preferred technique for making premium juice. The HRS MI and MR Series of pasteurisers use food-grade, multi-tube, corrugated

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heat exchangers to speed up the heat transfer in pasteurisation systems. These corrugated tubes create extra turbulence in the fluid as it flows through the tubes. This extra turbulence means that the orange juice can be heated up to pasteurisation temperature much faster – typically by up to 30%. Because of the high heat transfer rates of the corrugated tube technique, HRS’s pasteurisation systems use water at a lower temperature to reduce the risk of product damage. Another benefit of higher heat transfer rates is that the system footprint can be reduced by using shorter heat exchanger pipes. The shorter length of the heat exchanger also results in a reduction in pressure drop, which saves pumping power and further reduces energy costs – often by 40%.

One issue with flash pasteurisation is that it still takes time to evenly heat the product, adding to the total processing time and increasing the risk of adversely altering the product’s organoleptic properties. In contrast, ohmic heating, which uses electricity to heat the product rapidly and uniformly, has been scientifically shown to be highly effective while maintaining flavours and quality.

The HRS ohmic system works by passing electricity between two electrodes in the product in a 1m ceramic tube, so the electricity has to pass through the product. The result is that the juice is heated up to 105 °C within one second. It is then held at this temperature for four seconds before being cooled. Ohmic technology itself is not new, but the HRS system uses the latest electronics to ensure that the temperature curve is very smooth, which not only helps to preserve product quality but also improves process efficiency.

Raw material handling The HRS I Series offers options to de-pack and crush (the IC Series) then melt (IM Series) frozen fruit juice (a process also sometimes known as re-melting) ready for storage or further processing. The IC Series features a roller conveyor which feeds individual drums into a tipper that empties them into the crusher. Here, a specially designed spiked roller crushes the solid ice into an icy slush, which is then transferred to the IM Series re-melting device.

Based on the tubular heat exchanger technology for which HRS is renowned, the IM Series raises the temperature of the juice from frozen to around 4°C in 90 seconds. From here, the cold liquid juice can be pumped to a holding tank, or straight into the next process step. hrs-heatexchangers.com

AGRICULTURE, FOOD & BEVERAGES

Keeping meat hot and fresh Continuous processing of mechanically separated meats is more efficient than dealing with batches.

Products such as mechanically separated meat (MSM) and meat emulsions are commonly used in a wide range of products including sausages, chicken nuggets, patties, and some minced meats. While different meat sources and products will have different processing and cooking requirements, it is important that the methods chosen to minimise the energy use involved, saving money, and reducing greenhouse gas emissions.

Part of the cooling system of a continuous system installed at a soup and sauce manufacturer.

Meat emulsions, slurries and reformed meat products have been used around the world since the early 1970s. Around the world there are strict rules, both about the raw materials used for the production of MSM, but also how it is processed and labelled.

Similar cooking, handling and cooling methods are also used for other food products, such as ground (minced) meat and soups, and these products can also benefit from the same approach to choosing cooking systems.

The European Food Safety Authority (EFSA) advises that, ‘Microbiological and chemical hazards associated with mechanically separated meat derived from poultry and swine are similar to those related to non-mechanically separated meat (fresh meat, minced meat, or meat preparations). However, the risk of microbial growth increases with the use of high-pressure production processes.’

Additionally, ‘High pressure mechanically separated meat must be immediately frozen and can only be used in cooked products.’

These products are often cooked in batches prior to final product formation, often using large steam-powered kettles or pressure vessels. Some companies processing large volumes of product may have ten or more vessels in various states of operation at one time. This is because, while these vessels are an effective method of cooking and pasteurising a range of products including MSM, they are limited in their capacity because it is important that the product is cooked through thoroughly. Because each vessel must be heated from scratch for every new batch of product, and the heat used is then lost when the vessel is emptied, this is an incredibly inefficient method of cooking such products.

A much more energy efficient method is to cook a continuous stream of product using a scraped surface heat exchanger such as the HRS R Series or Unicus Series. The HRS R Series uses a rotating action to scrape the tube surface and a helix to ‘push’ material through the heat exchanger, ensuring thorough mixing and heat distribution. It provides an economic solution for situations where product mixing is a benefit in processing, or where physical integrity is less important than heat transfer. For example, it is ideal for MSM, meat emulsions and co-products (such as materials which are destined for the pet food market).

In some situations, the robust mixing action of the R Series can damage the product. For example, some minced and ground meat products, or products containing definite pieces or product. In this case the HRS Unicus Series is preferred. This patented design uses as reciprocal action to prevent fouling of the heat exchanger by the product and to ensure thorough heating of the product to the required temperature. Importantly, once the unit has reached the required temperature, the heating medium is only required to maintain the temperature as the heat is not lost between processing batches. This continuous processing saves large amounts of energy compared to a batch approach.

The same is also true of the equally important cooling process, which must be conducted in a timely manner. In fact, this cooling allows for the use of heat generation, where the heat removed by the cooling process is not lost but can be returned to the start to pre-heat the product, so that less energy (for example steam) is

required for heating. Further economic savings are also achieved by reducing the need to fill and empty separate cooking vessels, and the fact that cleaning-in-place (CIP) can be performed when required, rather than simply between each (smaller) batch.

HRS have provided clients with continuous processing solutions to replace batch-cooking and cooling systems. One Colorado-based manufacturer of sauces and soups replaced their batch-based system with a continuous process based on a number of HRS products in order to increase their manufacturing capacity to meet increasing demand.

HRS complete systems not only include the HRS R Series and Unicus Series scraped surface heat exchangers for cooking and then cooling the product, but also transfer pumps, balance tanks, other heat exchangers for pre-heating and pre-cooling, and auxiliary equipment such as CIP systems and steam-powered hot water sets. Such systems are designed to have simple intuitive controls and to occupy the smallest possible footprint in order to fit within existing production facilities.

HRS Heat Exchangers is located in Melbourne, part of the EIL Group (Exchanger Industries Limited) which operates at the forefront of thermal technology. HRS offers innovative heat transfer solutions worldwide across a diverse range of industries. With more than 40 years’ experience in the food and drink sector, specialising in the design and manufacture of an extensive range of turnkey systems and components, incorporating our corrugated tubular, and scraped surface heat exchanger technology, HRS products are compliant with global design and industry standards. hrs-heatexchangers.com

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DeakinAgriFutures AgriFutures Australia reveals trailblazing insights from its Carbon Initiative Program.

In a monumental leap towards a greener future, AgriFutures Australia proudly presents the outcomes of the Carbon Initiative Program, a $2m commitment fueling 15 pioneering research projects.

The 15 projects have not only enriched current industry-specific endeavours towards a net-zero future but have also forged new frontiers in cross-industry carbon research. Venturing into unchartered territory has yielded remarkable revelations, including five hero insights across the 15 projects: Innovative Carbon Testing: The fusion of cutting-edge machine learning with satellite sensing technology is re-writing the rules of soil organic carbon testing. By driving down costs, these methods are racing to surpass the Australian Government’s ambitious target of three dollars per hectare.

Reimagining Farm Irrigation: Exploration into emissions from Australian farm irrigation dams has stunned the scientific community, where traditionally there has been a lack of carbon footprint data.

The discovery showcases nitrous oxide emission rates that defy conventional wisdom, sitting four times lower than the estimations by the Intergovernmental Panel on Climate Change (IPCC).

Nature's Methane Solution: Unlocking the potential of native freshwater plants and seaweed species has unveiled an ingenious solution to curbing methane emissions in cattle. This foundational evidence opens new pathways for research into freshwater alternatives to red seaweed.

Precision in Valuation: A fresh set of guidelines caters to rural valuers, promising enhanced precision when valuing carbon projects. This leap will elevate the accuracy of assessments, paving the way for more robust carbon initiatives.

Empowering Producers: Embarking on a mission to empower producers, a user-friendly online tool has emerged. This digital companion assists producers in navigating the complex landscape of carbon methods, ensuring alignment with their unique business

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vision, risk tolerance, and individuality. AgriFutures Australia General Manager, Rural Futures Michael Beer, said supporting efforts to enhance the effectiveness and adoption of carbon farming was a pivotal role for the organisation.

“This was a strategic investment borne out of the conversations we’d had with farmers, landholders and rural industry participants who said they wanted to enter the carbon space but were not sure how to do it or where to find the right information,” Beer said.

“This is a complex and rapidly evolving area so guidance from trusted sources is essential, especially as the nation accelerates the decarbonisation of the economy and seeks to meet emissions reduction targets,” Beer added.

AgriFutures Australia’s Managing Director John Harvey says he is proud to be investing in programs that will help our rural industries transition towards net zero emissions.

“Through the course of the AgriFutures Carbon Conversations events, it became clear there was a considerable and growing thirst for knowledge about emission reduction efforts in our agricultural sector and the desire for people in communities across Australia to be heard,” Harvey said.

“The discussions we’ve had with Australians has brought home the importance of research programs like the 15 Carbon Initiative projects in providing guidance for those who are directly affected,” Harvey added.

The Program, launched in 2021, explored novel approaches to carbon storage, greenhouse gas emission reduction and emission avoidance, as well as methods to drive awareness, overcome barriers and develop market pathways for farmers, fishers and foresters. The Program was led by Julian Hill on behalf of AgriFutures Australia. agrifutures.com.au/carbon-initiative-program/

AGRICULTURE, FOOD & BEVERAGES

Fixx Nutrition Leading Australian nutrition brand launches new manufacturing facility to cater for growing global demand.

To cater for growing global demand, Queensland headquartered nutrition and wellness company Fixx Nutrition is expanding its manufacturing capabilities as both domestic and international customers seek out its all-natural sports and dietary supplements.

For Fixx Nutrition Co-founder Jan Buchegger, this new manufacturing facility is the ideal way for the business to build market share while still being able to produce their all-natural product range only five minutes away from the iconic Burleigh Heads beachfront.

This new manufacturing facility located in the heart of Burleigh Heads, on the Gold Coast, will see the business double production volumes of its CrampFix, Fuel X and Energy Gel product lines by a factor of more than 100% as it looks to launch in the South African market, off the back of further growth in international markets like the United Kingdom, South Korea and the USA.

“Professional and amateur athletes from sporting codes across the globe use Fixx’s range of all-natural world-leading sports and dietary supplements and this new facility is designed to allow us to meet demand in established domestic and global markets while embarking on new ventures in places like South Africa,” Mr Buchegger said.

Founded in 2017 by keen athletes Michelle and Jan Buchegger, Fixx Nutrition draws on 20+ years of experience in food manufacturing to research and explore innovative ideas to resolve cramping and provide nutrition for endurance athletes.

Its fast-growing market share among amateur and professional athletes alike is being matched by the ubiquity of the Fixx brand at iconic athletic events as diverse as the Gold Coast Marathon and Sydney Marathon, as runners, cyclists, footballers and cricketers alike use it as their method of choice to deal with cramp and muscle fatigue.

“Our clients include professional cyclists, triathletes, local sporting codes such as the AFL along with the NRL, the New Zealand, English and Pakistani international cricket teams, national Rugby sides like the Wallabies and the Springboks, along with most of the English Premier League clubs. We believe the greater care athletes are driving this demand are taking to around what they put in their bodies and our products are designed to provide them with an all-natural formula to relieve their fatigue-induced symptoms like cramping or improve performance using legal and approved products. “ fixxnutrition.com

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Sea Forest Tasmanian manufacturer brings new meaning to surf and turf with methane-busting livestock feed.

Tasmanian manufacturer Sea Forest is ready to take the equivalent of hundreds of thousands of cars off the road and help the red meat industry meet its net zero goals through support from the AMGC and a unique Australian species of seaweed.

The seaweed asparagopsis armata has been known to have giant methane-busting potential when added in tiny quantities as a supplement for ruminant animals. Thanks to a collaborative project led by Sea Forest and aided by $675,000 in co-investment from AMGC, the company now boasts a state-of-the-art manufacturing facility at its Triabunna headquarters.

“This is a great Australian idea that has now been turned into a successful commercial business via manufacturing. Through the commercialisation process, Sea Forest has developed a local product with global potential, while generating jobs and supporting global moves to reduce emissions,” said Dr Jens Goennemann, Managing Director, AMGC. The $3.2m project took just over 18 months to complete and has created nine full-time roles and upskilled a further eight staff at Sea Forest, which has been growing seaweed at Triabunna, Tasmania since 2019. Over the coming years, the project has the potential to create over 50 new jobs in Triabunna where the company focuses its manufacturing and market development.

As a result of the project, Sea Forest has systems and practises in place for industrial-scale processing and packaging of asparagopsis extract, which is delivered to beef, milk, and wool producers in an oil-based solution.

Specifically, the extract’s compounds change the enzymatic behaviour in the final chamber of animals’ stomachs. Thereby, reducing methane emissions with just 0.2% of Sea Forest’s product needed in ruminate feed to reduce emissions by up to 98 per cent.

Methane is a greenhouse gas 28 times more potent than carbon

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dioxide, and a significant contributor to the 15% of Australia’s greenhouse gas emissions that come from the agricultural sector.

Overall, Asparagopsis provides a triple benefit. It cuts digestionrelated emissions from animals, grows and sequests carbon more rapidly than a land plants, and increases the rate at which livestock grow.

“AMGC has greatly assisted Sea Forest in reaching its commercial outcomes as the funding allowed us to fast track the completion of our commercial-scale processing plant which has enabled us to meet our ambitious supply targets,” explained Sam Elsom, CEO of Sea Forest. “The process of detailing each project milestone, together with its associated budget and regular reporting has also been very helpful and ensured that project costs were largely contained, limiting the risk of budget overruns and timing delays.”

Sea Forest is one of a handful of companies using asparagopsisrelated IP licenced from FutureFeed, a commercialisation company based on IP developed by CSIRO, James Cook University, and Meat and Livestock Australia.

Sea Forest aims to hit its current capacity within five years, representing 7,000 tonnes per annum of asparagopsis – enough to mitigate the equivalent of 1.2 million tonnes of CO2, equivalent to removing 300,000 cars from the world’s roads.

Sea Forest currently has a number of trials underway in Australia, The most notable with burger chain Grill’d that began offering a “Gamechanger” burger in February.* The Gamechanger pattie is made of black angus beef fed asparagopsis supplements as well as grass which reduces livestock emissions by almost 70%.

The many years of Australian research into asparagopsis will be an important contributor to meeting the Australian red meat industry’s goal of carbon neutrality by 2030. amgc.org.au/project/asparagopsis-commercialisation-project/

AGRICULTURE, FOOD & BEVERAGES

Vertical Future in food University of Southern Queensland joins international space research mission.

The University of Southern Queensland’s Centre for Agricultural Engineering is investigating ways to grow plants in space.

They will join UK-based vertical farming research and design company, Vertical Future, to develop a Controlled Environment Agriculture (CEA) facility to be used in future space exploration mission funded by the UK Space Agency.

Vertical Future will work in partnership with international experts in both plant biology and space technology including Axiom Space, Saber Astronautics, the University of Southern Queensland, along with their Plants for Space (P4S) research partners at the University of Adelaide and the University of Cambridge.

consortium. “We will be involved in foundational discussions for the develop-ment of a space-ready ‘Fully Autonomous Controlled Environment’ during our workshop at the Kennedy Space Centre,” Professor McCabe said.

“Our collaboration brings specialist knowledge in automated realtime machine vision sensing of natural objects and plants, including subtle, non-obvious or non-visual features, and robotic systems for plant care including adaptive irrigation and nutrients” Vertical Future Chief Scientific Officer, Dr Jennifer Bromley, also highlighted that investment in research and development for spaceexploration technologies would benefit people on Earth.

The project will research the design requirements for a fully autonomous agriculture system that can be monitored and operated remotely or with artificial intelligence, which will be used to support future space explorations, including NASA's future Moonto-Mars Artemis missions. It will also test data transfer requirements between the Vertical Future facilities installed at the company's R&D site in London and at the University's Waite Research Institute.

"While this project may sound like the plotline of The Martian, it is important to develop new and innovative ways for astronauts to survive and thrive in their ventures to not just the Moon but also Mars and beyond," Dr Bromley said.

Professor Bernadette McCabe and Dr Cheryl McCarthy from the University of Southern Queensland will head to NASA’s Kennedy Space Centre and take part in a workshop where the project team can research and develop the specifications for a CEA facility that is able to cope with the constraints and challenges found in deep space, designed for the International Space Station (ISS) and Axiom Station. Centre for Agricultural Engineering Director Professor Bernadette McCabe said this was an opportunity for the University to extend it work in this agri-space sector as part of the international

UK Space Agency Chief Executive, Dr Paul Bate, said the ambition of the project was made possible by its international scope.

"As we have seen with many other technological advances thanks to the space industry, we will also be able to apply our findings here on Earth, where we continue to develop Vertical Future technologies."

"Projects like this, which will see Vertical Future work with the University of Cambridge and partners in Australia and the US to develop the use of autonomous agriculture technology for space exploration, highlight the many ways in which we can collaborate with the global space community to help humanity push the boundaries of space innovation," Dr Bate said. usq.edu.au

University of Southern Queensland’s Centre for Agricultural Engineering Director Professor Bernadette McCabe and Dr Cheryl McCarthy.

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ONE ON ONE

Caroline Wilkie is CEO of the Australian Railway Association. She speaks to AMT Editor Paul Hellard about where the ARA sits in the overall Australian transport landscape, and its vision for the future.

AMT: So, please tell me about what the Australian Railway Association does.

AMT: The next enquiry is about the supply chain for engine and carriage construction. Can you speak about the local content rules?

Caroline Wilkie: The ARA is the peak body for the rail industry across Australia and New Zealand. The ARA represents the full rail supply chain, from operators and track owners and maintainers, through to contractors, suppliers and consultants. Our vision is for a thriving rail industry enabling economic growth and driving sustainability.

CW: Local content policies in Australia have traditionally been implemented at the state level, which means working across Australia can sometimes feel like working in eight different countries. The ARA released new research earlier this year that found governments have missed out on $1.85 billion in savings over the last decade as a result of inefficient, state based local content policies applied to rollingstock procurement. That shows just how significant the benefits of a national approach to local content could be. We would like to see a national approach to local content policies so that businesses can gain the scale they need to innovate and grow, and governments can realise these costs savings to maximise their return on investment and enable further infrastructure development.

The ARA seeks to be a leading industry voice and is focused on delivering an exceptional member experience. We have three strategic priorities that drive our policy and advocacy agenda on behalf of the industry.

We are committed to supporting a thriving, diverse workforce. We are doing this by showcasing the wide range of rich and rewarding careers through our Work in Rail campaign, while also leading the development of national courses and competency management to support a strong and diverse workforce that meets our future needs. This is critically important as the rail industry faces sustained skills shortages over the next decade.

We are also working closely with our members to support a productive, safe and efficient industry. Advocating for national approaches to procurement and the harmonisation of standards and regulations is at the core of this work and has been supported by extensive research and member engagement. A greater focus on harmonisation would ensure improved productivity and efficiencies for both the rail industry and the associated supply chain, so this remains a key part of all that we do.

The ARA is also committed to supporting a sustainable and resilient industry that benefits communities. We are working closely with our members and other stakeholders to lead the regional dialogue to accelerate emissions reduction in the rail industry and the inherent sustainability benefits rail delivers.

In addition to this work, the ARA also provides a wide range of events, courses and programs to support the development of people working in the rail industry. We are expanding our courses in 2024 to support this effort and will continue to deliver a wide range of conferences and events to bring industry together to discuss the key issues and challenges they face.

AMT: What is your background? Let the readers get to know you a bit before the deeper questions begin.

CW: I have led industry associations for most of my career. I was previously the Chief Executive Officer of the Australian Airports Association for nine years, before joining the ARA. I really enjoy working in partnership with government and industry to create better outcomes for both the industries I have represented and the communities they serve. At the ARA, I have had the chance to work with the rail industry on issues that will shape how we live, work and do business for years to come – while also contributing to a more sustainable future. That is very rewarding and I am fortunate to work with some fantastic senior leaders from the industry through the ARA Board.

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AMT: I’m also interested in government procurement levels, and how this is being structured in the railway industry. How can it be improved in your view?

CW: We are experiencing a period of high levels of investment in the industry, with $154bn in rail construction activity planned over the next 15 years. We have also seen significant investment in new rollingstock as major projects enable greater capacity across the network. That investment will support the country’s growth and ensure we can support greater use of rail in the years ahead.

Continued investment in rail across construction, maintenance and operations will be essential to support a strong and sustainable transport network.

The ARA released a best practice guide for rollingstock and signalling tendering in 2020 and have been working collaboratively with industry and government on its recommendations for some time. There are a range of measures that would support improved national approaches and greater harmonisation across the rail industry. The ARA is currently working with a number of partners to explore the development of a national prequalification scheme to streamline the procurement process further.

AMT: How do smaller manufacturing companies engage with the rail industry to be considered in component generation?

CW: The ARA surveyed the rail supply chain in 2021 and found about a third of businesses surveyed have less than 20 employees.

So, ensuring those essential small and medium-sized businesses are well connected with key purchasers in the industry is essential.

The ARA has been hosting two successful member-only series in recent years to support this connection. Our Meet the Buyer series provides purchasers with the chance to brief suppliers on upcoming tenders and priorities to provide visibility of new work opportunities that are ahead. Our Meet the Innovator series allows suppliers to showcase new products, services or innovations that have developed for the rail market. This is supporting strong engagement and information sharing across the supply chain.

ONE ON ONE

Our 2021 research also identified nine actions to drive growth across the whole supply chain – including manufacturing companies looking to build their capability. Establishing strong national approaches and consistent standards were a key part of that, as were streamlined tendering processes. We also identified the need to enable technology and innovation adoption that encourages the development of new solutions.

AMT: What scale of manufacturing planned for our future commuter rolling stock?

CW: There has been significant investment in rollingstock in the last few years in particular, across a number of states. Last year, we saw new rollingstock commissioned to support the opening of the Metro Tunnel and to progress the Victorian Government’s Next Generation Trams program, while Queensland confirmed its plans for rollingstock expansion ahead of the completion of Cross River Rail. This builds on further work commissioned by NSW, Victoria and Queensland in 2019, as well as the WA Railcar Program underway to support the METRONET project.

AMT: What percentage of the rail systems in commuter/industrial is run on electric v diesel these days?

CW: Most metropolitan passenger rail services across Australia operate on electrified networks. These services are an incredibly sustainable way to travel, with one commuter train taking 578 cars off the road.

Freight services, while generally not electrified, remain an incredibly sustainable choice, generating 16 times less carbon pollution than road. There are a number of trials underway across Australia to explore options for diesel alternatives and further improve these sustainability benefits. Battery electric, hydrogen and biofuels are some of the options being explored. This represents a huge opportunity for innovation as the rail industry continues to progress its decarbonisation efforts.

competitiveness with road, while driving urban renewal and growth along the rail corridor. We were pleased to see the Federal Government investing in planning for the Sydney to Newcastle connection in its first budget.

While high speed rail is a longer-term proposition, it is essential that we plan early for that reality. Ensuring corridor preservation is progressed now would reduce costs in the long term and ensure we are ready for high speed rail when the time is right. The ARA has been engaging closely with the newly formed High Speed Rail Authority since its establishment earlier this year.

AMT: How does the future look for the railway industry in Australia?

CW: The next few years are going to be incredibly busy for the industry, with the current wave of rail construction activity expected to peak in FY2026. While we must deal with the immediate challenges that come with that growth – such as building a strong workforce that can meet our long-term needs – this current investment cycle also represents a huge opportunity for us.

Rail can and should play an important and growing part of our sustainable future. As we develop new projects, and the supply chain supports a growing rail network, we must look to how we can continue to support the best possible outcomes for the economy and community. The rail industry already makes such an important impact on our lives – it will be exciting to see that further develop as this next wave of investment continues. ara.net.au

AMT: How goes the plans for high-speed rail between capitals?

CW: There is significant potential for faster rail connections in Australia. Our research confirms that travel times on regional networks here in Australia lag behind our global counterparts. That is in large part due to a long period of historic underinvestment in rail, compared to road. But there are big improvements we could make immediately through upgrades to our existing network – through measures such as curve easing, passing loops and improved signalling.

Those sorts of changes would improve the speed, reliability and frequency of services and would make rail a much more attractive proposition for those travelling between cities and their neighbouring regional centres.

The establishment of fast rail lines on routes such as Melbourne to Geelong, Sydney to Newcastle and Brisbane to the Gold Coast would also increase rail’s

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PLASTICS, COMPOSITES & ADVANCED MATERIALS

Rethinking plastics with nature in mind Considering the damage plastic is doing to the world's oceans, it's the last place you'd expect a revolutionary new approach to come from, but one WA company has a secret ingredient. Drew Turney explores PHAs. It's no secret plastic and oceans don't mix.

You've probably heard of the Great Pacific Garbage Patch, a 1.6m square kilometre area full of discarded plastic between North America and Japan, hemmed in by the major Pacific currents. As of 2018 it contained 45,000-130,000 tons of toothbrushes, water bottles, pens, plastic bags and more, some of it up to 50 years old.

Then there's all the microplastics damaging marine ecosystems, broken pieces of fishing nets, microwave containers and car tyre rubber measuring 5mm or less. There were barely any in the oceans between 1950 and 1980, and today there's over half a million tons.

than petrochemical means. The process not only uses fewer harmful chemicals during manufacture, the resulting material is far less harmful to the environment, degrading like any other organic molecule.

The secret sauce is the polyhydroxyalkanoate, more often known as PHAs. A PHA is a polymer made in nature from polyester – not the leisure suit material, the category of polymers that contains esters (a compound derived from an acid).

Not so fantastic

Nature makes polyesters when microorganisms like bacteria ferment sugars or lipids, like they do fermenting beer or wine.

When bacteria creates a PHA it's far more environmentally friendly because it can be used as both as a source of energy and a carbon store – doing the same with synthetic polymers uses fossil fuels and plastic never breaks down.

There's a race to solve the problems of plastic production. Back in June, AMT reported on a company called Samsara Eco that uses a special enzyme which consumes plastic waste. Now, a company based at Perth's Indian Ocean Marine Research Centre is looking at the other end of the process – manufacturing.

What's more, PHAs can be rebuilt into 150 different types of monomers - the molecule that can react with others like itself to form a longer chain ('poly' simply meaning 'more than one' in chemistry), all of which have different properties and suit different applications we normally make plastics to address.

Uluu (the name pays homage to the surfing paradise of Uluwatu, Indonesia) is the brainchild of co-founders, oceanographer Dr Julia Reisser and former Mergers & Acquisitions Lawyer Michael Kingsbury.

To make biological PHAs, sugars are extracted from the carbohydrates in biomaterial using hydrolysis, a method where a water molecule is used to break chemical bonds in another substance (non-scientists know it as 'cooking'). The sugars are then fed into the fermentation process where micro-organisms go to work, and PHAs come out at the other end.

But now, a radical idea from Western Australia is posing a unique question; what if the ocean can actually save us from plastic?

Plastic, Kingsbury begins, is entrenched in society. “It protects our food, it helps us climb mountains with weatherproof clothing, it has all these great properties, and alternatives to plastic either don't have the same properties or they're a bit too much like it. They don't biodegrade, they have have the same persistent pollution plastic does, etc.”

The trick Reisser and Kingsbury hit upon was to produce a polymer – the building block of all plastics – using natural rather

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“The two issues we're addressing at Uluu is the feedstock and the material,” Kingsbury says. “Nature built them, nature understands them and nature can break them back down at the end of their life. But they have these really unique qualities and actually behave like plastics – great oxygen moisture barrier properties, durable, lightweight.”

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Gone to sea But what does all that have to do with the ocean? Uluu's secret ingredient to create PHAs is one hidden in plain sight – seaweed.

“Seaweed is fantastic because it sequesters carbon,” Reisser says, “it grows quickly, it contains lots of sugar, which is important for fermentation. It doesn't need fertiliser or fresh water like crops and it doesn't compete with arable land for food production.”

Not only does that seem like a huge improvement over other natural PHA producers that use corn or sugar cane, it has an added bonus because – like them – it can use the infrastructure already in place.

“You can process them on existing manufacturing equipment, so it'll help with adoption and scale,” Kingsbury says.

Reisser and Kingsbury realised seaweed would be a great raw input because their love of the oceans and – in Reisser's case, a career in it – gave them an understanding of the opportunities and challenges of marine fauna. In fact, the inspiration behind the company came partly from Reisser's exposure to the level of plastic pollution in the oceans in the course of her work as an oceanographer.

“We wanted to find a truly compelling alternative to plastics,” she explains, “and seaweed has the potential to be more attractive than others for decoupling our materials economy from fossil fuels.”

“Seaweed has carbohydrates, sugars and lipids like other sources, and after the process we have leftover seaweed biomass that now has a higher protein content. Raw seaweed is about 10% protein, which isn't very attractive for feed markets because there's too much carbohydrate. We take the carbohydrates out for PHA production and what's left has a theoretically higher digestibility level for livestock feed.”

All of which means Uluu actually has a two-pronged business model. Reisser calls the PHAs its 'flagship material', and the lipids and proteins that are left can be sold to feed producers – she says it's already being considered as a feedstock for farmed fish.

A natural polymer world We all duly put our PET bottles and Christmas present packaging in the recycling, but the dirty secret of plastic waste is that we can't recycle even 10% of what we use – the quality degrades too much every time it's heated, melted and reformed.

And as long as we can't recycle plastic effectively enough, we'll continue to make it the way we do now; using synthetic polymerisation with unsustainable fossil fuel inputs.

That makes efforts like using natural rather than synthetic processes to make PHAs seem like the best way forward. That way you can use milk bottles or Tupperware until it's too worn and dispose of it like you would vegetable scraps or livestock manure. If you live in a big city with enough waste to justify recycling facilities it ends up there, if you're in a rural community where there isn't as much waste infrastructure you just throw it in compost.

And as we've seen, it means not having to upend manufacturing the way we do it now. “The end product is a white powder, the same stuff that comes out of a petrochemical process, so it can enter the plastic supply chain seamlessly and manufacturers don't have to retool. In theory we can go into any vertical,” Reisser says.

And if seaweed-based natural polymers catch on, there'll be social as well as scientific knock-on effects. Today seaweed farming in a nascent industry found mostly in China, the Philippines and Indonesia, but if we can do it on a more industrialised scale it'll do more than just make better plastic.

Aside from climate change, we're facing nutrient pollution in the oceans thanks to sewage and fertiliser run-off. One of the most effective ways to combat that is more marine plants to sequester and repurpose pollutants, and expanded seaweed farming will not only provide that, it'll give many rural and developing world communities new job opportunities.

Tomorrow's plastic today Reisser and Kingsbury's blueprint is to establish Uluu as an owner/ operator with five or 10 PHA plants. Then, with a successful business in hand they'll then move to a franchising model, the way Kingsbury says a company like Coca Cola works, licensing the brand and recipe to third party bottling facilities worldwide.

When I make a joke there'll one day be Uluu plants all over the world and petrochemical plastic will be a thing of the past, Reisser and Kingsbury look expectant, like it's all part of the plan. But when supermodel Karlie Koss, celebrity chef Neil Perry and a host of other big names have invested in you like they have in Uluu, maybe that kind of success is assured. uluu.com.au

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PLASTICS, COMPOSITES & ADVANCED MATERIALS

Breaking perceptions on plastics Engineering and machining polymers are not new, but for most individuals, their knowledge of plastics is limited to bottles and chopping boards. Chris Davies CEng, MRINA, TMIEAust, sets out the cold hard facts on designing plastics.

When design is dictated to by bean counters and old school methodology, as an engineer, overcoming ingrained thinking to break perceptions is often harder than the engineering. As a Structural Engineer designing high-speed large craft, it took me over twenty years to introduce Nylatron sheaves to lifting mechanisms.

Engineering polymers have been doing heavy lifting for quite a while. Take this crane sheave and compare it to steel. It does not corrode; it is lighter, and the wire rope lasts longer. These factors play a big part in reducing longterm maintenance and operational costs. In engineering mechanics, the coefficient of friction is called, mu the Greek symbol ‘µ’. To simplify design calculations, the statement “ignoring friction” is often used but in the real-world, friction is everywhere. That’s where engineering polymers excel in reducing friction. The mechanics of a wire rope is not as simple as it turns out. The outer cables or lays are woven around an inner softer construction. Every time the wire rope travels around a sheave it deforms, or ‘works’. This causes the rope to generate friction resulting in heat and wear. If the sheave is made from nylon the sheave deforms to support the rope and shares the load evenly. In comparison, a metal sheave that does not deform any irregularity or small difference in the root radius of the sheave causes the wire rope to deform every time and this leads to premature wear.

How do I know so much about sheaves? Back in the 90’s, my father was the manager of a crane hire company. One day he announced there was a job for me. At the time, I was a young apprentice machinist, and I learnt how to machine up replacements from nylon sheet which we cut first on a bandsaw. He said the material was supplied by DOTMAR in sheets of up to 50mm thick. The sheaves had roller bearings and the replacements were machined by local firm Saunders & Ward. In use, they lasted longer than the original Liebherr sheaves which were brittle and chipped if impacted.

Twenty-five years ago, as a cadet at CPT I participated in the redesign of a new prototype release mechanism made from Ultra High Molecular Weight Poly Ethelyne (UHMPE). This involved machining from solid Ø300 bar stock. Amazingly the same release mechanism is still in production after twenty-five years with only minor changes to the FIOBOUY. What about the machining of plastics?

Currently as a new TAFE Metals Teacher I can now reflect on how as a younger person doing any traineeship or apprentice you tend to learn things the hard way and not always the first time.

Valuable lessons I have learnt.

Lesson 1: “Make sure you clean the swarf tray first.” I may have recalled my supervisor saying this as the entire contents of the swarf tray wound itself around the job I was doing and started to fly everywhere, I casually reached down to the red lever on the lathe carriage and turned around to see if anyone had noticed. (No foot brake and the E stop was not an option). As I did not heed this advice, this happened a few more times. I now appreciate how patient my supervisor was.

Lesson 2: Holding plastic parts securely can be difficult.: As I was machining the last pass on the thread the job dug into the tool and ripped itself out of the 3 jaw and flew past my head. The harder you

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This is one of the first Caterpillar Engines used in an Incat Vessel in the 90’s. The crane has nylon sheaves.

(Courtesy HIGHRIG Crane Hire)

tighten the 3 jaw the material relaxes. 4 Jaw would be better. Mental note: need to design a thread fixture to machine the other side.

Lesson 3: “Very” sharp tools. As I reapplied a large bit of gauze and sticky plaster to my hand after stabbing myself for the third time on the HSS lathe tool, I finished on a diamond wheel that looked more like a sharp knife the rake was so steep.

HDPE (High Density Polyethylene) Heavy Construction, Sleds and Marine Vessels A Tasmanian company that has a great understanding of engineering polymers is Elphinstone ENG in Tasmania, a company that manufacturers Logging Trailers & Antarctic Equipment.

You will find HDPE under its trade name POLYSTONE® on mining equipment such as chutes and mega dump truck liners. Because it does not leak. HDPE is used on gas pipelines, desalination plants, protective coating on steel pipes, submarine electrical cable, water tanks, and on skids in Antarctica. So why on skids in Antarctica?

Because friction generates heat causing ice to melt. HDPE is selflubricating and has a low coefficient of friction. So tough that you can drag it along with an excavator. Sentinel is a Tasmanian company that has had to overcome outdated perceptions and is now leading the world in innovative vessel design. They are using HDPE as a material for Vessel construction. The industry is at a similar point to that of aluminium ship building 30 years ago. They are leading the world in breaking the culture and perception of plastic boats.

In the 80’s there were papers proposing large passenger vessels built out of aluminium. Currently the limitation in HDPE Vessel size is around 12m but this might change soon. The construction of plastic HDPE vessels is remarkably like that of an aluminium plate boat. The HDPE plate is manufactured by ROCHLING Engineering Plastics in Germany. Frames are nested then cut on a water jet bed.

I hope this article has broadened your perceptions on plastics and engineering polymers.

Chris Davies CEng, MRINA, TMIE Aust, Member of ACA; Director at Corrosion Solutions; Chair of the Tasmanian Section Royal Institution of Naval Architects (RINA), Teacher in Metals at TAFE. corrosionsolutions.com.au

PLASTICS, COMPOSITES & ADVANCED MATERIALS

Solar Glazing ClearVue secures $250K contract for first US solar greenhouse.

ClearVue Technologies, an Australian smart building materials company has received its first commercial order in the United States for supply of ClearVue’s clear solar glass solutions for greenhouses.

The order valued at $252,000 has been placed by Greenhouse System USA Inc. of Watsonville, California. Operating for over 42 years, System USA is a leader in green housing solutions in the US and Canada.

ClearVue’s single glazing laminate will be seamlessly integrated into System USA’s existing greenhouse structure providing approximately 82kW of solar power and producing an estimated 107,000kWh per year. This clean, renewable power project will be eligible for incentives created by the Inflation Reduction Act lowering annual operating costs and reducing the facility’s carbon footprint.

Importantly, this initiative uses ClearVue’s innovative single glazing laminate developed by ClearVue in conjunction with research partner D2Solar in California since 2021.

“Greenhouses have been an integral part of our strategy from day one as we understood the growing global need for renewable energy solutions for sustainable agriculture,” Martin Deil, Global CEO of ClearVue Technologies, said. “Importantly, this new order validates our strategy for targeting the US protected cropping agriculture market and opens an opportunity in global solar greenhouse glass currently worth nearly $12bn per year and growing. We are thrilled the partnership is with System USA, a company setting the modern global standard for excellence in efficient greenhouse facilities.”

“The increasing demand for renewable energy in agriculture is bolstered by government incentives including the US Inflation Reduction Act as well as a consumer push for sustainability, and ClearVue and System USA are excited to deliver our solutions to the agricultural sector.”

“This project builds on the considerable success we’ve had with previous solar greenhouse projects, including the Murdoch University R&D Greenhouse in Perth, operational since 2021, as

well as the greenhouse constructed at Sendai Ignis resort in Japan

by ClearVue licensee Tomita Technologies.

ClearVue Technologies is an Australian technology company that operates in the Building Integrated Photovoltaic (BPIV) sector which involves the integration of solar technology into building surfaces, specifically glass and building façades, to provide renewable energy. ClearVue has developed advanced glass technology that aims to preserve glass transparency to maintain building aesthetics whilst generating electricity.

ClearVue’s electricity-generating glazing technology is strategically positioned to complement and make more compelling, the increased use of energy-efficient windows now being regulated in response to global climate change and energy efficiency goals.

Solar PV cells are incorporated around the edges of an Insulated Glass Unit (IGU) used in windows and the lamination interlayer between the glass in the IGU incorporates ClearVue’s patented proprietary nano and micro particles, as well as its spectrally selective coating on the rear external surface of the IGU. ClearVue’s window technology has applications for use in the building and construction and agricultural industries (among others). ClearVue has worked closely with leading experts from the Electron Science Research Institute, Edith Cowan University in Perth, Western Australia to develop the technology.

This agreement marks a significant step in ClearVue's mission to revolutionize sustainable agriculture and contribute to a cleaner, greener future. This announcement follows several significant milestones for ClearVue, including the co-development agreement for single-glazing and double-glazed IGUs (Integrated Glazing Units) with D2Solar, the demonstration of mass-scale manufacturing, and the company's inclusion of greenhouse solutions as one of its priorities to achieve short- and long-term revenue growth. clearvuepv.com

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Heart of a Dolphin From mechanical engineering with some iconic car companies in Australia, Mario Turcarelli pivoted to take Dolphin Products to the next level, as Managing Director.

Mario Turcarelli started working with cars at a very young age. From carrying a dream of becoming a motor mechanic, his father Isidoro pushed him to complete his Diploma in Mechanical Engineering at Caulfield Insitiute of Technology, (now Monash University) as a ticket beyond that motor mechanic he’d always wanted to be. He is eternally grateful for that pressure. Turcarelli started his dream job at Holden in November of 1979 down at Fisherman’s Bend, just outside of Melbourne.

“Back then, we had to run all the power, torque and durability tests for engines, then tear them down and make sure they performed,” explained Turcarelli, from his office at Dolphin Products, now many years later. But we’ll come back to Dolphin in a moment.

Turcarelli’s mechanical engineering career took off like a rocket.

“Holden had just moved from the red XT4 to the blue XT5 engines which had more power and better economy,” he said, “and I ran a whole series of tests comparing them and showing the improved performance and durability which was one of the features of the new VC 1980 model Commodore.”

Mario Turcarelli, Managing Director at Dolphin Products

“With my wife Silvana, and an old neighbour accountant Angelo Basile, we bought Dolphin Products, and proceeded to diversify the business into Medical, Mining, Defence, and most recently as a PPE manufacturer,” Turcarelli said. “We started manufacturing safety goggles, face masks and other products to hospitals across the country.” This contract allowed Dolphin to continue to operate through all the lockdowns, hiring more people, without any Job Keeper Government Assistance.

When Turcarelli bought the Dolphin Products business, he noted the previous owners had of course taken a few machines and some patents, but he’d kept the key to Dolphin Products’ success since 1946. This was the talented team of skilled employees, the engineers and toolmakers.

“Whilst Holden was a great place to work and learn,” he added, “I have applied my skills to developing the people at Dolphin. To teach them proper problem-solving skills. Design it right and first time, make it right at the machine first time and the proper process control to resolve problems quickly.”

Mario and Isodoro

But later on, General Motors began consolidating and shutting down factories. From 23,000 employees, by 1990 Holden was down to 6500 employees, after Pagewood, Acacia Ridge, then the Dandenong assembly plant closed down. As a trim engineer, Turcarelli managed the door trims, parcel shelves, the belt mouldings, spoilers, side skirts and badges. “It was an interesting job with lots of parts,” he said. “By the time I left Holden, there were about 20 engineers managing the bits I handled all on my own in 1990.”

“In those days, the engineer’s job was to work with the designers and drafters to turn the styling project into an engineered part,” he added. Mario became so involved in a door trim project, he left Holden to work with Nylex as a Development Engineer until 1995.

He learned a lot about manufacturing and dealing with other car companies like Mitsubishi, Nissan and Ford who Nylex supplied trims. “It’s a very key part of my past, but it became part of my future,” he said. “Without that expertise I would not be here running a plastics company.”

Dolphin products In 2013, EGT, the owners of Dolphin Products in Hong Kong, decided to sell and offered Turcarelli the Australian operation of Dolphin. They transfered the world-famous Dolphin Gaming Chip operations over to the New Territories, while still relying on Dolphin technical support here in Australia. “We took on the role, and the risk, and we are still here,” he said.

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These days, Dolphin supplies injection moulding, tool making, rapid prototyping and tool design services in the creation of complex plastic products of all shapes and sizes. In fact, Dolphion has 25 massive injection moulding machines for an array of different thinwalled high tolerance parts, tools with clamping forces from 50T to 450T. They are compliant to ISO 9001: 2018 and ISO 45001, and ISO 13485 for Medical clean room parts. They have access to Smart Scope CMM, Tensile testers, electrical conductivity testers, calibrated vernier caliphers and other gauges, and they have a lightbox within their own inhouse laboratory. Dolphin were automotive component suppliers to Holden, Toyota, Ford, HSV, ARB, and even Tesla in the last few years. “We made 44 different

PLASTICS, COMPOSITES & ADVANCED MATERIALS interior, exterior, and other plastic parts for the last model VFII, which was the best Holden Commodore ever made,” he added.

With the closure of the Australian motor vehicle industry in 2017, Dolphin had to diversify to survive. Now they supply a range of industries including defence, mining, telecommunications as well as medical cleanroom plastics. Dolphin also produce a range of recycled plastic parts for the ‘Happy Planet’ range of toys, all of which comply with Australian toys standards, made from HDPE recycled milk bottles. In a tour around the Dolphin Products’ facilities, several moulds for jobs were on display, some for undisclosed industrial projects, others packaged up for shipping, ready to be trucked out to clients. The facility is clean, ordered and a model of company fidelity. The staff were focused, quiet and upbeat.

“At Dolphin, we pride ourselves in having a safe, clean factory and a management team who cares for our people, our customers and the environment. We recently received a MedTech grant from the Victorian Government to upgrade our Clean Room to ISO 7 and ISO 13485 medical accreditation.

Dolphin’s capability support during COVID

The injection moulding process

During the first strike of COVID, Dolphin were asked to support local hospitals and the medical industry in a rapid response.

Injection moulding process is producing plastic products by inserting plastic granules, heating them, cooling them and finally giving the shape and size of the required plastic products. It is the rapid method of producing a large number of plastic products with high precision. The majority of the plastics we use in everyday life are produced from the injection moulding process.

“We were contacted by Monash Health and HPV to develop local face shields and disposable safety goggles. At the time, they were imported products in short supply world-wide, and in big demand.

We committed to producing five million safety goggles for HPV in three months,” added Mario. “We delivered these on time and have produced another two million so far. We also ended up making eight new tools and hiring an additional 24 staff, setting up a night shift, getting TGA approval for all our PPE and subcontracting some of the lens cutting to other Victorian suppliers.”

Dolphin tooled up three critical parts for the Grey Innovation Ventilator in two weeks. And helped make parts for the 2000 ventilators needed by Australian hospitals as part of an Australian Consortium. “We developed our own high reusable quality face shields made with anti fog material and adjustable head band, then had it TGA-approved,” added Turcarelli.

The chosen material is heated and then injected into a specially shaped mould to create a component that is exactly the right shape, colour and size required for a piece of machinery, moving part or other types of equipment. The moulds are normally made from a strong tool metal such as steel or aluminium to help it withstand the pressure of heavy use, and precision designed by engineers to fit their exact purpose.

Uses of injection moulded parts vary in size enormously, from the tiniest machine widgets to entire car body panels. Other popular uses for injection moulding include packaging, car parts, storage containers, toys, plumbing components and medical items. dolphinproducts.com.au

LOCAL SERVICE. LOCAL SUPPORT. LOCAL SOLUTIONS. Bodor Laser offer a comprehensive range of laser systems to suit all budgets and specifications.

• Processing sheet up to 3mx 25m and tube to 12m x 500mm diameter with zero waste • Bevel cutting and advanced laser technology for cutting thick copper and brass • Linear drive systems with over 200m/min and 4G acceleration • Easy to use software with timesaving SMARTS by Bodor • Our customers benefit from an experienced service team and local Bodor factory engineers.

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Visit our dedicated Bodor demonstration and customer training centre in Melbourne.

Email: sales@lasermachines.com.au • Phone: 1300 561 963 • www.lasermachines.com.au

9575LM•AMT OCTNOV23

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PLASTICS, COMPOSITES & ADVANCED MATERIALS

Innovating plastics circularity towards sustainability Looking into the challenges of developing the plastic production circularity. Dr. Paige Marie Morse, Senior Sustainability Director and Anand Gadgil, Area Sales Manager, Australia, Aspen Technology, break down the polymers.

“Great things in business are never done by one person. They are done by a team of people,” said the late Steve Jobs. At the crux of innovation, the journey towards sustainability will likely be accomplished via technological advances but the pathway will be secured via the human network. Coinnovation will be key, as the fast-evolving energy transition will lead countries and companies towards net-zero goals by reengineering the way we work.

A good way to imagine the massive shift required, is to look at the demographics involved. More than one-third of the world’s population now resides in India and China.

One can only imagine the intense pressure mounting on infrastructure, natural resources, workforces and environmental conservation. In the emerging markets of the world, tailwinds result in a new generation of engineering talent focusing on the challenge of delivering business performance and growth, while needing to address sustainability goals. This is the dual challenge.

The race gets exponentially harder High performance software enables assetintensive companies to better understand and utilise data. Industrial AI provides insight to help industries run production units to higher efficiency and safety standards; achieve operational excellence and reduce emissions. With domain expertise, digital technology providers bridge the industry’s generational deficit, as experienced workers retire and newer operators onboard, especially in Asia’s massive talent markets.

While the basic cornerstones towards netzero goals, begin with energy efficiency, the final laps towards success remain harder to achieve. Companies need to think longer term, likely two to three decades down the road, and completely rework the approach to performance and delivering the products that market will demand. Alternative energies, such as hydrogen, solar and wind, and geothermal, will become increasingly important. The circular economy approach towards reducing waste and energy consumption is an important example of the path to netzero. AI is an excellent enabler to redesign the value chain for process companies and enable collaboration across the value chain.

Great expectations for plastics circularity Plastics circularity has become an important component in many sustainability plans, and the demand for recycled

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Dr. Paige Marie Morse

Anand Gadgil

polymer is very strong. This demand reflects aggressive targets set by consumer product companies to integrate as much as 25% of recycled content in their products within the next few years. In contrast to the larger petrochemical industry, this is a case of demand greatly exceeding the supply of recycled polymers. Several large plastic producers have announced aggressive goals for recycling and are expanding their recycled production. For example, Dow plans to achieve three million tons per year of circular and renewable solutions by 2030. Nova has set a goal to achieve 30% of its polyethylene (PE) sales from recycled content.

Mechanical recycling is well-established across the globe, particularly for PET. DK Agarwal of Thailand-based Indorama highlighted that it currently recycles 650KTA of PET annually, using both mechanical and chemical recycling and is targeting growth to 1.5 billion tons per year by 2030.

The company is also active in community education programs to boost collection in regions, where they operate.

Where technology anchors Plastic recycling technologies are diverse and include both mechanical and chemical processes. In simplified terms, mechanical recycling requires melting of the plastic and does not alter the polymer structure when it is reprocessed, while chemical processes break the polymer structure, reducing it into smaller molecules, or all the way to base gases, such as carbon monoxide and hydrogen.

The preferred approach typically varies by the type of polymer and existing infrastructure to support the operations.

Most companies agree that the technologies can be complementary.

Mechanical recycling works well for clean and clear polyethylene terephthalate (PET) and high-density polyethylene (HDPE), plastics with #1 and #2 recycling symbols that are typically well sorted before sent to recycling processes. Mixed and dirty plastics streams require chemical recycling, to convert the range of materials into usable feedstock to make new plastics.

For companies pursuing chemical recycling, technology is earlier in the development cycle, and most production units are in pilot scale currently with more process optimisation needed. These companies are working quickly and collaboratively to meet the high demand by consumer brand owners for recycled polymers, but more effort is needed.

Chorus of industry voices on circularity Success on the sustainability journey requires innovation at all stages. From developing new recycling technologies, to reframing the value chain for market needs. A great example is the Center for Regenerative Design and Collaboration (CRDC) had repositioned dirty waste plastic as a raw material for building materials, with operations here in Australia as well as in Latin America, Africa, and is just opening its first US unit. This project is supported by the industry consortium Alliance to End Plastic Waste, which provides funding for early stage projects. Indeed, the parameters for technology has already been drawn. It is the human network that unlocks its greater potential, as co-innovation holds the key towards future sustainability. aspentech.com

PLASTICS, COMPOSITES & ADVANCED MATERIALS

ActionLaser plastic recycling MeltFilter disc product range Australian manufacturer develops laser-drilled micro-perforated screens and sieves for export market.

ActionLaser, a laser drilling filtration screen specialist, will enter the global market for plastic recycling machinery through a collaborative project supported by a Federal Government’s co-investment managed

by Advanced Manufacturing Growth Centre (AMGC). Established in 1988 by researchers of laser drilling technology from the Commonwealth Scientific and Industrial Research Organisation (CSIRO), ActionLaser initially set out to manufacture next-generation perforated centrifuge screens for Australian sugar processors before branching into equipment for other industries.

Since its foundation, the company has gone on to supply precise, laser-drilled filtration screens to the food and beverage, mineral and chemical processing, agriculture, water and recycling sectors. Most recently, ActionLaser has turned its unique separation know-how to melt filtration systems – widly considered the heart of any plastic recycling machine.

“What this AMGC project has done is completely changed this 35-year-old company. It has helped us increase our sales, increase our staff to 30 and export nearly 80% of what we make,” explained Bevan Rashford, the company’s CEO and original researcher behind the MeltFilter technology. “Precision is in our DNA and we are very good at drilling small holes with lasers. But applying this to world-

class melt filters involves not just precise laser drilling techniques, but access to the correct steels, various kinds of specialised hardening processes, mastery of some very complex design challenges, and high-level software and automation to ensure you can do it all competitively,” explains Steve Greer, Global Manager, MeltFilter.

The company’s MeltFilter brand is now selling internationally and has vast potential among recyclers who have been limited to one single supplier in the world for a vital, highly complex consumable.

“ActionLaser is the kind of manufacturer that reminds you of what works, and what can be achieved in Australia by commercialising and exporting our great ideas and products,” said Dr Jens Goennemann, Managing Director at AMGC, which backed the project with $558,500 in co-funding through its Commercialisation Fund. “Founded with the specific aim of meeting a global need, ActionLaser focussed on solving that problem, basing its competitiveness on technical superiority rather than cost, and willing to invest in difficult R&D programs to progress.”

AMGC’s co-invested project drew on expertise from Senarc Services, run by cofounder of ActionLaser and former CSIRO industrial laser group leader Dr Ken Crane, as well as stage engineering business Simple Motion.

Simple Motion was essential in programming software for automating a rotating table used in ActionLaser’s processes. Thermal hardening specialist Heat Treatment Australia is another important partner in ActionLaser’s supply chain. It provides core hardening technologies and invests in equipment for specialised surface treatment, currently performed overseas, to help meet the predicted demand for melt filters.

ActionLaser expects to grow its revenues by 25% next year and the same amount the following year from new business, and to hire technologists with STEM backgrounds in the process.

Commercialising laser technology originally developed by the Australian Commonwealth Scientific and Industrial Research Organisation (CSIRO), Actionlaser began life as a solution for improved centrifuge screening within the sugarcane and beet industry and continues to be a significant supplier in this market.

The company has since leveraged its capability within the industrial food processing sector, to service wider applications in the mining and minerals processing, petrochemicals, water treatment, pigments and powders, and pulp and paper industries. actionlaser.com

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PLASTICS, COMPOSITES & ADVANCED MATERIALS

Carbon fibre azimuth arms EM Solutions partners with Advanced Composite Structures Australia to develop the next innovation in Satellite Communication: Azimuth Arms engineered with Carbon Fibre Composites.

Satellite communication (satcom) plays a vital role in our everyday lives and to industries such as aerospace, defence and telecommunications. One of the key components of satcom systems is the antenna reflector assembly which must be highly manoeuvrable for optimal continuous coverage. The next critical structural parts of the satcom system are the azimuth arms, which support the antenna load and enable 360-degree rotation with precise and rapid response manoeuvrability.

Advanced Composite Structures Australia (ACS Australia), in partnership with EM Solutions, is leading the way in the development and series production of state-of-the-art carbon fibre composite azimuth arms for ship-borne satcom. The partnership between ACS Australia and EM Solutions is a testament to the strength and capabilities of Australian manufacturing and highlights the benefits of industrial collaboration in driving innovation in Australian industry.

ACS Australia, based in Port Melbourne, specialises in the design, analysis, manufacture and repair of composite structures. “We are committed to delivering advanced composites technology to EM Solutions, helping develop the next generation of SatComs that are lighter and more durable in demanding environments,” said Paul Falzon, General Manager – ACS Australia. “It is very rewarding to partner with EM Solutions, they value innovation and successfully translate this into real-world application.” With over three decades of experience, ACS Australia has built a reputation for taking on composites development in the ‘too hard basket’ and providing high-quality and cost-effective solutions to a variety of industries.

EM Solutions is an Australian-based company, one of the world’s leading providers of satcom systems that designs and manufactures a range of satcom products, including the sub-systems, antenna systems, amplifiers, and modems for defence and civil industries.

ACS Australia finite element analysis of carbon fibre composite azimuth arms at a specific in-service load case.

EM Solutions King Cobra satcom with composite azimuth arms (left); and installed and commissioned satcom on a sailing navy vessel (right).

Together, ACS Australia and EM Solutions have developed an innovative all carbon fibre composite azimuth arm that offers a simplified one-piece, corrosion resistant and light-weight alternative to metallic constructions. Carbon fibre composites offer unparalleled advantages over traditional materials, including higher strength-to-weight ratio, corrosion resistance and greater durability in fatigue environments, an important requirement for Australian Defence applications. The new single-piece design offers significant improvements over traditional metallic azimuth arms in terms of weight, assembly time and maintenance cost. ACS Australia engineers validated the novel design with static and dynamic finite element structural analysis to meet varying load conditions and deliver an all-carbon fibre epoxy composite structure optimised for both manufacture and ease of installation for end-user application.

The carbon fibre composite design meets all static and dynamic requirements, including the high blast requirements of topside naval structures. The optimised design reduces overall weight by approximately 65% compared with the metallic design and achieves a significantly reduced part count (approximately 50 parts less), resulting in far fewer fittings and fasteners being required. This advanced design helps to reduce top-side weight for navy vessels, as well as reduces power consumption and sizing requirements for sub-systems due to the light-weight composite construction.

ACS Australia has in-house capabilities to develop composite structures of different sizes and complex geometries, supported by advanced design tools and Industry 4.0 manufacturing equipment.

This capability enables the unique azimuth arm manufacture to be less labour-intensive using automated carbon fibre ply cutting, reducing labour time whilst increasing accuracy and minimising material waste. EM Solutions is proud to share that the first new King Cobra product is now installed, commissioned and sailing on Navy vessels. The EM Solutions King Cobra is a two-metre class naval maritime satcom terminal, with full extended Ka Band and simultaneous X-Band coverage and enabled to access GEO, MEO, HEO and LEO satellite constellations. The King Cobra is a robust tracking terminal offering both military and commercial bands in the one terminal that is designed in Australia and trusted by the Australian Border Force, the Royal Australian Navy, allied navies and the US Government for reliable offshore military satellite communications.

“We have been collaborating with ACS Australia for the past three years,” said Georgios Makris, Vice President Operations at EM Solutions. “The team has been very professional and responsive, exceeding our expectations to design and manufacture this critical light-weight arm structure for our SatCom terminals.” acs-aus.com emsolutions.com.au

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PLASTICS, COMPOSITES & ADVANCED MATERIALS

Sustainable GrainCorp GrainCorp is partnering with plastics recycler Sustainable Plastic Solutions (SPS) to eliminate grain tarpaulins from landfill by 2027.

GrainCorp has already recycled more than 100 tonnes, or 107,679 kilograms of tarps, which cover and protect bunkers of grain against weather and damage, from sites in Queensland, New South Wales and Victoria over the last year. The companies are also investigating how to take the next step and restore the recycled tarp material into new tarps, in a circular economy set-up.

GrainCorp Head of Sustainability Mick Anderson said the innovative partnership will help to build a more sustainable tarp management process for the grains industry.

“Tarps are a critical part of our storage network, each one covers and protects up to 3,000 tonnes of grain or oilseed in GrainCorp’s bunkers,” he said. “We treat them carefully to keep them in operation for as long as possible, but they’re exposed to the elements and eventually wear out, which can put anywhere from 250 – 600kg of material out of action each time. It’s great to secure a sustainable waste solution for the end-of-life tarps, and to be exploring the potentials of a circular solution over time.”

SPS formed in Hamilton, Victoria in 2022 to offer solutions for plastics in the agriculture sector. CEO of SPS Matt Nettleton said once the tarps reach SPS, they go on quite the journey to be reclaimed for other uses.

“The tarps are washed, shredded, melted and pelletised before being sent off to our industry partners to become anything from industrial walkways or floor grids for shearing sheds, to seats for our sport stadiums,” he said. “We’ve received tarps from as far north as Emerald in Queensland, right down to the sites here in the Western District of Victoria.”

GrainCorp’s goal to achieve zero tarpaulins to landfill by 2027 reflects the company’s commitments to minimising plastic pollution and forge a more sustainable future for the agriculture industry. “We’re excited to partner with GrainCorp and take a significant step towards a greener future for the bulk handling sector, and for GrainCorp’s east coast network of receival sites,” Nettleton said.

Sustainable Plastic Solutions (SPS) is an Australian owned and operated End-to-End plastic recycling business, based in Hamilton in regional Victoria. SPS was established in 2022 and focuses on collection and recycling of agricultural plastics. Our mission is to develop circularity in agricultural plastics that have historically had low recycling rates. We recycle these products into high quality resins developed to customer specifications, that can go back into producing the original products in a true circular economy. graincorp.com.au

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TACCA Industries Implementing an AGV system in conjunction with an existing ASRS shuttle system for warehouse optimisation.

The client is a prominent distributor in the logistics industry, faced significant operational challenges in their existing warehouse facility.

The lack of organisation and haphazard arrangement of pallets resulted in inefficiencies, with difficulties in locating stock leading to unnecessary delays and increased manufacturing costs. Safety concerns arose from tall pallet stacks and incidents of forklift operators damaging racking structures. To address these issues, the client sought a solution that would streamline warehouse operations, improve stock management, enhance safety, and integrate seamlessly with new, RA specified ASRS (Automated Storage and Retrieval System) shuttle system.

The key obstacles in this project were twofold: firstly, the requirement to integrate the new AGV (Automatic Guided Vehicle) system with the ASRS shuttle system, and secondly, the need to transition the entire warehouse inventory into the new system without interrupting ongoing operations.

System installation: a tailored solution A phased approach was adopted to implement the solution effectively. The following steps were taken:

AGV deployment A fleet of four MAXAGVs was introduced into the facility. These state-of-the-art vehicles are designed to autonomously navigate the warehouse environment, retrieve, and transport pallets of product (sometimes x2 high) with precision.

Inventory transition and scanning All existing stock in the disorganised warehouse was systematically removed and scanned into the new Warehouse Management System (WMS). This process enabled accurate tracking of each item while ensuring uninterrupted warehouse functionality.

Pallet scanning and placement Pallets arriving from the manufacturing area were meticulously scanned by forklift operators. The WMS, armed with real-time data, determined the optimal rack location for each piece of stock, thereby enhancing storage density and accessibility.

AGV Stock Movement Once the storage location was determined, the AGVs seamlessly transported the pallets to the designated rack location. The AGVs also controlled the ASRS shuttle system, commanding it to store items logically in the up to 22 deep rack positions, maximising warehouse space utilisation.

Order Fulfilment Automation The AGV system facilitated autonomous order fulfilment. Upon receiving an order, the AGVs efficiently retrieved the required combination of stock types and delivered them to the outfeed area, streamlining the order processing workflow.

3D Visualisation The incorporation of a 3D visualisation component within the new WMS enhanced visibility and navigation within the warehouse and can be easily viewed on smart phones, pads and laptops.. This visual representation of the warehouse layout enabled efficient stock identification and retrieval.

Equipment and Integration The core elements of the solution included: Four AGVs, engineered for optimal navigation and precision.

Seamless integration of the AGV system with the existing ASRS shuttle system, ensuring synchronised and efficient operations.

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The introduction of a 3D visualisation feature within the WMS, providing a comprehensive and intuitive view of the warehouse layout and stock distribution.

Benefits Realised The implementation of the AGV system in conjunction with the existing ASRS shuttle system yielded several significant benefits: Enhanced Operations: The warehouse transitioned to a 24/7 operation, significantly improving operational efficiency.

Streamlined Stock Management: The 3D visualisation feature made stock identification and retrieval simple and efficient, reducing the time taken to locate items.

Autonomous Order Fulfilment: The system enabled seamless and autonomous order processing, further expediting customer deliveries.

Optimised Space Utilisation: The AGVs and ASRS shuttle system collaboration maximised warehouse space utilisation with a gain of 2 – 3 times the volume of pallets utilising the same footprint.

Enhanced Safety: The organised storage system also reduced safety risks with tall pallet stacks no longer required and more space available, forklift-related incidents have been reduced.

Conclusion By effectively integrating a sophisticated AGV system with an ASRS shuttle system, the client transformed their chaotic warehouse into a streamlined and efficient operation. The innovative solution not only resolved the initial challenges but also laid the foundation for improved productivity, safety, and customer satisfaction.

This successful case study serves as a testament to the power of advanced automation and integration in modern warehouse management.

“I am extremely satisfied with the efficiency and reliability of our automated warehousing solution,” said Domenic Tacca, Managing Director at Tacca Industries. “The after sales service and technical support provided by the RA team has been exceptional.” ragroup.com.au

ROBOTICS & AUTOMATION

Robots at the UTS Tech Lab AI and robotics leader Advanced Navigation opens high-tech robotics manufacturing facility.

Advanced Navigation has unveiled a new high-tech robotics facility for autonomous systems based at UTS Tech Lab. Located in Botany NSW, the facility will scale up the manufacturing of Advanced Navigation’s world-first AI navigation systems for GPSdenied environments, including its digital fibre-optic gyroscope (DFOG) technology, Boreas.

Advanced Navigation is one of only four companies in the world with the capability to manufacture strategic grade fibre-optic gyroscopes. This technology empowers reliable navigation for marine vessels, space missions, aerospace, defence, autonomous vehicles and flying taxis. The company deploys its unique AI-based physics algorithms to solve complex challenges earth-bound and beyond.

Strengthening Australia’s sovereign capabilities Xavier Orr, Advanced Navigation CEO and co-founder, said, “There is a critical need to improve Australia’s economic complexity and sovereign capabilities. A key step is to build our industrial capacity in high-tech, as well as drive knowledge exchange and propel collaborative initiatives between government agencies, academic institutions and industry leaders.”

State-of-art robotics manufacturing for autonomous systems There is a seismic shift across the landscape of sovereign manufacturing, driven by advanced technologies like AI, automation and precision engineering. In the context of autonomous systems, the importance of precision and reliability is non-negotiable.

Adopting a vertical integration framework, the facility houses equipment and processes for automated manufacturing utilising machine learning. This guarantees the delivery of reliable, durable and high-quality navigation systems.

Collaborating with UTS academics and community In addition to the manufacturing capability, the facility will be home to extensive research collaborations between Advanced Navigation and the University of Technology Sydney (UTS). This will expedite the commercialisation of several socially impactful technologies, including:

Light Detection, Altimetry and Velocimetry (LiDAV) system - LiDAV delivers precise three-dimensional velocity and altitude information relative to the lunar surface, enabling complex autonomous landing procedures and confident exploration on the moon. The technology is set to board US-based space systems company Intuitive Machines’ Nova-C lander as part of NASA’s ongoing Commercial Lunar Payload Services (CLPS) program.

Cloud Ground Control - A revolutionary cloud-based solution that allows pilots and mission planners to remotely command and control a swarm of uncrewed vehicles across air, land and sea through a web browser. By enabling real-time video feed, and telemetry, and easy access and management of captured data, Cloud Ground Control provides full remote visibility and situational awareness in search and rescue, emergency response and disaster relief operations. Guiding visually impaired passengers - As part of the NSW Small Business Innovation and Research (SBIR) program, Advanced Navigation has developed an indoor positioning technology to support members of the visually impaired community navigate safely inside underground train stations.

Bolstering societal demand for STEM roles The facility appeals to the Federal Government’s ongoing commitment towards building a science, technology, engineering and mathematics (STEM) workforce. It is set to drive employment in robotics, manufacturing, photonics, mechatronics and mechanical engineering and other fields. Chris Shaw, Advanced Navigation CEO and co-founder, said, “Our new facility will help drive rapid growth in Australia’s STEM industry. Determined to be the catalyst of the autonomy revolution, we are commercialising technologies that are key to addressing some of humanity’s biggest challenges.

We are honoured to partner with UTS, who has a reputation for supporting multidisciplinary research and opening access to nextgeneration technologies.”

Advanced Navigation was founded on a culture of research and discovery. Powered by a deep curiosity to apply ground-breaking technologies to uncover and explore new frontiers, the company is ultimately extending human capabilities to build a more resilient and sustainable future with safer outcomes, on and off planet. advancednavigation.com

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Australia needs robots The case for integrated robotics. By Meighan Heard, Executive Director, Commercial and Corporate Mitsubishi Electric.

Almost every day the media reports on prominent businesspeople, government representatives, or politicians who have highlighted the urgent need for Australia to achieve ‘productivity improvements, including maintaining and enhancing our quality of life. This is critical in a world of ever-changing demands, an ageing workforce and fluctuating labour availability, where the pressure to improve performance and enhance responsiveness to shifting needs has never been greater.

In fact, a recent intergenerational report by the Australian Institute has noted that Australia’s productivity levels have fallen in previous years. Yet improvements in productivity continue to be elusive for many businesses.

One solution for manufacturers lies in the seamless integration of robotics to optimise performance, increase efficiency, and ensure top-notch productivity. As robotic technology continues to evolve and seamlessly integrate with control systems, both electrically and mechanically, the cost of adoption decreases. This reduction in pricing, combined with simplified programming, revolutionises the design, operation, and maintenance of robotic systems.

Below are some reasons why manufacturers need to look to integrated robotics for productivity enhancing benefits.

Streamlined communications and enhanced coordination The integration of information transfers and controlled machine behaviour is paramount to manufacturers achieving increased productivity and managing fluctuations in labour and demand. Direct communication between controllers and planning or warehouse systems plays a pivotal role in ongoing optimisation efforts and the pursuit of maximum efficiency.

By integrating robots into the system, speed and coordination are significantly improved, minimising the need for constant operator intervention and extensive training. For example, the immediate reporting of maintenance needs ensures swift scheduling of necessary downtime, preventing production losses.

This approach optimises the availability of parts and services at the right times, thereby maintaining and improving operational efficiency.

Real-time monitoring and analysis Going beyond simple integration is something that all manufacturers should consider. Robot behaviour and production

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status can be logged, monitored and saved to the Human-Machine Interface (HMI). This generates real-time data which provides operators with instant insights and analysis, ensuring prompt decisions can be made.

The same HMI then serves as a dualpurpose tool for both production operation and maintenance troubleshooting.

The HMI can be custom designed to meet specific needs. For example, operators and maintenance personnel can access specific screens tailored to their requirements.

This safeguard ensures sensitive data can remain secure while also facilitating efficient management. Authorised users can reprogram and reconfigure robots using the same interface, enhancing adaptability and operational efficiency.

The cloud connection: Scaling behaviour monitoring For industries embracing multiple robots and integrated machines, such as AGVs (Automated Guided Vehicles) or ASRS (Automated Storage and Retrieval Systems), it may be beneficial to connect fleet information to the cloud. This enables large-scale behaviour monitoring and anomaly detection, a crucial strategy for predictive maintenance and seamless demand fulfilment.

The integration of robots into cloudbased systems also provides valuable insights into predictive behaviours and maintenance requirements at scale. This ensures production continuity, creates a safer environment for workers and reduces the risk of damage to equipment.

Robotic advancements: Precision and handling redefined Advancements in robotics have opened a realm of possibilities for end-of-arm tooling. These include grippers, pinchers, magnets, vacuums, and suction devices, coupled with integrated vision systems.

This comprehensive integration at the end of the robotic arm enhances package placements, reduces maintenance costs, and simplifies mechanical complexities.

Shaping tomorrow: adaptability

Collaboration

and

The future of robotics lies in collaboration.

With advanced sensors and safety capabilities, robots are becoming more adaptable, capable of working intelligently alongside humans. This calls for increased integration of automation systems to ensure seamless cooperation and interference avoidance. au.mitsubishielectric.com

ROBOTICS & AUTOMATION

AI thought leadership "AI is revolutionising manufacturing,” says Anders Billesø Beck, Vice President Strategy & Innovation, Universal Robots.

Artificial Intelligence (AI) is by no means a new phenomenon. For decades we have been talking about AI as a technology with the potential to radically disrupt our society and impact the future of mankind – some being optimistic, others dystopic in their view on AI. But with the emergence of technologies like ChatGPT, it looks like the future is now and it’s hard to think of a time when AI has been a hotter topic than at present.

One of the key reasons why AI is now being discussed in workplaces all over the world is because computer processing has taken giant leaps forward in recent years. We now have the processing power to handle the vast amounts of information and data required for AI technology, something we simply didn’t have before.

This hardware development has paved the way for an AI breakthrough, including new software programs like ChatGPT. But while chatbots are still in the early stages of transforming how we communicate and gather information on the internet, AI technologies is already making a real-life difference in another arena – manufacturing.

Here are four examples of how AI is impacting industrial automation today, and how it can be used to benefit manufacturers all over the world by making it simpler to automate complex and diverse tasks even in unstructured environments.

1. Humanlike perception Humans can look at disordered objects – such as parts in a bin - and immediately see the difference and understand which of them can be handled without interfering with other objects. Automation engineers know that this isn’t always the case for robots, to put it mildly. As a result, bin-picking of unstructured items has traditionally been thought of as a notoriously difficult problem to solve. But this is changing with AI. Take for example Apera AI’s ‘4D Vision’ technology, which is challenging the status quo by providing collaborative robots (cobots) with “humanlike perception” – a claim that sounds hyperbolic at first, but is borne out on several levels and enables faster, more effective robot performance especially in bin-picking applications.

With the use of scanners and cameras, ‘4D Vision’ can identify the “most pickable” objects and inform the cobot of the fastest and safest path to handle them.

2. Handling variations without prior teaching or programming The mainstream understanding of AI is a technology that’s able to “think” by itself

and make decisions without prior teaching or instructions. Even though this is not always the case, these upsides are exactly what you get with the robobrain.vision kit from Robominds designed for the logistics industry for e.g. kitting, order picking or depalletising tasks.

With this kind of camera-based AI technology, the robot can pick up different - objects regardless of their shape or size. And by not having to spend time on teaching or programming the robot, customers are given even greater flexibility and can change the objects being handled without spending time on re-programming.

3. Moving parts precisely Another example of how AI enables industrial robots to deal with variance in position, shape or movement is MIRAI from Micropsi Industries.

Instead of being dependent on specific measurements being pre-programmed, it’s able to generate robot movements in real-time. This means the robot can do e.g. assembling, gripping, screwdriving or testing tasks, even if the position of machines or objects fluctuate from time to time. Inbolt's AI-based Inbrain is another technology using AI to handle variations and moving parts. It processes massive amounts of 3D data at high frequency and identifies the position and orientation of a workpiece, adapting the robot trajectory in real-time, which makes it ideal for assembling, handling, finishing, and testing.

4. It just keeps getting better Another important upside of AI in industrial automation is that its constantly improving - automatically.

The more your robot is working, the more data the AI application is gathering, and with this data the underlying algorithm can continously optimise, adjust and improve the robot’s performance.

This level of self-learning means that, as a customer, your automation solution will improve by the day – without you having to spend time and money on updates or upgrades to your solution.

AI brings flexibility and simplicity to new levels The upsides of this new synergy between AI and cobots are evident. Manufacturers looking to cobot automation to overcome their business challenges – whether its labor shortage, improving employee’s wellbeing or raising quality or productivity – are now able to solve extremely complex tasks, even in unstructured environments. And, at the same time, AI products are presenting manufacturers with an unforeseen level of flexibility and simplicity, as well as raising quality and reliability.

It's clear AI is already making an impact on industrial automation, but the best part is we’re only just scratching the surface.

The future might be here, but the best it yet to come. universal-robots.com

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ROBOTICS & AUTOMATION

New partnership to grow robotics ecosystem A new partnership between AROSE and the Robotics Australia Group will help connect and grow Australia’s maturing robotics ecosystem.

The affiliate partnership will explore new opportunities for growth, collaboration and advocacy of remote operations technology and expertise. The partnership will significantly benefit both organisations, as well as the various members and stakeholders we jointly represent. AROSE and Robotics Australia Group work with a similar range of stakeholders across industry, State and Federal governments, research institutions, and fellow industry associations.

Both organisations recognise automation and robotics as tools that unlock human potential, modernise the economy, and build national well-being and sustainability. Robotics is an interdisciplinary field that includes mechanical and electrical engineering, computer science, design, social sciences, creative arts and law.

Robotics Australia Group was established to facilitate the growth of a sustainable and internationally competitive national robotics industry. It is the peak body representing the robotics and roboticsrelated technology sector in Australia.

Social, economic and environmental benefits Robotics Australia Group CEO Nicci Rossouw said growing Australia’s robotics sector has the potential to generate enormous social, economic and environmental benefits.

“The development of robotic technologies will lead to the creation of new companies and new jobs,” Rossouw said. “Robotics and automation are central to addressing a range of issues of national importance including our ageing population, servicing regional and remote communities, and labour shortages.”

AROSE CEO Leanne Cunnold said the growth in robotics, automation and artificial intelligence presents many opportunities and challenges requiring the highest levels of cross-industry collaboration. “The partnership between AROSE and Robotics Australia Group will help elevate collaboration and improve outcomes for the robotics ecosystem across Australia, while boosting the national presence of both organisations.”

Cunnold said robotics will impact every sector of the Australian economy, creating the jobs of the future and helping us tackle some of the great challenges facing humanity.

“Robotics has the potential to achieve enormous social and environmental good. A wide range of robotic technologies will be required to deliver on the world’s decarbonisation aspirations, as well as help monitor and mitigate environmental challenges such as bushfires, drought and floods.”

Expanding collaboration across industries AROSE Program Director Michelle Keegan said the partnership has the potential to deliver significant benefits for industry.

“While Australia is regarded as a world-leader in the design and management of autonomous vehicles, robotics and interoperability for the Resources sector, greater investment in robotics and workforce development is required to maximise the opportunities across all industries.” Keegan said the biggest challenges industry faces are the need to achieve zero emissions, zero harm and zero waste.

“The Resources and Space sectors recognise the need to collaborate to achieve these ambitious goals. Now we need to expand collaboration across industries. This partnership will be a major boost to that important national enterprise.”

Another key area of collaboration between AROSE and Robotics Australia Group will be in education and training.

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Boosting workforce skills, diversity and STEM Robotics Australia Group Chair Dr Sue Keay said both organisations are committed to boosting workforce skills, increasing diversity and inspiring students to pursue careers in STEM. “In order to have a thriving robotics industry in Australia it’s important to have a workforce with the capability to meet the requirements of competitive business,” Dr Keay said.

“The education side of the equation is crucial to providing a pipeline of workers who are appropriately skilled and passionate about robotics and automation.”

Cunnold said that for many students in classrooms today, the automation and robotics sector is the career of choice.

“It’s critical we invest here in Australia in the talent and technologies we are developing in remote operations. This will grow our businesses and create jobs at home for our future workforce.”

Industry and policy context In 2021, Australian robotics companies were estimated to be worth $18bn in annual revenue, up from $12bn in 2018. Automation was forecast in 2019 to add an additional $170bn to $600bn to Australia’s annual GDP by 2030 given sufficient investment across the private and public sectors.

The growth of analytics and robotics capabilities in the Resources sector alone is estimated to add $74bn to the economy by 2030 and create 80,000 new jobs. Robotics and Automation on Earth and in Space is a key priority area under the Australian Civil Space Strategy.

Both AROSE and Robotics Australia Group were key contributors to the Australian Space Agency’s Robotics and Automation on Earth and in Space Roadmap 2021-2030, and more recently to the Federal Government’s National Robotics Strategy discussion paper.

In 2022 Robotics Australia Group produced its own Robotics Roadmap for Australia that outlines its plan for Australia to achieve a sustainable homegrown robotics industry. arose.org.au

ROBOTICS & AUTOMATION

Motopal Gripper Arnotts gets the grip on boxing with robots from Motopal.

Retailers are continuing to drive the movement toward shelf ready packaging (SRP) or retail ready packaging (RRP), essentially meaning that stock is presented to store as easily brand identifiable, ready to place on shelf, and easy to dispose.

While the movement toward SRP is beneficial for the retailer in terms of reduced handling and waste, and ease of merchandising, to gain true efficiencies the processor or manufacturer must ensure that their palletising process (whether manual or automated) is designed to handle a more challenging array of palletised product.

Shelf ready cartons are one of the hardest products to palletise in most production facilities as SRPs can vary widely in size and shape, weight, and rigidity – and can adopt various configurations including addition of perforations, use of corrugated trays, and removable plastic wrap – that can serve to increase risk of damage.

This lack of packaging uniformity and increased fragility presents a particular problem for a manufacturing facility that runs numerous product lines in the selection of a robotic palletiser. Conventional product grippers simply do not provide the flexibility and handling ‘care’ demanded by the broad range of SRP configurations available.

Ensuring product ‘survivability’ through the supply chain is key.

As the market has shifted, we at Robotic Automation have had to shift our thinking too in developing a robotic palletiser to accommodate the dilemma of managing high-speed automated palletising of SRP to ensure appropriate handling and no breakages through the packaging process.

Our patented and proven MOTOPAL robotic grippers (MOTOPAL-780 and MOTOPAL-1120) were specifically designed at Robotic Automation to resolve these challenges, being pre-programmed to handle most SRP patterns and carton sizes.

The grippers were originally trialled over a period of almost two years as part of a new palletising solution at client Arnott’s Huntingwood factory, where they proved capable of handling every possible carton configuration, achieving a rate of up to 30 cartons/minute.

In an industry where the only certainty is change, we are proud of our design ability to adapt and innovate to meet the needs of our clients. The MOTOPAL grippers represent a highly efficient fully servo gripper perfect for both end of line and multi robot centralised palletising applications, and represent a modern solution to the SRP dilemma.

Key Benefits • • • • • • • •

A fast, flexible and powerful package with small footprint; Reduction of damage to cartons; Pre-programmed for most patterns and carton sizes; Simple to edit; Low cost palletiser infrastructure; Easy to install and simple to maintain; Offline programming via “MotoLogix” on a PLC of your choice; Designed for use with Embedded AGV’s.

ragroup.com.au

www.raymax.com.au

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Richmond rolling robotics Australian businesses can make warehouse order picking faster and more accurate in one powerful way.

By Breon Winslow-Moore, CEO, Richmond Rolling Solutions.

Every day we see more and more businesses adopting the latest rolling solutions to update their material handling workflows, helping improve productivity, the movement of products and the day-to-day safety of workers. However, despite rapid advances in warehousing and logistics technology, order picking in Australia is still largely dominated by manual processes.

While manual picking methods have up until now managed to service a growing e-commerce customer market, traditional paper-based systems are struggling to keep up with the needs of the modern market. Some of the factors driving this include, increasing customer demand and a pressure on faster delivery time, unpredictable supply chains and growing global competition, and the need to automate processes where possible.

We all know that Aussie consumers love the convenience and relative delivery speed of online ordering. But the way in which their favourite products get to their front door has not changed significantly over the last decade.

Are manual picking methods still holding back your customer deliveries?

The speed and accuracy of order picking forms a vital part of e-commerce, manufacturing, hospitality, and retail industries - basically any company that deals with products stored in warehouses awaiting customer orders.

Common methods used in both small and large Australian warehouses include: batch picking, zone picking, pick-and-pass picking and wave picking. These methods all generally rely on five labour intensive steps: 1. Set-up > 2. Travel > 3. Search > 4. Pick > 5. Pack Even if you’ve implemented new processes for optimising your picking method - such as putting popular items closer to the front, using LED screens to guide pickers, digitising inventory levels in real time, or installing conveyor systems - there will always be a productivity gap and the risk of picking and packing errors, which impact your bottom line.

Improve each step and transform your order picking workflow

The best part of these AMRs is they can operate in almost any warehouse environment without the need for pre-installed guiding systems that are necessary with Automated Guided Vehicles (AGV).

Next-generation Autonomous Mobile Robots (AMRs) will be a key feature of Australia’s transition to smart warehousing and are already being used in many distribution and fulfilment centres across the country.

Make the switch: replace your paper-based picking methods

Faster, smarter and more flexible than anything previously available, they’re set to transform picking methods by reducing repetitive tasks, enhancing efficiency, and improving overall worker safety.

We recently announced an exclusive partnership with ForwardX Robotics - a global leading person-to-goods AMR manufacturer to distribute its next generation products across Australia and New Zealand.

Working alongside your picking team, the latest AMRs offer a range of benefits for today’s warehousing operations looking to gain a commercial edge, including: • • • • •

Improving picking speed and accuracy by reducing wasted movement between zones.

Intelligently choosing the best route for each order, with autonomous rack locating and docking capability.

Ability to follow simple on-screen instructions that make it easy for an employee to pick the right item the first time, every time.

Making the lives of your workers easier by minimising the manual strain and risk of injury throughout each shift.

Reducing recruitment and training costs by improving overall staff retention.

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At Richmond Rolling Solutions, we’re witnessing the steady expansion of these AMRs into a wide-range of businesses, helping to replace traditional, paper-based manual methods.

This state-of-the-art fleet, developed by a team of more than 250 world-class computer vision scientists and robotics experts, represents the pinnacle of technological innovation.

With the global warehouse automation market expected to reach $60bn by 2027, smart solutions like those from ForwardX Robotics will revolutionise point-to-point material handling in nearly every major industry.

Our commitment to improving the material handling performance of our customers goes back over 60 years. These new AMRs give businesses the opportunity to keep pace with global trends and ensure they can meet tomorrow’s customer demands. richmondau.com

ROBOTICS & AUTOMATION

HaaS is the new normal Hardware as a Service. The new Paradigm for service contracts. Robert Bush, the CEO of Rivelin Robotics, speaks about how industry is already changing.

Across the ever-evolving landscape of technology and business, Hardware as a Service (HaaS) is proving to be a transformative concept. The world at large has become familiar and comfortable with software delivered as a service commodity via subscription model both for professional organisations and individuals. This has laid the foundation for a similar approach to hardware service contracts, which are increasingly being viewed as a savvy way to scale up in-house capabilities without huge capital expenditure.

This innovative approach to managing hardware needs is changing the way many manufacturing organisations handle their hardware portfolios and associated service contracts. With the increasing use of automated hardware and connected manufacturing solutions, together with the software that enables it, the potential impact on productivity, and adopting a flexible revenue approach makes HaaS a significant paradigm shift. In this article, we will explore these themes, shedding light on how HaaS is shaping the future of technology management and service contracts.

Driven by Automation Automation has become a driving force behind improving the efficiency and scalability of modern business operations. Automated manufacturing hardware can significantly enhance operational efficiency by streamlining processes and reducing human error.

Robots, with the right programming, ensure precise and consistent output which in turn leads to higher quality products. Moreover, it can accelerate production speeds.

Automated manufacturing processes have also proved to greatly enhance workplace safety by handling dangerous tasks, thus minimising and at times eliminating the risk of accidents and injuries to workers. In so doing, workers are released from laborious, repetitive tasks and can dedicate their time and skills to other disciplines.

The benefits of automation are demonstrable across many manufacturing sectors today, however, automated robotic systems often have hefty capital costs associated with them, and this is where HaaS can offer a creative and versatile approach.

A Flexible Revenue Approach A flexible revenue approach is a defining feature of HaaS, offering organisations a ‘pay-as-you-go’ model instead of the traditional CapEx hardware purchasing model. This offers manufacturing organisations, regardless of their size, several advantages.

HaaS reduces the need for significant upfront capital investment in hardware, making it a cost-effective solution. Organisations pay only for the hardware and services they need, for as long as they need them, aligning expenses with actual usage.

Businesses, especially in the manufacturing sector, often face changing needs and market fluctuations. The flexibility of HaaS allows organisations to easily scale their hardware resources up or down, adapting to evolving circumstances and according to their requirements. It also allows for a slow start to prove out a technology, and conduct any necessary R&D and/or testing before scaling up for full production at required volumes.

Another positive financial benefit of HaaS is that budgeting becomes more predictable and transparent. Monthly or quarterly payments replace large, irregular capital expenditures, simplifying financial planning and reducing financial risks.

Additional Business Benefits Adopting HaaS ensures that hardware remains up-to-date and functional. Companies that provide HaaS invariably schedule

regular maintenance of the systems and, for automated systems this includes software updates. This greatly mitigates the risk of hardware failures and security vulnerabilities. Moreover, this proactive approach minimises downtime and maximises efficiency.

Utilising HaaS contracts can bring significant productivity improvements through cost-effective access to the latest technology. With HaaS, manufacturing organisations gain access to cutting-edge hardware and technology without the upfront capital expenditure.

To the Next Level >> Robots as a Service (RaaS) At Rivelin we have kind of coined the phrase ‘RaaS’, because offering Robots as a Service is what we do. Rivelin Robotics exists to offer automated solutions for post processing metal parts, and the company’s powerful Netshape® software drives some of the most advanced robots to do this for powder removal, base plate removal, support removal and polishing and finishing. Rivelin Netshape® Robots provide solutions to some of the AM industry’s greatest challenges.

Our approach to how we do business has been as well thought out as the robots themselves: Rivelin is committed to supporting customers throughout the production journey — NPI (New Product Introduction), Pre-Production Trials, FAT (Factory Acceptance Tests), SAT (Site Acceptance Tests), In-Production and PostProduction Decommissioning.

The goal is to maximise value for our customers who we see as partners, and to achieve this Rivelin takes care of the software, hardware, service and preventative maintenance. We work with you every step of the way, from our factory floor to yours.

Conclusion The flexible revenue approach of HaaS, with its pay-as-yougo model, ensures cost-efficiency, scalability, and predictable budgeting. As increasing numbers of manufacturing organisations embrace digital transformation and navigate the complexities of today's business environment, HaaS offers a practical strategy that goes beyond traditional hardware procurement and service contracts with a number of key benefits that should not be ignored.

HaaS is therefore reshaping the way organisations manage their hardware needs, offering numerous benefits that extend to productivity, safety, and financial flexibility. As technology continues to evolve, HaaS business models can support organisations striving to remain competitive and agile in an ever-changing world. Think of the Rivelin solution as an OpEx. Think of it as your new 12-month labour contract. rivelinrobotics.com

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SYSPRO insights Fast tracking operational efficiencies with MOM and ERP, by James Robinson, APAC Vice President for Services, SYSPRO. Australia's manufacturing industry continues to adapt to an everevolving business environment. Despite challenges, the sector remains focused on meeting global demands while keeping costs low and waste to a minimum. One noticeable shift has been Australian manufacturers’ ability to seek out improved efficiencies and increased productivity through the adoption of advanced technologies designed for manufacturers.

According to the 2023 CommBank Manufacturing Insights Report Australian manufacturers are prioritising investment in new technology as their top business focus for the upcoming year, with 87 per cent of manufacturers planning to increase their technologyrelated spending. This inclination is even higher in regional locations, where 99 per cent of manufacturers intend to boost their investments in new technology. Additionally, businesses in the manufacturing sector are looking to enhance efficiency, productivity, quality and capacity as key objectives in the next 12 months.

The Manufacturing Insights Report also found that manufacturers are not only focusing on established technologies but are also exploring emerging ones to drive efficiency and improve customer satisfaction. The report also found that anticipated growth areas in technology adoption over the next two years include nextgeneration enterprise resource planning (ERP) systems at 31 per cent, autonomous systems and equipment at 31 per cent, and artificial intelligence at 30 per cent. These trends underscore a commitment among Australian manufacturers to embrace cuttingedge technology to remain competitive and responsive to evolving market demands.

Manufacturing is undoubtedly a globally competitive field and it often grapples with market volatility and unpredictable conditions.

For domestic manufacturers in Australia, maintaining operational efficiency can be a considerable challenge. However, there are solutions available that can provide a competitive edge by improving operational efficiencies. To enhance operational efficiency in manufacturing, it is crucial for manufacturers to fully embrace connected and automated manufacturing processes. Digital transformation, involving the integration of machines to obtain realtime data without manual inputs, is a key driver of efficiency and transparency in managing operational performance.

In today's manufacturing landscape, data is a critical asset. Many manufacturing businesses possess an abundance of data sources that can often operate independently. To harness the full potential of big data analytics and operational optimisation, it's essential to ensure seamless interoperability between these data sources. Each machine theoretically generates megabytes of data that often go underutilised but when managed through one system, managers can make better data-driven decisions for the business.

The AF Gason Australian Success Story AF Gason, renowned for designing and manufacturing top-tier broadacre farm machinery, industrial and wood-heating products, has made significant strides in improving its operations. In 2011, the business needed an enterprise system which could be used across the entire length of its supply chain to ensure one source of the truth. This Australian company has efficiently embraced modern technology by implementing SYSPRO Enterprise Resource Planning (ERP), with SYSPRO Manufacturing Operations Management (MOM), to streamline its manufacturing processes.

MOM focuses on plant-wide manufacturing lifecycle management, covering planning, scheduling, data collection, analysis and optimisation. Within MOM, the Manufacturing Execution System (MES) integrated with an ERP system ensures precise control over manufacturing operations, reducing costs and improving quality.

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AF Gason achieved a remarkable 100 per cent improvement in its results over the past few years. Job recording accuracy levels improved by more than 20 per cent and shop floor efficiency increased nearly 50 per cent. This success is attributed to the ability to harness data effectively, enabling better decision-making across the organisation.

The AF Gason success story is just one example that demonstrates the potential for Australian manufacturers to achieve operational efficiency and stay ahead in a highly competitive global market. This success story highlights the transformative impact of ERP systems and Industry 4.0 technologies, emphasising the importance of datadriven decision-making in today's manufacturing landscape.

The key takeaway According to ABS data, around 905,000 people were employed in the manufacturing sector in March 2023 – representing about one in every 16 Australian workers. The Australian manufacturing industry earnings grew 17.8 per cent in 2021-22, representing a $7.6 billion increase. During this same period the industry value added (IVA) for manufacturing, which is the measure of the contribution by businesses to gross domestic product, increased 15.2 per cent (A$16.1 billion). This is a positive direction for the industry and one that technology adoption will help to try maintaining.

As Australia's manufacturing sector continues to evolve and navigate global challenges, digital acceleration and Industry 4.0 technologies are becoming essential tools. By embracing these innovations and understanding the value of interconnectedness through an ERP system, manufacturers can gain the competitive edge needed to thrive in the post-pandemic world.

Implementing an ERP that has a MOM system will ensure effective execution of manufacturing operations to help improve efficiency.

Only by understanding and harnessing the technologies driving Industry 4.0 and understanding the value of ERP, will manufacturers achieve the competitive edge they are seeking. au.syspro.com

BUSINESS MANAGEMENT

Sevaan Group trials four day week Leading parts contract manufacturer Sevaan Group, is trialling a four day week to evaluate improvement in staff wellbeing, attracting new talent, and increasing productivity.

The trial period will run for three months, from 11th September until the 31st December.

The Group is spreading the normal 38-hour, five-day work week over four days. Each day encompasses two shifts, morning and afternoon, consisting of 9.5 hours each.

doubt attractive to prospective staff, and helps to further differentiate Sevaan and reinforce the Group as an employer of choice,” said David.

According to Sevaan Group’s CEO, David Green, the management-led initiative gained traction as a result of the positive outcomes attained by overseas companies that have already trialled the four-day week. “The evidence suggests that these firms are benefitting from improved productivity, reduced sick leave and unapproved absenteeism, and a general increase in their employees’ well-being.” “The improved wellbeing of staff is particularly of interest because it aligns so strongly with Sevaan’s culture. We are a very employee focused organisation and our staff’s well-being is paramount. We have already introduced an EAP - LifeWorks - which provides staff with confidential, expert counselling across a broad range of issues, should they request it.

We are hoping that a 4-day working week will further support our staff’s wellness. The evidence suggest that it helps to reduce anxiety, stress, fatigue and burnout,” explained David.

A four-day week is also appealing when it comes to attracting and retaining talent. “The manufacturing market in Australia is already very tight when it comes to hiring new staff. The four-day week provides employees with a shorter working week, and more free time to spend as they please. This greater work-life balance is no

Evidence from US and UK companies which have already trialled the shorter week indicates that there is no fall in productivity, and that in some cases it has increased. When the working week is condensed into four days, the longer weekend allows staff to re-energise themselves. This can translate into better concentration and morale on the shop floor and in the office, and an increase in productivity.

With staff backing the initiative 100%, David is quietly confident that the three-month trial will yield positive outcomes all-round. “As management, we can only provide the framework to help make it happen. It’s our staff who are critical to the trial’s success. They understand the positive impact it will have on their work-life balance and well-being. And given their commitment to making it work, I believe that at the very least, productivity and service deliverables will not falter. In fact, they will probably improve.”

Sevaan will monitor the impact of the trial and collate data weekly across a range of factors including well-being, absenteeism and productivity. The results will be displayed on the shop floor.

Prior to the end of the three-month trial and before deciding whether to extend for a further three months, the Group will assess all metrics and develop a report for its senior management team. sevaangroup.com.au

ANYTHING ELECTRONIC? PROMPT ANALYSIS & REPAIR SERVICE Injectronics Industrial offer a unique service to business owners, manufacturing line managers and service repair agents alike - a fault analysis and repair service for many applications including difficult to source and obsolete items.

Introducing a new, time sensitive and cost-effective option when it comes to making a decision on your industrial repair.

The range of repairs available include: • Human Machine Interface (HMI) • Variable Frequency Drive (VFD) • Servo Drive • Servo Valves

• Spindle Drives • Stepper Drives • PLC • Timer and Counters

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• CNC Boards • Industrial Control Panels • Preventative Maintenance

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Tidy your room Getting your shop in order with BAC systems.

Cleaning up your workshop is the ultimate “rainy-day” job; however, with the La Niña about to end, some may be hurrying to fit an eleventh-hour workshop upgrade in before the El Niño hot, sunny weather is upon us, hopefully with increases in productive work. Investing in an improved workshop benching and storage solution may be that critical step to be taken towards and increase in productivity and ongoing prosperity, but, ‘how to approach this’ should be a question one asks.

For most, prosperity does not simply fall into one’s lap, but is the process of sound investment, patient planning and attention to detail. When you take this approach, you will eventually reach a point where you need to address some key questions in your production zones: • •

How do I cut-down on innocent time wasting in production; How do I customise an environment to suit the tasks we are performing • How do I prevent mistakes in part picking and ID • How do I protect my components from dust and UV light.

At BAC Systems, an Australian manufacturer of an industrial workshop furniture range that is currently in use in all seven continents, we offer our customers special design assistance in order to help them address these four points.

Most time wasting in the workshop is not malicious, but is, in fact, a result of poor workshop layout. A poorly considered layout will result in excessive travelling, stock-shuffling, a high handling:production ratio, costrained production space, and even miserable working conditions. The focal point of your workshop should be the point of production, and this is most often found on a workbench or, at least, closely associated with one. At BAC Systems, we ensure that the workbenches we incorporate into any planned workshop layout are designed with consideration given to the available space, the way you wish to work and the items you wish to store in the space. We ensure that you have enough storage included without including too much, and we try to get the balance between bench space and standing/sitting moving space – this is different for each workplace, of course.

When it comes to workshop storage, whether it be tools, parts, or consumables, plain shelving will only result in wasted space, too much walking, and parts being damaged/dirty/lost. Shelves are fantastic for boxed items and larger items, and the space

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requirements of shelves are a necessary allowance in these instances; however, for small to medium items, loose items and sensative items, drawer storage has to be the storage solution at the top of your list. With drawer storage, you have an adjustable solution that adapts easily to changes in your inventory, protects items from dust and UV, offers a unique location for each type, uses far less floorspace, compresses more parts closer to their point of use, and has no ongoing power/maintenance to account for.

Drawers are the most reliable high-density storage all-rounder and are flexible enough to be encorporated into racking, production benches, counters, trolleys, or even just as free-standing storage.

This modularity makes them flexible and suitable for most environments.

Working out how to best take these elements to create a workshop layout is best achieved by combining your knowledge of what you are doing with our knowledge of what is avaialble to be used. To this end, BAC Systems offers a complimentary site survey service whereby a technical rep comes to site to measure up, survey inventories and interview workers and foremen to ensure that layout proposals will actually achieve the desired results. If you buy an imported product out of an industrial catalogue, you will never come close to this type of custom-purpose solution. It is a combination of this particular planning service, combined with the fact that BAC Drawers and Benches last for decades, that makes BAC Systems the popular choice for Australian workshops bacsystems.com.au

BUSINESS MANAGEMENT

Robotic Process Automation Infor introduces Enterprise Automation Solution, a set of cloud services built on Amazon Web Services (AWS), so companies can scale automation in business.

Infor has announced its Infor Enterprise Automation solution, a set of Infor Operating Service (Infor OS) multi-tenant cloud services, built on Amazon Web Services (AWS), which will help companies rapidly scale automation across their organisations by connecting data integration, artificial intelligence (AI)/machine learning (ML), and robotic process automation (RPA) capabilities into a single platform.

Massimo Capoccia

With the release of Infor (RPA), Infor delivers complete automation solution addressing front-end, decision, and back-end automation.

With Infor Enterprise Automation, companies can continuously expand enterprise resource planning (ERP) automation capabilities across diverse applications and achieve business results faster – while minimising integration costs and risks. The solution enables customers to create unlimited automation processes that interact directly with Infor CloudSuites or any other application experience without human intervention. Infor’s Enterprise Automation solution is unique because it delivers automation capabilities through a single composable platform, Infor OS, which connects systems and people through back-end automation, decision automation and – with the release of Infor RPA – front-end automation.

Steve McEnany, senior vice president at Midwest Wheel Companies, one of the largest truck parts distributors in the Midwestern United States, said, “Infor Enterprise Automation allowed us to bring our entire proof of delivery system into one repository online, so our customer service team can give a quick response to a customer inquiry. With a 95% productivity improvement, our people can focus on servicing customers instead of searching for information in boxes or other applications. RPA Bots process our pickup paper tickets, and Gateway APIs process our electronic truck delivery tickets from a third-party application, all without human intervention.”

Infor RPA completes Infor’s Enterprise Automation solution With the release of Infor RPA, Infor now provides a complete automation suite, which addresses front-end automation, decision automation, and back-end automation: Infor RPA address front-end automation, which includes labourcentric/repetitive, rule-based and high-volume/low-value tasks that are needed to complete a business process.

• Infor AI addresses decision automation through natural language processing (NLP) and machine learning services to streamline task execution, recommend next-best actions, and predict potential issues and adjust systems accordingly.

• Infor iPaaS (integration platform-as-a-service) addresses back-end automation through integration services for the development, execution and governance of workflows connecting any combination of on-premises and cloud-based applications within individual or across multiple organisations.

“We have a differentiated solution because we started by addressing the more complex back-end automation,” said Massimo Capoccia, Infor chief innovation officer. “With RPA, we now provide the frontend automation, which enables us to deliver a complete package for enterprise automation. This gives us an advantage over stand-alone vendors.”

•

Deploying end-to-end automation Many companies have been challenged to successfully deploy end-to-end automation because various automation tools have not worked well together. Creating automation flows often has proven too difficult for business users. Further, business users have struggled to select the right processes to be automated. Current

Rick Rider

solutions have been brittle and subject to failure. They also have been too expensive to justify the investment and have not generated quantifiable ROI.

How Infor address challenges to end-to-end automation & RPA success With Infor’s Enterprise Automation solution, all automation technologies, including RPA, are integrated through a common platform, Infor OS. Infor RPA provides a comprehensive set of components to develop and deploy bots that execute tasks just like humans would across a variety of applications, content and actions.

Infor offers a complete automation solution with a growing library of pre-built automation use cases to help customers scale value-driven automation rapidly across accounts payable, accounts receivable, delivery processing, compliance and more.

Customers realise immediate ROI, because Infor provides industryspecific RPA flows for select Infor CloudSuites. Additionally, Infor Enterprise Automation runs on AWS, ensuring consistent reliability, performance and scalability. Infor also provides a simple and flexible pricing model, based on execution hours, which allows for unlimited bots and developers. This democratises the creation of automation flows and empowers business users and IT. “With Infor Enterprise Automation, we’re delivering all the required technology pieces in a differentiated way that connects all levels of automation, regardless of the apps in the composed ecosystem,” Rick Rider, Infor senior vice president of product management said. “Ultimately, we’re helping customers blur the lines among RPA, process intelligence, workflow automations, and connected machine learning-based insights,” he noted. “Our goal is to provide customers with a platform, which can help them, regardless of their situation, continue their automation journey without having to be hardcore developers or automation experts – or having a host of prerequisites or costs just to even get started on an idea.” infor.com

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Artificial Intelligence is not new Barry Urquhart, Business Strategist with Market Focus, reminds us that most businesses have had AI within their operations and systems for 10, 20, possibly 60 years.

Main-frame computers, in and from the 1960s, were early incarnations of the concept. In many respects their capabilities and scope were never realised because of a lack of knowledge, vision and expertise of the internal interactive operators.

Get on board

Underutilisation persists, primarily because of a lack of recognition of the available resources. That alone contributes extensively to poor, if not stagnant productivity, and compromises returns on funds invested.

On balance, many business owners and managers are like commuters at a railway station awaiting the arrival of the train (read: AI). They are actually already “on-board” but are not enjoying the ride.

Detailed critical reviews of current philosophies, policies, practices and systems, when perceived through differing perspective (that is, artificial intelligence) will doubtlessly identify countless prospects to embrace existing AI.

Classification

Reality check

The term artificial intelligence is a collective noun. Few branded and packaged units are accessible on shelves and therefore, are not collectable. ChatGPT is a rare exception, but it has narrow applications.

A number of AI aficionados who have been at the forefront of the conception, design, development and implementation of the concept have in recent times expressed concern about the possibility and probability that sophisticated AI will have the capacity to ‘think’ and ‘act’ independently of human control.

AI is a broad generic term which can and does utilise algorithms, lasers and multiple other modes of technology. Substantial potential exists in manufacturing, logistics, transport, mining, rural, services hospitality, tourism and the throughout the public sector.

Displaced resources Professional and employment redundancy because of artificial intelligence is a widely held fear. Rapid uptake of the concept represents a threat in the ability to, and the time involved in reeducation of the broader, and specifically affected workforces.

However, forecasts of a pending doomsday scenario appear to be exaggerated – shades of Y2K. AI is not a contemporary “greens-field” revolution. It is an extended, progressive evolution whose presence and contributions enabled men to walk on the moon. Sadly, it has been a long time since human footprints have been left on the lunar surface. Exploration of that earthly satellite and beyond has been limited and restricted to non-human journeys.

Capacity has broadened and deepened exponentially, particularly within entities. Information and raw data are more readily retrieved, collated, and stored. But detailed analysis and application have been sparing.

Select communication, distribution and sharing is possible, but not widely exercised or evident. Much marketing, advertising, promotion, loyalty and reward missives are generalised, repetitive and to some considerable extent not relevant to recipients. That benefits and advantages no-one.

Like algorithms in the early years of the current millennium, considerable hope was held for these applications. Everyone, it seemed, was developing their own, to little commercial and financial success. Paraphrasing the words of a former Australian Prime Minister:

“Every pet shop had its own algorithm galah”.

Ask the operators Frontline team-members, whose primary functions involve interaction with, and use of components, technology, data, IT and a scope of systems are seldom asked about and involved in creating a new and imaginative uses of existing formats of artificial intelligence. Sub-optimal performance prevails, and opportunities remain unfulfilled.

Individually and collectively, they (the human quotient) are closely aligned to existing internal artificial intelligence resources of differing standards and ages. They are seldom recognised and tapped.

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One individual authority has left employment with a hi-tech monolith, established his own foundation and is actively lobbying governments, particularly in the USA, to legislate for a pausing of enhancements to artificial intelligence in all forms.

Prospects for rogue AI are real and no amount of legislation, regulation, monitoring and control will be universally possible or effective in countering its evolution. However, it could be an emerging repeat of the Y2K crisis during the closing years of the twentieth century. Billions of dollars outlaid with little or no return.

The palatable alternative, safe AI is shorthand for technology which is controllable and controlled by human beings. At this time AI has notable parameters. It is reliant on information and data input. By nature, that content is historic. Moreover, AI is unable to discern facts, preferrable sources and nuances which are best recognised and taken on-board by intuitive humans.

Therefore, artificial intelligence needs to be embraced, integrated, included in considerations for future recruitment, induction, training, development, marketing, service and competitive strategies.

An appropriate and good start will be a forensic audit of all existing AI, no matter how rudimentary and the review of its current status and potential to improve productivity, efficiency and effectiveness.

Considerable scope appears to exist, albeit largely dormant.

Adept leaders and team-members can typically adapt. It is an essential narrative. Start the conversation. Ask questions. Provide answers, with and without input from artificial intelligence.

Plan long. Manage short Artificial Intelligence in its current guise has arrived with a rush.

Growth, differing applications and potential could be exponential in the short and immediate terms. However, lifecycles will be short.

Accordingly, outlays will need to be capitalised in periods as short as three years. Hence, a 10-year horizon (for a possible doomsday scenario) will likely experience up to three incarnations of AI. Disciplined visionary planning will be imperative, complemented with astute and assertive shorter-term management of this dynamic new variable and the associated infrastructural support.

That mix has two dimensions. One will not, or should not, be prioritised over the other. Adaptations and malleability will need to be innate because, if culture eats strategy for breakfast, artificial intelligence has the latent potential to consume both. Welcome to the new world of commerce, politics and society where, obsolescence will be death. marketingfocus.net.au

BUSINESS MANAGEMENT

Innovation at its finest Data and Cloud’s impact on modern manufacturing. Martin Dube, Vice President of Public Cloud in Asia Pacific & Japan at Rackspace Technology takes up the chalice.

Data has emerged as the driving force behind innovation, efficiency, and competitiveness.

But how can we unlock the full potential of data despite its complex challenges?

With the disruptive technologies and processes introduced with Industry 4.0, technological innovations have generated vast amounts of data. Data in manufacturing has become a valuable asset to the industry, offering insights that can optimise operations and increase visibility. It can also help provide rapid fixes for inefficiencies and expedite and connect the supply chain to enhance product quality and drive collaboration and semi-automated process.

Two trends stand out: harnessing the power of robust data platforms and digital threads and embracing the transformative capabilities of cloud-driven innovation.

Challenges and the role of a robust data platform The manufacturing landscape is facing a range of challenges, from data harmonisation and equipment optimisation to quality assurance and regulatory compliance. Successfully navigating through these challenges requires a comprehensive approach, and a strong foundation for this is a robust data platform. This platform serves as a digital thread that connects different stages, from research and development to final product manufacturing. By bringing together diverse data sources, it offers manufacturers valuable insights across all operations.

For instance, Kellogg Asia Pacific, had faced difficulties harmonising data across countries, various Enterprise Resource Planning (ERP) systems, and diverse data formats. This problem is not uncommon and often hinders companies, from fully capitalising on integrating tools that cater to specific business needs. This is where a cohesive data platform proves its worth, overcoming challenges and providing a unified operational view.

Harnessing the potential of the digital thread The idea of a digital thread goes beyond just integrating data.

It involves aligning business processes, IT systems, and decisionmaking frameworks, resulting in streamlined operations and a boost in innovation. Manufacturers can use this digital thread to improve quality assurance, optimise equipment usage, and transition into smart factory setups.

But what about the gap where individual machines don't communicate with each other? Machine builders possess data that allows them to make accurate predictions about the functioning of individual machinery. However, it's important to consider the larger flow of operations since these machines frequently operate in isolation. Having a complete view of the entire plant's operations allows for the implementation of optimisation measures that span across the entire facility.

Empowering data-driven decisions through modernisation Given that many manufacturers struggle with tasks like designing, migrating, securing, operating, and optimising data environments, they lack the necessary insights to make informed, data-driven decisions that drive business growth. A solution to gain these insights is by modernising data infrastructure, which involves moving from legacy databases to more modern alternatives.

This shift is especially crucial for manufacturers, particularly those dealing with unstructured data storage needs.

Cloud's role in manufacturing innovation Cloud-driven innovation has emerged as a game-changer for manufacturing excellence.

The multi-cloud approach, encompassing public and private cloud environments, has gained a lot of traction in recent months.

Savvy manufacturers recognise that this approach minimises financial risks, optimises costs, and avoids vendor lock-in.

Importantly, multi-cloud strategies empower manufacturers to customise cloud services based on specific business needs. This flexibility enables experimentation, idea validation, and outcomebased scaling. Effectively, the cloud transforms into a playground for innovation, nurturing business-driven creative solutions. Microsoft provides a notable illustration of a successful multi-cloud approach through the seamless integration of Azure, Office 365, and Dynamics.

In this instance, elements such as authentication, governance, and management seamlessly converge, even extending to a shared understanding of the threat landscape.

Transitioning to multi-cloud excellence The journey to multi-cloud excellence is not free from challenges per se. While multi-cloud environments offer great potential, we do need to keep in mind consistent management, monitoring, and security measures. As manufacturers adopt multi-cloud strategies, automation becomes a pivotal tool. Automation simplifies and streamlines the management process, enhances scalability, and optimises the advantages of a multi-cloud approach.

It can take a slow change as organisations often begin with manual approaches, gaining insights that guide the transition to automation.

This evolution necessitates best-of-breed tools and skills that mature alongside cloud platform advancements.

The way forward Unified governance and oversight are important as manufacturing embraces data platforms and multi-cloud innovation. Striking the balance between flexibility and control, manufacturers must strategies governance methodologies that steer cloud choices while empowering business units. The agility and scalability of cloud, proven during the COVID-19 crisis, shows its ability to support evolving business needs.

Leader’s decisions regarding authentication, governance, and multicloud management shape success. By adopting a multi-cloud management system, manufacturers can drive innovation while mitigating risks, leading to enhanced efficiency, competitiveness, and growth.

As manufacturing continues to evolve, embracing the potential of data and the innovation capabilities of the cloud will define success.

The interplay between data, cloud, and business needs will shape the future of manufacturing, ensuring this industry modernises and remains at the forefront of progress. By harnessing the power of data and leveraging multi-cloud innovation, manufacturers can be prepared for the future, and be equipped for anything to come. rackspace.com/en-au/

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City of Whittlesea The beating heart of Melbourne’s manufacturing industry.

Located in Melbourne’s north, Thomastown and Epping are an established and industrious manufacturing base, collectively home to over 7,600 businesses, employing 39,000 workers.

Manufacturing is the leading sector in Thomastown and fifth highest in Epping.

boasts an abundant array of businesses offering the local goods and services we rely on and value.” Peter Sutton, Managing Director, Sutton Tools

The local eco-system is recognised as a key ingredient in the ongoing vitality of the area, which continues to diversify, expand and develop, despite challenging tough market conditions.

“Our company thrives on unparalleled access to local, national and international trade routes, our exceptional team drawn from the local skilled workforce, is further supported by top-tier infrastructure.

Beyond business, City of Whittlesea offers a vibrant lifestyle for our staff, ensuring a balanced work-life harmony. The city's growing population stands testament to its promise and potential. We're proud to call City of Whittlesea our home, and even prouder to contribute to its dynamic economic tapestry.” Amir Arjmand, CEO Edlyn Foods

The region plays a pivotal role in business and employment opportunities for Melbourne’s north, with government investment in infrastructure and roads supporting rapid growth. The recent announcement of Federal Government investment in the Beverage Intermodal Freight Terminal will increase connection to regional, national and international markets, and reduce reliance on air and road transport.Thomastown is 15km from the CBD and one of the largest consolidated areas of industrial-zoned land in Metropolitan Melbourne.

"An exporter of more than twenty years, we love having Aromababy's head office in Thomastown and the ease of ensuring urgent air freight reaches Tullamarine quickly. As a regular business traveller both interstate and overseas, it's also a super convenient commute from home to office to boarding gate. Many of our packaging suppliers are also a short drive away and we're 'sandwiched' between two amazing cheese factories!" Catherine Cervasio, Owner, Aromababy

Epping is located 20 kilometres from Melbourne’s CBD and is a Northern State Significant Industrial Precinct.

In recent times Epping has been dubbed ‘the heart of the north’, with growth supporting infrastructure, an established eco-system, rapid population growth and direct access to major road, rail, air and sea trade transport routes.

“Epping is a great base for our operations. Its easily accessible for our customers & suppliers and provides access to a talented and eager workforce. There is a good local network of similar businesses, and best of all we work closely with the City of Whittlesea on our future plans and development.” Chris Polites, Managing Director, New Age Caravans

Manufacturing history in Thomastown dates back to the 1880’s when the area played a critical role in providing Melbourne’s milk and dairy supply until early in the twentieth century. It later went on to become the birthplace of Pura Dairy, a link to the dairy industry that still exists today, with dairy manufacturers such as That’s Amore Cheese, Floridia Cheese and Jalna Yoghurt all based in the area.

Home to two hospitals, Melbourne Wholesale Fruit Vegetable and Flower Market and a developed base for major industries including healthcare, wholesale trade, transport and warehousing, the area is a priority focus for major developers and government recognising the opportunity to leverage the current pipeline of opportunities expected.

In 1927 Fowlers Pottery built the first major manufacturing plant in Thomastown by utilising world-first processes that undoubtedly contributed to substantial growth of the local manufacturing industry at the time. Now covering over 14 square kilometres situated along the M80 ring road, Thomastown provides operators with direct access to local, national, and international trade gateways, one of the area's key strengths.

"Relocating my business to Epping in the City of Whittlesea created such a positive turning point for my manufacturing business. With the strong support from council staff members, their encouragement, and inclusion, provided me with the additional confidence to keep going. Now, we're exporting to a growing number of countries and increasing our manufacturing. A supportive council, I feel, is an essential tool for success." Michelle AndersonSims, Owner, Wine In a Glass

“Sutton Tools was established in 1917 and relocated from Northcote to Thomastown 60 years ago. History has proven this was great foresight, with our manufacturing and distribution operations now located in a prime hub from a logistical stance and more importantly, an ideal area for accessing a skilled and growing labour force. Thomastown and the greater City of Whittlesea also

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With so much history and so much evolution in the area still to come, it makes sense to consider Thomastown or Epping when you consider a new location for your manufacturing business. whittlesea.vic.gov.au

We help businesses save money on their energy

Obligation-free to check 13 years industry experience We do all the work for you

www.zembl.com.au/energy/commercial

Zembl Pty Ltd. ABN 29138847757 of Level 5, 100 William Street, Sydney, NSW, 2011 Availability of retailers and plans can vary state by state and is dependent on the property and connection type. At times commercial relationships may impact what retailers or plans are made available. Zembl do not represent every retailer in the market.

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Making views PCW Commercial Windows opening the door to a more sustainable future.

Located on the NSW Central Coast, PCW Commercial Windows is a longstanding and respected market leader in manufacturing and installing commercial, industrial and upmarket residential windows and doors.

Their exceptional portfolio of work spans the Central Coast, Sydney and Hunter Regions of NSW and includes many schools, civic buildings, institutions and architectural homes.

"Our extensive industry experience and product knowledge means we can offer advice and design ideas for projects of virtually any size,” says owner and Managing Director Leigh Spinks. “We’ve forged strong relationships with many builders, big and small and are very proud to be 100% Australian owned and operated and manufacturing all our products to Australian Standards.”

Keeping abreast of changes within the construction industry is a high priority for Spinks and his team. “It's constantly changing; in particular, windows and glazing are undergoing great changes at the moment, energy provisions are tightening, and the performance of windows just needs to be better than in the past. More and more of our projects are double-glazed, and we are seeing increased demand for energy efficient products, particularly in commercial building applications. We prioritise ensuring our team is across the changing codes and provisions and technically capable of delivering exception-compliant products to our projects every time.”

Compliance is not the only place clients, architects, and builders are expecting more from their window and door providers. In the past two years, Spinks and the PCW team have observed a noticeable shift in perceptions about windows and sustainability, noting that transparency regarding the sustainability of the products they provide is becoming a necessity.

“Many of our clients want to know exactly where their products are coming from, how they have been manufactured, what materials are used, what the environmental impact of these products is,” adds Spinks. “Where sustainability was something people asked about occasionally, it has now become part of our daily conversations with clients and a critical component of all our commercial tenders.”

This shifting focus is not surprising, given the growing recognition of the importance of embodied carbon in buildings.

In 2022, Capral Aluminium, PCW's leading supplier of Aluminium Window and Door Systems, introduced LocAl® a Lower Carbon Aluminium offer as standard across their full range of residential and commercial windows, doors and framing systems. Providing PCW access to a lower carbon aluminium option for their clients at no additional cost.

At eight kilograms of carbon emissions per kilogram of aluminium, the LocAl® Green offer has 50% lower carbon emissions than the current global average for primary aluminium. It allows Australian window and door manufacturers like PCW to make more responsible procurement decisions when they source extruded aluminium.

"The ability to provide our clients and the Architects they work with access to Lower Carbon Aluminum without any price premium has been essential for PCW; it answers the questions our clients are asking and gives them access to cleaner, green aluminium for their projects,” says Spinks. “It has enabled us to respond to the needs of the Architecture and Design community in their commitment to reducing embodied carbon within the built environment.”

Access to window, door and framing systems extruded from lower carbon aluminium will ensure PCW is well-positioned to support Architects and Builders seeking Green Star certification on their projects.

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Green Stars' updated rating system has set a target for all project certifications to achieve a minimum of 40% reduction in upfront carbon by 2030. To achieve this target, it is imperative to address the use of aluminium. From this year onward, new projects registering for Green Star certification will be required to achieve a minimum of 10% reduction, with a 20% reduction required for a five-star scheme.

In addition to being extruded from Lower Carbon Aluminium, the aluminium extrusions that make up the window and door systems PCW sources from Capral are also ASI Performance and Chain of Custody Certified.

Green Star's Responsible Products Framework is linked to ASI Certification, which helps achieve credits under the Responsible Envelope initiative. This further connects the sustainability picture from embodied carbon to the broader social, economic, and environmental aspects of a material's provenance.

Capral is the only ASI Certified extruder within Australasia and, currently, the only window and door systems supplier offering ASI Certified aluminium extrusions within Australia.

"We are very grateful that our supplier, Capral, is taking the lead in this space, making it possible for PCW to source lower-carbon aluminium products that have been ASI-certified throughout the value chain. It gives us a unique point of differentiation in the marketplace and the confidence to speak with full trust and transparency about the source of the aluminium used to produce the window and door systems we manufacture," adds Spinks. capral.com.au

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STATE SPOTLIGHT

Swisslog Off-the-shelf warehouse automation gives SMEs the same gains as the big players.

Warehouse and intralogistics automation is often thought of as a highly customised solution that benefits the major players once they have reached a certain scale.

But as technology advances, it is becoming increasingly available and affordable for Small-to-Medium Enterprises (SMEs), which account for 99.8% of businesses (more than 2.5 million) in Australia and 97% (more than 550,000) in New Zealand. (Sources: Australian Bureau of Statistics, and the New Zealand Government’s Ministry for Business, Innovation & Employment.)

Intralogistics leader, Swisslog, has introduced to Australia and New Zealand a standardised ‘off-the-shelf’ version of its AutoStore roboticised storage and order processing solution, for which it is the world’s number one integrator, with more than 300 major projects globally, incorporating efficiency gains that readily scale down to SMEs. “The standardised model was replicated from Europe, where it has seen great success across a range of industries. Australian companies have been quick to take up the technology, where they have been seeing immediate benefits. They’ve recognised our experience in implementing these types of standard systems,” said Swisslog Business Development Manager of AutoStore, Ken Chen.

“With increasing labour costs and soaring commercial real estate prices, SMEs are looking for ways to increase storage density and maximise the efficiency of their picking and put-away processes,” he said.

“This is where a standardised off-the-shelf solution can provide major benefits, because it can easily be deployed into a running supply chain, with only minor adaptations, where it can greatly improve logistic capacity and unlock further market potential.”

“Off-the-shelf warehouse automation solutions like the standardised Swisslog AutoStore system can be implemented with lower costs and a faster installation time, due to shorter design and software implementation time before and during commissioning. This means a faster time-to-market, helping SMEs stay competitive locally and globally. It’s then easily scalable, so it can grow as the business grows in the future,” he added.

Swisslog AutoStore allows SMEs to act fast AutoStore is a high-density cube-based automation solution that uses robots and bins to quickly process small parts orders. Its unique design allows the direct stacking of bins on top of each other, and multiple SKUs in a single bin, thereby maximising use of available warehouse space. AutoStore solutions implemented by experienced Swisslog automation engineers can typically deliver the same throughput with a 60% reduction in warehouse space.

“With Swisslog’s extensive global experience with implementing AutoStore solutions, we are able to help customers achieve the best value for money, fastest payback time, and best ROI for their investment,” said Chen. The system integrates with Swisslog’s SynQ software, which will allow it to naturally learn which products have a higher rotation, so that these can be automatically stored on the top layer to deliver faster picking times.

“The grid-like structure of AutoStore makes it simple to fit around any existing warehouse space, even around structural columns, different floor heights, or other spatial irregularities. Swisslog works with each customer to deliver the optimal outcome to their warehouse configuration,” said Chen. “For SMEs, this means they can respond quickly to market changes, and can choose to automate particular product lines or sections of their warehouse that need to scale up. Swisslog’s standard AutoStore solutions can typically be implemented in 8-10 months, with companies seeing a return on investment within 2-4 years,” he added.

Energy efficiency AutoStore is also a highly energy-efficient system, with each robot using approximately 0.1kW of energy per hour. For comparison, 10 robots would use the equivalent of a toaster.

“Sustainability is central to Swisslog’s company culture – from regenerative braking technology to reducing warehouse space to save energy, which has particularly strong benefits in cold storage facilities – and AutoStore fits with our vision to consistently improve the sustainability of our own operations, as well as those of our customers,” added Chen. swisslog.com/en-au

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CUTTING TOOLS

When the job is worth special attention When deciding on the appropriate cutting tool for a particular application, it is difficult to determine whether a standard tool or a special tool is preferable. Jason Allen from ISCAR casts a critical eye onto the tool at hand.

The ideal tool selection is contingent on various factors, such as the nature of the business situation, the manufacturing program, the production type, and sometimes personal preferences. Standard cutting tools, produced by a specific tool manufacturer, offer high versatility and are appropriate for machining a diverse range of parts that come in different shapes.

Furthermore, the tool exhibits excellent performance capabilities when cutting various engineering materials. To ensure seamless production processes, it is crucial to have the cutting tools delivered in a timely manner. This is why standard tools are the foundation of tool stock management on metalworking production floors.

A special cutting tool is designed for specific operations on a particular part, made of a specific material, and used on a machine that requires a specific work holding fixture. This custom-engineered tooling solution aims to provide the best possible performance and outcome. However, there is a downside to this solution as it limits the tool's versatility, making it less adaptable to different applications. As a result, special tools are primarily used for high-volume mass production, especially in the automotive industry.

A special tool is not readily available and requires significant engineering effort, including concept design, coordination with the customer, detailed design, and production. The delivery time for special tools is significantly longer than that of standard tools. Metalworking shops often face a dilemma when choosing between standard or special tools, which can impact project timelines. The question remains: which tool will provide the best solution?

Should shops rely on readily available standard tools or opt for a highly efficient special tool with a longer delivery time?

Naturally, economic factors such as cost per unit and tool costs should be taken into consideration. All things being equal, in an ideal situation where production programs, processes, and inventory are planned, the answer is clear. Therefore, the maximum short lead time is an important factor when choosing a special tool.

Special tools vary in their design complexity.

Some are simple modifications of standard tools, such as changes to the corner radius or tool length. These modifications fall under the category of "semistandard" products, which can be manufactured relatively quickly. The design complexity of a special tool is determined by a pre-

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Fig. 1 - A wide variety of exchangeable heads, shanks, adapters, extensions, and reducers feature MULTI-MASTER as a versatile modular system.

Fig. 2 - The complex-shaped head of NEOSWISS for Swiss-type machines is a modular quick-change head system created by 3D printed technology.

Fig. 3 - A disc-form blank head with MULTIMASTER adaptation substantially expands the customer's ability to produce tailor-made milling shapes.

design study that assesses the customer's manufacturing limitations, accompanied by cost calculations and production time.

The results of the study determine the limits and cost-effectiveness that correlate to the special tool's delivery time. However, there are additional ways to reduce the delivery time of special tools, such as using solid tools with exchangeable heads, bodies of indexable cutters, or replaceable inserts.

The tool manufacturer's delivery times and production abilities play a significant role in the final decision on how to proceed.

enable the configuration of the required tool for diverse machining operations.

One alternative to engineered special tools is modular tooling, such as ISCAR's MULTIMASTER (shown in Fig.1), which features rotating tools with exchangeable solid carbide heads. This tooling system includes a wide range of tool bodies (referred to as "shanks" in the family nomenclature), adapters, extensions, and reducers that

Additive manufacturing (AM) presents new opportunities for special tool solutions. This technology allows for the quick production of tools with complex profile designs.

Although finish cutting and grinding operations are still necessary, the fast manufacturing of pre-shaped products that are very close to a final shape is fascinating (as shown in Fig. 2). Additionally, 3D printing can be used to fabricate carbide inserts without the need for a die-set, which significantly reduces production time and costs. This process is an excellent way to create insert prototypes during the development stages and produce lowbatch special inserts. AM of carbide inserts and heads is gaining momentum and is highly capable of ensuring fast delivery of customized tools and their components.

CUTTING TOOLS

Fig. 4 - PENTACUT-27 starlike blank inserts enable fast customized solutions for complex profile grooving.

Metalworking shops can quickly manufacture and customize a special tool if an appropriate off-the-shelf product is not available. However, they may not have the means to complete the full cycle of toolmaking. In such cases, tool manufacturers can provide semi-standard tools as standard items, which can be adapted by the customer to their final shape. These semi-finished products can include blank bodies, blank inserts, and blank heads. Some cutting tool manufacturers, such as ISCAR, offer this option and include blanks in their standard product range.

The MULTI-MASTER family offers extra-long shanks with an inner MULTI-MASTER thread on the front face and a center hole on the back face, which

can be cut and shaped by the customer.

Recently, ISCAR introduced uncoated carbide blank heads with two sections: a disc-form front area with a hexalobular (TORX) recess on the face, and a rear area with an outer MULTI-MASTER thread (Fig. 3). These heads are intended for producing special items to be mounted on MULTI-MASTER shanks at the customer's machine shops for different machining operations such as milling slots, grooves, threads, splines, gears, and more.

ISCAR has also added a group of unique PENTACUT-27 blank inserts with five edges for tailor-made profiles to their product portfolio (Fig. 4). These starlike carbide blanks can be ground by the end-user to form different shapes for

shallow profiling and grooving depths when machining pulleys, bearings, and fittings. Customers who produce special tools from blanks are limited compared to ordering specially tailored tools from cutting tool manufacturers. However, when time is of the essence, customers can find the most appropriate solution within given constraints by creating their own specially tailored tools. By providing customers with the ability to create their own tools, new horizons are created to overcome the everyday obstacles of manufacturing. iscar.com.au

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Auditing your cutting tool jobs Software audits help laser cutting job shops maximise efficiency.

Is software saving you time, or adding to your workload? If you feel it could be the latter, it might be time for business owners to conduct their own software audit.

If you’ve ever worked in, managed, or owned your own laser cutting job shop, you’ll know there is a huge range of software out there designed to help you do your job better, faster, and more efficiently.

When software is implemented and utilised successfully, it’s brilliant.

It can take time-consuming manual tasks and turn them into some simple clicks of a button.

But if it is under-utilised, or just left in the background, software could be adding more time, rather than saving it, and that can hurt business productivity, efficiency, and the bottom line.

Software audits – what to look for As a business grows, it can be highly worthwhile for owners and managers to conduct an in-depth software audit, to make sure you’re using these resources efficiently. Here’s what to look for: 1. Are you using the software to its full benefit? So often people just use a few of the basic functions, and don’t realise the software is capable of so much more.

2. Is there duplication of effort? Is someone doing it manually and then re-doing it via software? Or are workers having to do the same task across multiple different software programs? Look out for these counterproductive inefficiencies.

3. Does your software talk to other software? If so, it can create a highly efficient business workflow, but if not, it can sometimes create more work than it saves, because employees have to go to great efforts to transfer data from one software to another.

4. Is the software up to date? If you’ve paid for software, it’s important to keep it updated so that you can capitalise on the latest features and benefits, as well as keep it secure and functioning optimally, without bugs or errors.

5. Do you need all of these software programs? Sometimes, as technology advances, a new program is capable of performing multiple functions, which renders an old software obsolete, but this can go unnoticed. Worse, workers can stop using a software, but the business might still be paying the subscription fee. (In fact, according to a new working paper from researchers at Stanford and Texas A&M submitted to the National Bureau of Economic Research, forgotten subscriptions can boost the revenue of the business selling that subscription by as much as 200%.)

For any software to be beneficial to the business, it must increase efficiency and decrease workload. Sometimes it does this by doing a process faster and more simply, and sometimes it adds capabilities that were not previously practical or possible.

It is helpful if it integrates or communicates effectively with existing software, and it is ideal if you plan to utilise the majority of the features it offers. Then you will start to see the best value for money, and the best return on investment.

So often we hear comments like this one, which came from a customer, “Most software that job shop owners will come across is both really complicated and also expensive, with long implementation times. This means you'll spend months only to find out it might not fit, but by this stage, you've invested the time, so you put up with it.”

We knew there had to be a better way.

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ToolBox – the laser cutting job shop’s multi-functional software program ToolBox, by Tempus Tools, is a multi-functional laser cutting quoting software that is provided using a SaaS (Software as a Service) model.

With more than 100 years of combined experience in its leadership team – extending from the job shop floor to the formation of entire laser cutting enterprises – Tempus Tools designed ToolBox to not only increase laser cutting quoting efficiency, but to integrate with other software programs, and to perform a range of functions in one, saving the need to purchase multiple subscriptions or programs.

ToolBox can: 1. Split multi-file parts, delete unwanted paths, and perform other drawing issue corrections, which can remove the need to purchase a CAD software package in a lot of cases.

2. Convert a vector PDF into a CAD file instantly, ready for quoting, removing the need for manual PDF conversion tools.

3. Identify, extract, and unfold sheet-metal parts directly from 3D assemblies, which can remove the need to purchase a 3D software package (example pictured below).

4. Quote tube and pipe parts, handling RHS and circular profiles, saving you from requiring dedicated tube software.

5. Offer an online quoting portal for a job shop’s customers, removing the need for simple e-stores or complex custom software development (with credit card payments and additional secondary processes coming soon).

6. Produce production documentation, like work orders, delivery dockets, and part labels, removing the need for expensive production management systems.

7. Integrate with external applications, including accounting systems like Xero and QuickBooks.

Next in line for development is multi-part nesting, which will remove the need for separate expensive nesting software.

The Tempus Tools development team is constantly using customer feedback to develop new features and new integrations to benefit more job shops. tempustools.com

CUTTING TOOLS

Partnership to boost precision Advanced Robotic Technology partners with HSG CNC fibre laser machines to boost precision in Australian manufacturing.

Advanced Robotic Technology (ART), the leading innovator in CNC technology solutions based in Brisbane, has announced a strategic partnership with HSG CNC Fibre Laser Machines, a global pioneer in high-precision laser technology.

HSG CNC Fibre Laser Machines are renowned for their highprecision capabilities, and their addition to the ART lineup is a game-changer for businesses requiring accuracy in demanding manufacturing environments.

This collaboration is set to dramatically enhance precision and efficiency in the Australian manufacturing sector, especially in metal machining processes. With ART's long-standing dedication to robotic solutions and HSG's cutting-edge laser technology, the industry can anticipate substantial improvements in productivity, product quality, and overall operational efficiency.

An HSG CNC Fibre Laser Machines spokesperson added, “We are extremely excited about this partnership with Advanced Robotic Technology. Together, we have the potential to redefine precision manufacturing and assist businesses in reaching unprecedented levels of success.”

Integrating HSG's laser technology into ART's solution portfolio will provide companies in various fields, including mechanical equipment, engineering machinery, agricultural machinery, shipbuilding, and mining machinery, the opportunity to significantly upgrade their manufacturing processes.

David White, CEO of ART, elaborated on the partnership, "We believe that HSG's commitment to innovative design and reliability aligns seamlessly with our mission at ART. This collaboration will enhance our offerings and offer our clients unparalleled precision and efficiency in their manufacturing and machining operations."

As Australian manufacturing continues to evolve, integrating innovative CNC technology like HSG's fibre laser machines is a significant step towards maintaining the sector's competitiveness on a global scale. About Advanced Robotic Technology Advanced Robotic Technology (ART) is a world-leading CNC routers and plasma cutters manufacturer. With a strong commitment to innovation and cutting-edge technology, ART provides solutions that improve efficiency and performance in diverse industries.

Based in Brisbane, ART has been supplying innovative solutions to the Australian manufacturing sector for over two decades. advancedrobotic.com artcnc.com

ATQ Metro Inspecting solid carbide cutting tools is of paramount importance in the manufacturing and machining industries.

Proper inspection of these tools ensures the quality of the machining process and the finished products.

A Cutting Tool Inspection Machine is specialised equipment used in manufacturing and machining industries to inspect and evaluate cutting tools. Cutting tools such as drills, end mills, reamers, taps and form tools are critical components in machining processes.

Ensuring their quality and precision is essential to maintain consistent and accurate manufacturing processes.

Cutting Tool Inspection Machines are designed to perform various inspections and measurements on cutting tools to verify their dimensions, geometry, and overall quality. These machines are equipped with advanced sensors, cameras, and measurement devices that allow for precise measurements. Some common features and functions of a Cutting Tool Inspection Machine include: Visual Inspection: High-resolution cameras and imaging systems are used to capture detailed images of the cutting tools. These images can be analysed to identify surface defects, wear patterns, and other imperfections that could affect the tool’s performance.

Accurate and precise measurements: ATQ Tool Inspect Machine has high-resolution cameras, precision stages, and advanced optics to measure dimensional characteristics of tool with high accuracy and repeatability. This is crucial for ensuring that manufactured tools meet specified tolerances and quality standards.

Dimensional and geometry measurements: Cutting Tool Inspection Machines can measure various dimensions of cutting tools, such as Helix angle, Axial relief angle, Primary relief angle, secondary relief angle and Tilting Edge angle , Primary and Secondary Land , Front Rake, Pitch Angle, Web Thickness, Rake Angle, Core Dia, Centre offset etc. These measurements help ensure that the tools meet the required specifications.

Documentation, traceability and reporting: The measurement data collected by the machine can be analysed to generate reports and statistics about tool quality and performance. This data can assist in quality control and process improvement efforts.

Comparative Analysis: ATQ Tool Inspect can compare the measurements of a tool against a reference model or master tool to determine the degree of wear or deviation from the original design.

Cost Savings: While ATQ Tool Inspect can be a significant investment, they can lead to long-term cost savings by reducing the need for rework, minimizing scrapped parts, and improving overall process efficiency.

Overall, ATQ Cutting Tool Inspection Machines play a critical role in maintaining the quality and accuracy of cutting tools used in manufacturing processes. By ensuring that cutting tools are in optimal condition, manufacturers can achieve consistent results, improve efficiency, and reduce the likelihood of defects and downtime. atqmetroind.com

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CUTTING TOOLS

Tool coatings for more sustainable machining Solid carbide end mill with Zertivo 2.0 coating delivers tool life advantages.

There has been a huge shift in manufacturers’ attitudes around sustainability in recent years. Research by Schneider Electric and Omdia found that 49% of manufacturing companies expect improved performance and cost savings when investing in sustainability. But, while the conversation around manufacturing sustainability usually focusses on Industry 4.0 solutions, companies mustn’t overlook the significant role that machine tools like coated solid carbide end mills can play. Here, Anders Micski, Manager of Grades and Technology for Business Unit solid round tools (SRT) at Sandvik Coromant, explains how an advanced tool coating can support more sustainable machining.

production sustainability. Longer tool life can certainly support sustainability and ties into a number of other advantages, including reducing the number of tools required in a production run and reducing the need for costly tool replacements. Another advantage of longer-lasting tools is the ability to produce more versatile products, for two reasons. First, a tool with a longer lifespan can be used for a greater number of production cycles before it needs to be replaced or serviced. Second, with longer tool life, the tool maintains its precision and performance over an extended period, which results in improved quality and consistency of the products being produced.

Machine shops now realise that a proper sustainability strategy is the difference between success and failure — especially in light of today’s continuing supply chain challenges, and shortages both of materials and knowledge and skills. However, roadblocks stand in the way of manufacturing becoming more sustainable. Almost a third of manufacturing leaders surveyed by Schneider Electric and Omdia said their organisations legacy assets and infrastructure are an obstacle to becoming greener. 27% identified cost or budget is a key roadblock, and 19% cited culture change as a challenge, or the risk of changing their existing processes.

That isn’t to say that gaining a competitive edge in manufacturing is not challenging. On the one hand, reducing costs with the right tooling and optimisation strategies are shown to help dramatically cut machining times and extend tool life up to two-times or more.

On the other hand, continual research and development of the current challenges facing machine shops is essential to ensure that tools are technologically-ready and up to the challenge.

As a solution to these obstacles, manufacturers should instead consider the significant advantages of better machine tools on

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Different kinds of wear Let’s focus on solid carbide end mills. Several factors determine tool life in mills, such as the different kinds of wear, including crater and flank wear, and chipping of the cutting edge that is often a result of vibrations in the workpiece or machine tool.

CUTTING TOOLS

Several design aspects of an end mill affect its wear resistance, including the tool’s substrate, coating and geometry. Geometry particularly effects the tool’s functionality — as written in the report Study on tool life and its failure mechanisms by India’s Kamala Institute of Technology & Science (KITS): “The geometry of the tool has some key influence in deciding the tool life, among which the rake and clearance angles are an important one.” In addition, the choice of material or grade for a tool can significantly affect its speed or feed in machining processes, by influencing such factors as tool wear resistance, tool hardness, heat resistance, and friction and chip flow.

Sandvik Coromant’s Department of Grades and Technology, part of its Business Unit for Solid Round Tools (BU SRT), continually researches these factors to find new ways to improve tool life.

The team collaborates with another department within Sandvik Coromant R&D that is focussed on developing physical vapor deposition (PVD) coatings for tools. PVD is a process where the coating is deposited on the surface of the tool, in order to enhance its durability and functionality — and particularly tool life.

In order to explore new opportunities to extend tool life, the departments for Grades and Technology and PVD chose to focus their research on the influence of PVD coatings, excluding other factors like substrate and geometry. Sandvik Coromant’s research was also informed by input from its own customers, whose input helped Sandvik Coromant’s engineers further optimise the properties of the PVD coating. As a results of this research, new coating solutions were developed to achieve further improvements in tool-life and therefore enhance the performance of the tool itself.

They included one solution for ISO-P and another for ISO-M.

New coating Sandvik Coromant’s ongoing R&D has led it to develop of a range of new coatings for solid carbide end mills. The latest is the Zertivo™ 2.0 range of coatings that combine world-class productivity with exceptional metal removal rate and the highest possible process security. This allows the full potential of the grade to be exploited.

The Zertivo™ milling grade offers a very resilient cutting edge. This tough substrate and the optimised coating effectively resist edgeline chipping and cracks that can arise from difficult machining conditions.

Reliable milling The Zertivo™ 2.0 coating is wholly unique and designed especially for use with CoroMill® Plura HD solid end mills for heavy-duty roughing in steel and stainless steel with two new grades for ISO-P and ISO-M. CoroMill® Plura is a range of high quality solid carbide end mills that offer productive, efficient, and perfectly reliable milling solutions.

CoroMill® Plura HD is Sandvik Coromant’s first choice solution for heavy-duty applications in steel and stainless steel (ISO-P and ISO-M), offering safe and efficient solid end milling. Thanks to the new Zertivo™ 2.0 coated grades tool life, process security and productivity are improved even further. The new grades allow for 30% higher cutting speed recommendations in primary application areas ISO P and ISO M, as well as ISO K and ISO S materials, due to their optimised flute shape, which provides effective chip evacuation.

Featuring tools for heavy roughing and finishing, CoroMill Plura® works in various applications and materials, including difficult-to-cut materials and very hard steels up to 63 Rockwell hardness (HRc).

The grades designed for stainless steel machining come in two variants: one with internal coolant for improved temperature control and chip flow, and one without internal coolant.

Performance tests CoroMill® Plura HD enhanced with Zertivo™ 2.0 has been subjected to many performance tests against competing solid carbide end mills. One test involved machining an SS1672 (C45) 160 HB ISO-P workpiece, and another test machining a 1.4404 (316L) ISO-M workpiece.

The ISO-M workpiece was subjected to slot milling, for which the tools were run at the following parameters: a cutting speed (Vc) of 90 m/min, feed per tooth (fz) of 0,05 mm/tooth, radial depth of cut (ae) of 10 mm and axial depth of cut (ap) of 5 mm. CoroMill® Plura HD exhibited a 65% tool life increase. The ISO-P workpiece was subjected to dry shoulder milling with the following cutting parameters: a Vc of 235 m/min, fz of 0,1 mm/tooth, ae of 7,5 mm and ap of =5 mm. For that process, CoroMill® Plura HD exhibited a 150% tool life increase of the competitor’s tool.

Sandvik Coromant recommends the use of CoroMill® Plura HD and Zertivo™ 2.0 in general engineering, automotive, stainless steel and steel. Going forward, Sandvik Coromant’s engineers specialising in machine tools and R&D plan to expand Zertivo™ 2.0 coatings across its tool line. In doing so, it expects the coating will help customers achieve improved performance and cost savings, as the shift among manufacturers towards sustainability continues. sandvik.coromant.com

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COMPANY FOCUS

Think Fencing Breathing new life into recycled PVC, Jack Fitzgerald has jumped onboard an exciting and profitable race.

Jack Fitzgerald is full of energy. He bounces out of the back of the sprawling office which is home to Think Fencing. The factory is set upon land on a hill out the back of Portarlington. Here, the company makes residential and rural fencing, but also Titan Rail, Ecoduct and all kinds of decking, and all out of recycled Polyvinyl Chloride, or PVC. This is a widely used polymer which is economical, versatile, chemically and electrically stable, and weather resistant with good processing characteristics.

Now, Fitzgerald’s Think Fencing was brought to our attention after the company took out the Leader in Manufacturing award at the 2023 Victorian Manufacturing Gala Hall of Fame Awards. That night in August, Jack brought to the stage with him a couple of engineer staff members, Ben Zappia, and Elise Vella who’d built a plastics extruder in her bedroom at home. “Elise created it all on her own, and is still studying at Deakin University, doing her fourth year in Mechatronics,” says Jack. “Elise looks after the whole technology division we're working on here.”

Beginnings As a precocious teenager, Jack Fitzgerald was pretty confident he’d invented a perpetual motion machine. “I was always tinkering, always playing around with machines,” he says. “When my father retired in the nineties, he bought this place here in Portarlington, and there was an old extruder sitting in the shed.” The property was so large, Jack’s Mum kept horses on it. “After an accident one day, it became urgent that we make the wire fence area more visible to our animals, and therefore safer.” The invention was an instant hit in the industry.

Think Fencing has some other new bespoke machinery designed and being built right now to join the assembly line at the warehouse.

They also have a unit of tech which leverages Artificial Intelligence, Machine Learning and vision systems for PVC recycling. There is so much going on. “The technology that we’ve developed there works really well,” he adds. “In fact, we’ve decided to spin this tech off from being attached to an extruder and put it into its own pilot production line. That was only a pilot line that we built here. Just to prove the concept. Well, we turned it on about eight months ago, and we haven't turned it off.”

PVC Recycling

From here, their company grew to become the largest manufacturer of composite fences in the Southern Hemisphere, extending to manufacture of PVC Running Rails for horse race tracks. During COVID they got a huge boost, updating and replacing racing track barriers across the country. “This was a very busy time for us,” says Jack. “Most major tracks in WA, NSW, then QLD, and then Victoria.”

PVC as a natural, virgin polymer has a certain amount of heat stability in it. But in its raw form it cannot be processed. It can't be extruded. It can't be moulded. It can't do anything. As soon as heat and pressure is exerted on that polymer, it just goes black.

You need to add a variety of additives, into raw resins. The external lubricant is to allow the material to flow through the screw barrel.

Jack takes up the story.

“We had a new high-speed extrusion line built in Austria,” explains Fitzgerald. “And we air-freighted it over here to run that one line, so that we could keep up with demand. It cost us over a million to design, build, import and set up.”

“The internal lubricants are added so when the polymers process, it doesn't create too much heat or friction. Then there is the heat stabiliser, a calcium and zinc mixture. Now, if you put too much calcium or zinc in your polymer, it won't fuse, it won't homogenise or gel. If you put too little, it burns up,” he says.

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“You want just the right amount of heat stabiliser in a formulation, so it can go through that process. This might be a process to turn the powder or the formulation into a compound like a pellet, then the pellet goes into an injection moulder. This moulder makes the part and spits it out. Or from a powder through an extruder, then to an end product.

“Too much heat stabiliser and it won't fuse. Too little and it burns up,” Jack repeats for effect. “You have to put in just the right amount of stabliser for that product, for that machine that you’re running.

So what we've done is we've created an analyser that measures the residual heat stability of a polymer to be recycled. And by analysing how much heat stabiliser is left in a recycled formulation, the recycled product grind material, we can then dose it accurately, to then make the product we need.”

Colouring the product is not a problem either for the Think Fencing team because as the product is extruded, a 0.8-1.5mm ASA capping layer is added from the die head.

OK, Fences Think Fencing has an online order system which makes it easy for the end-user to jump in and order. They’re even working with Bunnings’ Special Orders system through Bunnings Trade. The front of their ordering system is similar to the Kaboodle kitchen measure-up system. “That spits out enough information for our technical team to then decipher and create a fence. There's a lot of automation and CNC controlled technology in this. All this information feeds through into the design program. Everything's automated. If you look for a residential fence on this system and fill in all the measurements, by the time you get to the end of it, that's your design and a customised quote spits out for you.” Jack is sharply focused on having this kind of system built so it would be scaleable.

“There are hundreds of fencing construction contractors across the country who use and are familiar with our product,” says Jack.

“About a third of our orders would be DIYers, another third would be fencing contractors. Then the other third would be businesses, large construction projects, builders, or the racing industry.”

“We're a small company, but we've got a lot going on.”

Recycling The work Think Fencing is doing right now with CSIRO is still being developed. “We’re going through a patent process with CSIRO but we’re the only company that can deal with such wide spec PVC,” said Fitzgerald. CSIRO did a presentation to the American Vinyl Institute. They looked at what we are doing and said, ‘this is the

holy grail’.” Jack is adamant to strike out any greenwashing claims.

“This is the real thing.” He showed me a large box of ground PVC granules, made out of five different feedstocks.

He spoke of PharmaCycle, who’ve set up a deal for recycling pharmaceutical blister packs. “And we’re the ones to do it,” he says. “We're the only company in the world that's been able to actually successfully make another product out of that using this technology. And we’re turning it back into an A grade polymer.

That's one of the success stories.”

The Australian Resilient Flooring Associations’ Sophi Macmillan (ARFA) contacted Jack wanting to recycle all the waste vinyl flooring they knew was out there. “From that first conversation, we managed to take this material, analyse it, put it through our proprietary technology, then dose it with certain additives, and turn it into a usable product,” Jack describes. “We managed to get it into an extrudable, workable polymer that had some interesting properties.”

That was great, but Fitzgerald wanted to go further. Think Fencing now uses this recycled flooring material to extrude and are about to launch it into Bunnings in three different sizes. There’s also recycled PVC pipes, electrical conduit, PVC window profiles, ducting. “Even the excess from what goes into making credit cards. All of the stuff that no-one wants to touch.”

Think actually began diversifying about five years ago, purely to find an outlet for all of their scrap. “We developed technology which helped us analyse our scrap PVC,” explains Fitzgerald.

“Companies have a problem and we want to help” This time next year Jack wants to have a fabrication recycling division in Sydney and then Brisbane the following year. “It’s going to be a very steep growth curve,” he quips. The reason he’s expanding interstate is that freight is the big killer from here in Portarlington. “It costs as much to go from Geelong to Melbourne as it does from Melbourne to Sydney with pallets.”

As we speak, a truck has arrived with about 20 tons, of PVC plastic in large white bulker bags. These are vinyl record blanks from Program Records. “These are their offcuts from manufacturing records. We take all of that,” says Jack. “It would have gone to landfill but now it’s going to be fences.” Think Fencing converts that back into product, which they sell.

From this, Think Fencing will produce new fences and other new product, going to South Africa, Hong Kong, Singapore, Israel and UAE, and Inner Mongolia for their thoroughbred racetracks. thinkfencing.com.au

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Renewables win by a shine and a gust AEMO and CSIRO confirms renewables are cheapest power for industry.

Renewables, led by wind and solar, have retained their position as Australia’s cheapest new-build electricity generation source despite a 20% average rise in technology costs, according to the latest GenCost report.

“Australia’s energy challenge lies in the transformation of our existing energy system, while ensuring the continuing delivery of sustainable, reliable and affordable energy as we strive to achieve net-zero emissions by 2050,” Dr Tourbier said.

Released by CSIRO, Australia’s national science agency, the 2022-23 report marks the first time that all technology costs have increased from the previous year since GenCost commenced in 2018. The report highlights industry concerns that the rapid pace of the global energy transition will contribute to escalating cost pressures. This is attributed to the immense scale of manufacturing, raw materials and labour required to develop and deploy clean energy technologies consistent with net zero goals.

“This imperative is not only essential for environmental stewardship, but also to maintain Australia’s economic competitiveness in the global market,” Dr Tourbier said.

GenCost modelling projects that technology cost pressures felt in Australia will revert to normal levels by 2027 but are delayed to 2030 in global scenarios where the speed of the energy transition is highest. GenCost is an annual collaboration between CSIRO and the Australian Energy Market Operator (AEMO) that actively consults industry stakeholders to revise domestic electricity generation and storage, as well as hydrogen production costs.

CSIRO’s Director of Energy, Dr Dietmar Tourbier, said GenCost’s rigorous scientific and engineering analysis represents Australia’s most comprehensive projection of electricity generation costs.

CSIRO’s Chief Energy Economist and GenCost lead author Paul Graham, said that the COVID-19 pandemic had resulted in lingering global supply chain constraints which impacted the prices of raw materials required in technology manufacturing as well as freight costs. The Ukraine war exacerbated the global supply chain inflationary pressures by raising energy input costs for all industries.

“During the recovery from these global events, various input costs are showing signs of moderation, however there is an expected delay due to future price uncertainties and the robust demand associated with the global energy transition,” Graham said.

“GenCost analysis anticipates that technology costs have mostly peaked and the risk of cost pressures extending beyond 2030 will be mitigated, as the global manufacturing capability established by that time will adequately meet deployment needs.” csiro.au

Sustainable flying Air bp scoops Australian Aviation’s Sustainability Initiative of the Year Award.

Air bp has won Australian Aviation’s 2023 Sustainability Initiative of the Year Award. Air bp was recognised for introducing the first allelectric hazardous goods vehicle and refueller approved for use in Australia. The all-electric refueller has been in operation at Brisbane Airport since August 2022 and represents one small step in Air bp’s sustainability journey as it continues to work collaboratively across the aviation industry to help accelerate decarbonisation.

The Australian Aviation Awards recognise outstanding professionals and businesses from across the Australian aviation industry.

The Sustainability Award recognises the business that has most effectively demonstrated sustainable practice through products, services and culture, all while strengthening Australia’s aviation capabilities, its advancement and its recovery.

Justin Walker, Air bp’s technical sales director, accepted the award on behalf of Air bp Australia on August 31 and said: “I am honoured to accept this award on behalf of Air bp and would like to thank Australian Aviation for selecting us. I am delighted that Air bp has been recognised for this project as we work towards our aim of becoming the energy partner of choice for sustainable aviation. We collaborated with SEA Electric and Refuel International in the EV refueller’s design and construction and so it represents a celebration of Australian engineering and manufacturing of zero fuel and zero- tail pipe emission technology.”

Designed for customers lifting Jet A-1, the EV refueller provides a reduction in both operating and maintenance costs, as well as reduced greenhouse gas emissions, when compared with traditional diesel-powered refuellers. It is anticipated that the refueller will be introduced at other Air bp operated sites across the globe, including in New Zealand.

Air bp is in action to help the Australian aviation industry work towards its decarbonisation initiatives and has recently been appointed to a seat on the newly formed Australian Jet Zero Council. The Council aims to lower carbon emissions, supporting Australia’s net zero targets and is chaired by the Federal Minister

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for Infrastructure, Transport, Regional Development and Local Government, the Hon Catherine King MP. As the aviation division of bp, Air bp is one of the world’s leading suppliers of aviation fuel products and services. It has been investing in the aviation industry for more than 90 years to keep people flying safely around the world. In 2019 we supplied over 6.7 billion gallons of aviation fuel, fuelling over 7,000 flights per day at over 700 locations in more than 55 countries – that’s more than five planes a minute. airbp.com

ENERGY & SUSTAINABILITY

Not so rare earth ripe for public investments in green industry $60-100bn public investment in key post-carbon industries over 20 years can convert latent advantages into global green industry leadership. Toby Philips is Program Director, Sustainable Economy at the Centre of Policy Development.

The federal government has committed to develop a package by the end of 2023 to “leverage Australia’s competitive strengths in renewable energy, critical minerals and highly skilled workforce to accelerate our other clean industrial and manufacturing capabilities”.

Toby Philips' report focuses on the opportunity to export emissionfree iron, alumina/aluminium, and ammonia; energy-intensive commodities with large global markets.

His report refers to them collectively as future “green export industries”. Other industrial goals – such as processing critical minerals or onshore component manufacturing – should be seen as secondary outcomes. Pursuing the primary goal (exporting energyintensive commodities) will contribute to these secondary outcomes, and they can be further supported at the margins.

Australia has impressive natural endowments of (potential) renewable energy and the raw inputs to make green iron, aluminium and ammonia. Over the long-term, these green export industries should thrive in Australia. But in the medium term, the emergence of green export industries is held back by unpredictable technology costs and a global market that gives a significant ‘grey discount’ to emissions-intensive industries. Overcoming these obstacles will require significant policy support, in the range of at least $60-100bn, and possibly more.

With this investment, the Commonwealth can have a bigger impact on global emissions than all domestic decarbonisation combined, and secure future industries in the process. Such a policy package will need to balance many competing interests. With this in mind, the government should balance several principles in designing a package for green export industries. The Green gold report from the Centre for Policy Development’s sustainable economy program identifies refined iron, green aluminium and ammonia as the industries most suited to public investment, saying that these industries – once established – will deliver Australia a long term comparative advantage.

The report identifies these industries as ripe for public investment because current market distortions apply a “grey discount” to fossilfuel intensive competitors.

It says green exports are the most significant contribution Australia can make to global emissions reductions. It finds that onshore green refining of 12% of Australia’s annual iron ore exports would have the same impact on global emissions as Australia’s target to reduce domestic emissions by 43% by 2030. The report says that industry support should take several forms, including subsidies, tax credits, concessional loans, contracts for difference, grant funding, and equity investments.

The report recommends guiding principles for the design of public industry investment packages. Public investment should ensure additionality, avoiding public support for actions that would have been taken anyway. It should reduce economic risk to catalyse private investment in green export industries, and address market distortions that provide a ‘grey discount’ to fossil-fuel intensive competitors. It should also catalyse technology deployment, discourage ongoing reliance on government support, provide clarity to market participants, and capture upside to socialise the benefits of emerging industries receiving support. Centre for Policy Development sustainable economy director Toby Phillips said that careful design, firm ambition and swift action were necessary for Australia to convert the economic opportunities presented by global energy transition.

“Australia is famously well-positioned to become an industrial powerhouse in the post-carbon economy thanks to our abundant natural resources, our unmatched potential for renewable energy generation, our highly skilled workforce, our stable institutions and our world-class research and development,” Phillips said..

“Transforming these advantages into a leadership position requires us to take strategic, decisive and well-designed action that will create new export industries, support living standards, mitigate climate change and make our economy resilient and prosperous in the postcarbon era. “By carefully selecting the right industries for the right investment at this crucial time, we can lock in future industries and make an important dint in global emissions, putting Australia at the head of the pack for industrial and economic leadership over the coming decades.” cpd.org.au

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EPICS World-class researchers collaborate to find solutions for sustainable societal growth.

Six of the nation’s leading research institutions, including Australia’s national science agency CSIRO, have united with international researchers to spearhead innovation to address challenges in clean energy production and storage.

In a joint effort between Australia, the US, Canada, and the UK, two multi-lateral research projects have been announced today as part of the National Science Foundation Global Centres in Climate Change and Clean Energy (NSF Global Centres) program.

Together, these countries have pledged more than A$118m in investment in the NSF Global Centres program over five years to tackle challenges posed by climate change as the world moves towards net zero.

Kirsten Rose, Acting Chief Executive of CSIRO, said as Australia’s national science agency, CSIRO is proud to be part of a strong national contribution to solving this critical global challenge.

“CSIRO is proud to stand alongside numerous Australian research organisations to combine our shared expertise, strengthening our national response to accelerate the transition to a cleaner, sustainable energy future,” Ms Rose said.

“Collaborative initiatives like CSIRO’s Hydrogen Industry Mission and Smart Energy Mission are essential in ensuring solutions are co-designed with industry, research, and our communities.

“Partnering with the NSF’s Global Centres means Australia remains at the global forefront of work to build a clean hydrogen industry, build integrated and equitable energy systems, and partnering with regions and industries for a low emissions future.”

Two projects earmarked by the multi-national collaboration are being steered by Australian innovations: •

•

The Electric Power Innovation for a Carbon-free Society (EPICS) Centre will be a global scientific leader in developing transformative computing, economic strategies, engineering solutions, and forward-thinking policy to enable a completely renewable energy power grid. This joint project involves the US, UK, and Australia and is led by CSIRO and AEMO, the University of Melbourne, and Monash University in Australia.

The Global Hydrogen Production Technologies (HyPT) Centre is pioneering large-scale net-zero hydrogen production methods. It explores three innovative technologies: renewable energy-integrated water electrolysis, methane pyrolysis with valuable solid carbon co-products, and solar-driven water splitting. The University of Adelaide, Flinders University, and

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Curtin University represent Australia in this international collaboration, working with partners from the US, Canada, the UK, Egypt and Germany.

The institutions will pool resources and expertise to confront the challenges of a changing climate and continue the charge towards net zero emissions.

Speaking on the EPICS Centre, the University of Melbourne Chair of Electrical Power Systems and Australian EPICS Centre Principal Investigator, Professor Pierluigi Mancarella, said, “This Global Centre is an unprecedented opportunity to partner with major international institutes in the US and UK, and harness world-leading research to address some of the most pressing scientific challenges that Australia and other jurisdictions worldwide are facing during the energy transition towards net zero.

“These challenges range from guaranteeing stable and secure system operation in the presence of ultra-high penetration of variable energy sources and distributed energy resources, most of which are based on power electronic interfaces, to identifying reliable and resilient investment paths across the whole energy system in the presence of deep, long-term planning uncertainty,” Professor Mancarella said.

Speaking on the HyPT Centre, the University of Adelaide’s Deputy Vice-Chancellor (Research), Professor Anton Middelberg, said the University of Adelaide is delighted to be working with CSIRO and other partners to advance the commercialisation of technology that has the potential to be game-changing for hydrogen production.

“Our world-class researchers will be collaborating on finding solutions that will help create a more sustainable future for society,” Professor Middelberg said.

As the national science agency, CSIRO plays an important role in connecting and strengthening the Australian innovation ecosystem. This ensures we are equipped to meet our biggest challenges for the future and allows us to harness global networks to facilitate opportunities for collaborative research across industry, government, and science organisations.

CSIRO’s missions are large-scale scientific and collaborative research initiatives that aim to work across the innovation system to make significant breakthroughs. Through missions, CSIRO aims to accelerate the pace and scale at which the nation can solve our challenges and unlock a better future. csiro.au

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Old tyres go round Deakin partners with industry to convert old tyres into electricity.

A new collaboration between Deakin University’s Recycling and Clean Energy Commercialisation Hub (REACH) and industry partner Clean Energy Resources (CER) will see tyres take on new life as electricity, hydrogen and other important resources after their time on the road.

Cable-less Data Collection

Each year in Australia, 48 million tyres reach the end of their life, with only a small number recycled domestically. Around two thirds of used tyres in Australia end up in landfill, are stockpiled or are illegally dumped. The partnership between Deakin and Geelongbased business CER will develop a technology that provides a new way to generate electricity from end-of-life tyres without harming the environment.

Deakin scientist Professor Abbas Kouzani and his multidisciplinary team will work with CER on the project, leveraging the team’s success in creating a solar panel recycling plant and capitalising on Deakin’s unique research facilities and ability to translate research ideas to real-world solutions.

“The development of novel scalable technologies that can address real-world problems is a significant challenge for the Australian recycling industry and one that my team is very enthusiastic about working on,” Professor Kouzani said. “Innovations in this space have the potential for immediate global impact and can assist in solving a pressing environmental pollution problem.” While tyre recycling is happening in places around the world, including the United States, China and Turkey, this project will focus on developing a technology that will produce no harmful emissions.

Clean Energy Resources Director Tony Carr said the end-of-life tyres pilot-plant would be the first stage in CER’s circular economy vision to tackle the global challenges of clean electricity production, waste management, and recycling.

“This project is the culmination of 30 years of work by members of the CER team and research across the world in recycling, which in the past 10 years has focused on zero emissions solutions for the problems the world faces with all forms of waste,” Mr Carr said.

Backed by a $50m grant from the Australian Government’s inaugural Trailblazer Universities Program, with industry and university support taking the total project value to $380m, REACH is facilitating the development of greener supply chains and accelerating business success as markets move from a throughput economy to a circular economy. deakin.edu.au/reach

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Pulsed-power EPF saves energy during comminution Electric Pulse Fragmentation is ideally suited to recycling high end technology into separated parts. Dr Cameron Chai of AXT Pty Ltd and Dr Daniel Parvaz of Lightning Machines in the UK break it down.

Since the dawn of man, we have been breaking things like rocks down to extract components from them to suit our needs.

Over several millennia the principles haven’t changed much: It is still a case of applying a mechanical force to the object until it breaks. The only thing that has really changed is the amount of force we can apply to achieve this goal, and how we apply it. Electric Pulse Fragmentation (EPF) is a new, smarter way to achieve this goal of breaking things down, and without using mechanical forces!

Comminution When we think of ways to break things down, reduce particle size or disaggregate things, the first process that come to most people’s minds are crushing and grinding, also known as comminution. You could perhaps add a shredder in there for completeness. In terms of crushing and grinding, these techniques simply apply large forces indiscriminately via jaws, anvils, rollers etc. to the input material, until they break apart and can pass through an aperture of the desired size. There may be several of these crushing and grinding stations that progressively reduce the particle size to the desired level.

These processes are widely used in industries such as mining, minerals processing, ceramics, electronics and recycling. While they do achieve the goal of reducing particle size, they often produce large volumes of fines which can be undesirable, as well as dust which can be equally as undesirable. Furthermore, according to energy.gov.au, comminution accounts at least 40% of a mining and minerals processing operation’s total energy usage.

Electric Pulse Fragmentation EPF uses high voltage pulsed-power to cleave materials along discontinuities and grain boundaries.

It works by passing a high voltage (up to 200kV) electrical discharge through a material. The discharge tries to take the fastest route to ground, which just happens to be a samples’ internal contacts between different materials, such as metal and plastic, or between two different minerals. This means the energy is selectively delivered to the contacts between phases or materials, ‘selectively’ fragmenting them along these boundaries. The breakage is caused by a

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Representation of how the high voltage fragmentation process works. (Image courtesy of Selfrag)

shockwave that forms at the same time as the discharge, which can be thought of as being like thunder and lightning.

The lightning travels through the material delivering energy to these boundaries, and the following thunder causes a shockwave that disintegrates our sample.

The process occurs in water, which acts as an insulating medium to direct the electricity to the sample, and also helps prevent dust formation.

Advantages of Selective Fragmentation Selective fragmentation has several benefits over traditional comminution technologies.

These include: • • • • • • •

High selectivity leading to increased recovery Reduced energy consumption Better control over size reduction No wear of components e.g. grinding faces, rollers etc No contamination from wear of components No dust Less down time

Geochronology While this case study may seem completely removed from recycling, it clearly demonstrates the value of selective fragmentation over conventional comminution techniques. Geochronology

allows geologists to date specific geological events and materials which can have commercial value to mining companies and paleontologists. For geochronologists, the collection of tiny zircon crystals is essential to their work as they hold valuable pieces of information allowing them to unlock geological secrets.

Separating out the zircon crystals from host rock requires liberation. Traditional crushing and grinding can often break the desired zircon crystals along with the host rock.

Their reduced size makes them difficult to locate amongst the refuse and reduces the quality of data they provide. Using selective fragmentation however, liberates these zircons intact, revealing larger specimens for scientists to work with and making them easier to find. An added advantage is the preservation of surface features which hold a lot of important data.

E-waste recycling In 2018, the SMaRT Centre at the University of New South Wales launched its first Microfactorie™ aimed at recycling e-waste. The Microfactorie™ is capable of converting e-waste such as computer circuit boards into valuable metal alloys such as copper and tin, while glass and plastic from e-devices can be converted into valuable micromaterials used in industrial grade ceramics and plastic filaments for 3D printing, contributing to the circular economy.

ENERGY & SUSTAINABILITY

Zircon crystal (under crosshairs) surrounded by other fragmented minerals, recovered from granite rock using EPF (Image courtesy of D. Parvaz)

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Demonstrating how the various components of an iPhone can be separated following electric pulse fragmentation. (Image courtesy D. Parvaz, Lightning Machines)

One of the key elements of the Microfactorie™ recycling process is the selective fragmentation system that is capable of separating individual components from electronic devices. This makes them much easier to sort and further process compared to dealing with a bucket of mixed powder that would require complex separation techniques to divide the powder up into usable streams.

Recycling incinerator slag SELFRAG officially inaugurated ‘Centro Uno’, the world's first waste-to-value EPFrecycling plant in Switzerland on July 13, 2023. Located in Full-Reuenthal, Aargau, it is now running at full capacity (35,000 tpy).

Centro Uno is the first of many similar plants planned for Switzerland that will contribute to a nationwide resource recovery.

Centro Uno is an incinerator bottom ash (IBA) waste treatment facility. It receives

slag from regional waste incinerators, which contains substantial amounts of metals that have been thrown away that become trapped within the slag after incineration. This slag is processed via selective fragmentation where more than 50% of the slag is converted into valuable materials (metal and minerals) which are separated out and reused: The metals can be separated and recycled, and the inert glass and ceramics can be turned into construction materials. This also means they are achieving a reduction of material going to landfill of greater than 50%.

Anton Affentranger, SELFRAG Executive Chairman commented at the inauguration, “With our technological leadership and recovery rates, we are revolutionising the way incinerator slag is treated. We are paving the way for a more sustainable future.”

IBA slag separated into metals (top), minerals (middle) and slag (bottom) streams that can all be recycled or repurposed. (image courtesy Alexander Weh, Selfrag and Daniel Parvaz, Lightning Machines.)

Conclusion Selective fragmentation via high voltage pulsed power is a smarter and more efficient way to reduce the particle size material compared to conventional crushing and grinding processes. With the ability to disaggregate feedstocks into their individual components by cleaving them along grain and phase boundaries, selective fragmentation can separate materials into discrete components, converting them into valuable material streams that can become part of the circular economy. axt.com.au

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Victor Precision Queensland company makes a significant mark in the field of precision engineering.

Founded by husband and wife team Victor and Lynne Oliveira in 2007, Victor Precision is today recognised nationally and internationally for its quality, precision and on time delivery particularly with regard to small highly complex components as well as firearms, firearm parts and accessories. Whilst more than 50% of Victor Precision’s manufacturing and sales are in firearms, firearm components and accessories, the balance of sales includes parts for laboratory equipment, mining, prototyping and machining of complex intricate components with extremely fine tolerances. This is made possible due to the quality of workmanship and the rigidity of the Okuma machines used. Victor Precision designs and machines parts in a range of exotic materials such as titanium, tungsten, all steels, brass, acetyl and aluminium supported by CAD/CAM software for the design of innovative ideas for prototyping and manufacturing. Inhouse heat treatment and hardness testing is also provided ensuring essential quality control on all parts.

Victor Precision is one of only a small number of fully licenced firearms manufactures in Australia, with the company producing precision hand guns and long rifle parts for competition sporting shooters, law enforcement authorities and military operations in Australia and has recently broken into the sporting shooter market in the United States of America through authorised dealers to that country.

Initially the company had procured at auction, sight-unseen, a second hand Okuma machining centre, which is still in operation and has been an outstanding machine according to Managing Director, Victor Oliveira. With the business expanding Victor Precision has recently invested in the latest Okuma LB3000 EXII MYWx800 CNC Lathe with a bar feeder. “The support we have received from Okuma’s Australian Queensland branch, even with a second-hand machine bought at auction, has simply been outstanding so when looking for a second machine we could not look past Okuma,” said Victor Oliveira. “It seems that we are seamlessly dealing back to the factory and the technical support and training we receive is priceless particularly for a smaller company such as ours. The machines are so good, rigid and stable that we seldom if ever have a problem” he said.

“With the introduction of the new Okuma machine with automation and bar feeder the operational times have halved impacting on our turnaround times through machine efficiency and at the same time in one instance the machining time has reduced from 20 minutes to 4 minutes,” he said.

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Along with Victor and Lynne, the company employs one tradesman who has just completed his apprenticeship with the company and in addition some casual employees are called in as required. The young tradesman is excited with the new technology the Okuma machine has introduced and is readily welcoming the challenges that this brings. As a manufacturer of firearms and related parts, it is understood that security measures are extreme with a purpose built facility meeting specific building codes, alarm systems and registration with the nearest police station. Firearm sales are all directed through registered outlets throughout mainland Australia only with exports now reaching approximately 12% of sales also via registered and fully licenced dealers and customers in New Zealand, USA, Europe and South Africa.

The company has taken advantage of support from the Queensland Government Business Assist program to upgrade its software in particular. This energetic company is already looking to the future with factory floor space already allocated for the next machine.

“Working alongside Victor and Lynne to assist with the specifications and features of the Okuma Lathe has been a pleasure,” said John Baker, Branch Manager- Queensland. “Since the installation, the team has had great satisfaction in supporting them and observing new opportunities the Okuma lathe has made accessible to Victor Precision,” Baker said. okumaaustralia.com.au victorprecision.com

FORMING & FABRICATION

Formero and Teschner Cyles Teschner and his journey towards achieving excellence in 3D-printed bike frame manufacturing.

With an extensive record of accomplishment in both Australian and international competitions, Teschner's achievements span multiple cycling disciplines, including road, time trial, track, triathlon, MTB and BMX. His accolades are quite impressive: 24 National Australian titles, ten first place finishes in both the Men's and Women's Australian National Individual Time Trial Championships, a Teams' Title at the Tour Down Under, ten World Gold Medals (including Pro and U23 Individual Time Trial), the World Pro and Junior Women’s Triathlon Championships, 11 national USA National Gold medals, and representation at four Commonwealth Games and three Olympic Games.

Photo credit Morgan Ho

Back in the early nineties, Peter Teschner embarked on a remarkable journey in the world of bicycle frame craftsmanship, starting with titanium frames. In 1993, he transitioned to Easton Sports aluminium tubing, eventually embracing full carbon in 2006. In more recent times, Teschner ventured into the realm of 3D printed materials, and pretty much revolutionised the bicycle manufacturing industry in Australia.

Following a two-year tenure as the General Manager of the Bike Division at Titomic, where he researched the groundbreaking Cold Spray supersonic deposition of metals in the manufacture of bicycle frames, Peter Teschner's fascination with Additive Manufacturing was ignited. This pivotal moment marked the commencement of his quest to identify the most suitable materials for 3D printing bicycle frame components. While titanium had witnessed a meteoric rise in its application within the bicycle industry, primarily for lugs, dropouts, and small parts, Peter's unwavering commitment to innovation led him to seek the expertise of the Materials and Minerals Department at the University of South Australia. Collaborating on a rigorous ninemonth project, they ventured into the realm of Markforged micro carbon-filled nylon (ONYX) using their Markforged Mark 2 printer.

Inspired by the design principles employed in 3D-printed titanium frame lugs, this endeavour faced significant challenges, particularly

in the Z-axis. The journey was marked by numerous setbacks and challenges, but Peter Teschner's philosophy remained steadfast: “It is better to create than compete.” This tenacity eventually led to success. After the University of South Australia project concluded, Simon Marriot, the principal of Formero, an industry-leading Melbourne-based provider of advanced manufacturing services in Australia, played a pivotal role by offering invaluable expertise and equipment to advance the project. Equipped with the state-of-theart Markforged FX20 printer, this collaboration became a pivotal moment in Teschner's journey towards achieving excellence in 3D-printed bike frame manufacturing. The research and extensive testing phase is expected to continue for the next four to six months, with an anticipated release of a fully competition-ready product.

The prototype bike received significant attention when it was showcased at the Formero stand during the Australian Manufacturing Week in Melbourne in 2023. It drew keen interest from various industries and attendees.

The images chronicle the progression of this remarkable journey, illustrating the evolution of Teschner's innovative approach and the transformative impact of additive manufacturing on the world of bicycle frames. teschner.bike formero.com.au

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Photo-chemical etching PCE is perfect for heat exchanger production. Jochen Kern, Head of Sales & Marketing, micrometal Etching Group.

Heat exchangers play a crucial role in various industrial applications, from power generation and automotive systems to HVAC systems and aerospace technology. The efficiency and performance of heat exchangers are directly related to their design and manufacturing methods. One manufacturing process that has proven to be ideally suited for producing high-quality heat exchangers is photochemical etching (PCE). This innovative technique offers numerous advantages over traditional manufacturing methods, addressing key challenges while paving the way for innovative heat exchanger designs.

Advantages of PCE for heat exchangers PCE, also known as chemical milling or photo-etching, is a precise and versatile manufacturing process that involves selectively removing material from a metal sheet using chemical reactions.

When it comes to producing heat exchangers, this method presents several notable advantages.

For example, heat exchangers often require intricate and complex geometries to enhance heat transfer efficiency. PCE excels in producing intricate patterns, fine details, and complex shapes that are difficult to achieve with conventional methods like stamping or machining. This allows engineers to design heat exchangers with optimal fluid flow paths and heat exchange surfaces.

In addition, PCE provides exceptional dimensional accuracy and consistency across large production runs. This is crucial for heat exchangers, as even slight variations in geometry can significantly impact heat transfer performance by altering fluid flow patterns and surface interactions, leading to changes in convection, conduction, and radiation mechanisms.. With minimal variation in tolerances, heat exchangers manufactured through the PCE process ensure reliable and predictable performance.

Heat exchangers must also withstand various operating conditions, including temperature, pressure, and corrosive environments.

The temperature at which heat exchangers operate, for example, directly affects the material used to make them due to its influence on thermal expansion, mechanical strength, and corrosion rates, determining the material's durability and performance under

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specific conditions. Extreme temperatures can lead to thermal stress, material degradation, and potential failure. PCE works with a wide range of metals, including stainless steel, copper, aluminum, and titanium. This flexibility allows engineers to select materials that are best suited for the specific application's requirements, ensuring durability and longevity.

Finally, the ability to create intricate patterns and surface textures through the use of PCE improves heat transfer efficiency. For example, heat transfer efficiency can be enhanced by creating intricate surface patterns and textures that promote turbulence and disrupt laminar flow, thereby increasing convective heat transfer coefficients. These engineered surface features amplify fluid mixing and boundary layer disruption, facilitating more effective heat exchange between the fluid and the solid surface, all of which contribute to improved overall heat exchange performance.

Challenges in alternative manufacturing processes While PCE offers significant advantages, alternative manufacturing processes present several challenges when it comes to producing heat exchangers.

Conventional methods like stamping, welding, and machining are constrained by their limited ability to create intricate and complex geometries, resulting in suboptimal fluid flow patterns and less effective heat exchange surfaces in heat exchangers. As a consequence, the overall performance of these heat exchangers is diminished. Additionally, these techniques struggle to reproduce intricate internal passages and features essential for efficient heat transfer and fluid dynamics.

Traditional manufacturing processes are also susceptible to tolerance variations caused by factors such as tool wear, thermal expansion, and machine inaccuracies. These inconsistencies can detrimentally affect heat exchanger performance by disrupting precise geometries and altering flow pathways. Suboptimal tolerances can impede proper fitment of components, hinder uniform fluid distribution, and hinder efficient heat transfer, ultimately compromising the overall effectiveness and reliability of the heat exchanger, and posing a challenge in maintaining consistent efficiency across a production

FORMING & FABRICATION batch. As discussed, certain heat exchanger designs demand materials with specific properties to endure extreme conditions.

However, the limitations of traditional manufacturing methods can restrict the range of materials that can be effectively utilised.

Many traditional techniques are optimised for specific materials and may struggle to handle newer, unconventional materials or those with unique properties required for specialised applications.

This restrictiveness hampers the ability to tailor material choices to suit specific heat exchanger requirements, limiting the design's overall performance, efficiency, and suitability for diverse operating conditions.

disrupt laminar flow, they can optimise convective heat transfer coefficients and improve overall heat exchange. This customisation of surface patterns to match specific applications enables heat exchangers to achieve elevated heat exchange rates, resulting in heightened performance and increased efficiency tailored to the precise operational requirements.

Finally, conventional manufacturing procedures, sometimes involving multi-step processes such as cutting, shaping, and welding, tend to extend production timelines and increase costs due to their inherent complexity and sequential nature. Each additional step requires specialised equipment, skilled labour, and quality checks, leading to longer lead times and higher costs. Moreover, the need for coordination among various processes can introduce delays and increase the risk of errors, further contributing to the overall time and cost overhead when making heat exchangers.

Also of critical importance, the rapid prototyping capabilities of PCE empower engineers to swiftly test and iterate heat exchanger designs. With PCE, engineers can efficiently create intricate surface patterns and textures, allowing for the rapid production of prototype heat exchangers with varying geometries. This rapid iteration process enables engineers to assess performance, fluid dynamics, and heat transfer efficiency more effectively, leading to quicker design refinements and a streamlined development cycle. This accelerates the development process and facilitates the exploration of innovative concepts, ultimately leading to optimised designs.

Innovations in heat exchange design and manufacture with PCE The adoption of PCE for heat exchanger production opens up exciting avenues for innovation in design and manufacturing.

Firstly, PCE enables the creation of micro-channels with intricate geometries. These micro-channels facilitate efficient heat transfer by increasing surface area and promoting turbulence, leading to highly compact and efficient heat exchangers. This innovation is particularly valuable in applications where space is limited, such as in electronics cooling or aerospace technology.

Second, engineers can use PCE to design and manipulate surface textures that enhance fluid flow and heat transfer efficiency.

By strategically creating patterns that promote turbulence and

PCE also allows for the precise combination of different metals and materials within a single heat exchanger unit. This opens the door to creating hybrid heat exchangers that leverage the strengths of various materials while mitigating their weaknesses, enhancing overall durability and performance.

Conclusion In the realm of heat exchanger production, PCE stands out as a revolutionary manufacturing process that addresses many challenges faced by traditional methods. Its ability to create complex geometries, maintain tight tolerances, and work with a wide range of materials makes it an ideal choice for producing efficient and innovative heat exchangers. As industries continue to prioritize energy efficiency, compact design, and performance optimisation, PCE is likely to play an increasingly pivotal role in shaping the future of heat exchange technology. micrometal.de

Are your standard form contracts up-to-date?

Significant reforms to the Unfair Contract Terms (UCTs) laws came into effect on 9 November 2023.

If you contract with your customers using standard form contracts that are not typically negotiated, your terms are likely to be caught by the UCT laws.

Changes to the law now mean that including or relying on a UCT in your standard form contracts will be unlawful and could attract penalties in excess of $50 million.

At Rigby Cooke Lawyers, our Corporate & Commercial lawyers can assist with reviewing and amending your contracts to ensure compliance with the UCT regime.

We can also carry out internal compliance training for businesses if necessary.

For more information on how we can assist you and our exclusive benefits for AMTIL members, please contact Julia Cameron, Lead Partner of our Manufacturing group, on +61 3 9321 7807 or JCameron@rigbycooke.com.au.

Rigby Cooke Lawyers has been advising manufacturers on their commercial needs for decades. And, that’s why we are the ‘go-to’ legal advisors for AMTIL members and the manufacturing industry.

Our people: Your success T: +61 3 9321 7888 | E: info@rigbycooke.com.au | www.rigbycooke.com.au

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Astroworx Making his own astronomy telescope and instruments with Autodesk Fusion 360.

Diego Colonnello immigrated to Australia from Venezuela in 2014, taking up a position working in high-end security systems. In his spare time, using internet tutorials and forums, he taught himself how to program a microprocessor and used this new capacity to build an Arduino-based CNC machine, a router made of MDF, with a Makita tool on it and stepper motors. “I remember I made the drivers myself by etching my own PCBs and installing H-bridge chips to control each stepper. I guess all of these hobbies gave me the basics to understand a software like Autodesk’s Fusion and then transform something digital into reality was the next logical step,” he explained when meeting him at the AMW2023 show earlier this year.

Colonnello is self-taught, an autodidact. “I have been lucky to be able to understand concepts and apply them to my life, learn a new software, a language or a skill,” he said. “This has been my best tool.” Having been passionate about astronomy for years, Colonnello bought a telescope from an ALDI store, “and that telescope, quite a simple model,” explained Diego, “showed me things I hadn’t seen before, like Saturn with its rings and moons, I could not believe my eyes.”

Before he knew it, he’d started a wonderful new hobby.

Astrophotography. He bought telescopes, lenses, cameras, attachments and accessories. But something was not right.

Colonnello found off-the-shelf telescopes needed a lot of improvement to work correctly. He started to modify them with new materials, new parts. He took up designing and fabricating them in Autodesk Fusion 360. “There were a lot of upgrades,” he quipped.

By then, he had his own observatory and a business dedicated to importing and selling. “We also started to offer astronomy accessories to our clients and a new need for premium telescopes emerged,” Fusion 360 has been my first choice for modeling parts and 3D print them, now that I have this business I was looking for ways of producing improved parts for my hobby, and to help other amateur astrophotographers.”

Fusion 360 allowed Diego to put together more complex assemblies, test fit accessories, and see how the materials will look and react on the final design.”This package makes precision design possible,” he explained. “It’s the first software I have ever used for 3D modelling, and now am making telescope components after small parts for model airplanes.” All the products are designed and manufactured with the support of Autodesk software, simulations, design, drawings and Cam.

“The day I started the design still makes me proud. A telescope with all the features anyone can dream of. Stable, fast, beautiful and reliable. Fusion 360 made it possible, with precision design and the capacity to manufacture using the same software is an amazing tool to have.”

Colonnello works with Aluminium 6061 and 5083, “and carbon fibre composites are a must for support structures in our telescopes, thermal stability is important when dealing with light,” he adds.

The optics are ordered from overseas, depending on the type and size of the telescope. Astroworx (Diego’s company) designs the support structures, and these are assembled digitally in Fusion360 and tested for movement and manufacturability. “In house production allows us the freedom of moving fast with the market, listen to our client feedback and evolve our designs,” he says.

Optical instruments require precise planning and the design includes support systems that hold optics in a position that allows the star light to be captured and focuser on a camera sensor. In the past, designers used pen and paper to lay out the design, calculate the position of optical elements and start building, all of this, can be done now with the help of Autodesk.

The workshop operates two Optimum CNC mills purchased at Hare and Forbes, one CNC lathe, one CNC laser and one 3D printer. All the design work for the products at Astroworx are done in Fusion, all the Cam and the post processing too, this lets Colonnello work from home on designs and manufacture the next day under the same platform. astroworx.com.au

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FORMING & FABRICATION

Saving fabrication The Accurl EB Ultra Press Brake revolutionising metal fabrication with energy efficiency.

In today's rapidly evolving industrial landscape, energy efficiency has emerged as a critical concern for businesses across various sectors. With increasing awareness about environmental sustainability and escalating energy costs, companies are seeking ways to optimise their operations while minimising their carbon footprint. Metal fabrication plays a vital role in numerous industries, and the integration of energy-efficient machinery is a significant step toward achieving sustainability goals. The Accurl EB Ultra stands as a prime example of how modern machinery is paving the way for energy-efficient metal fabrication.

There are many advantages for manufacturers The integration of energy-efficient metal fabrication machinery offers numerous advantages for manufacturers striving to optimise their operations:

comply with stringent environmental regulations, and address the global issue of climate change. The industrial sector is a substantial consumer of energy, and optimising energy usage is imperative for both economic and environmental reasons.

Energy-efficient metal fabrication machinery plays a pivotal role in enhancing the overall sustainability of manufacturing processes.

By utilising advanced technologies and innovative designs, these machines minimise energy wastage, decrease greenhouse gas emissions, and promote responsible resource utilisation.

Features and advantages of the Accurl EB Ultra Press Brake 1. Servo electric technology

By reducing energy consumption, businesses can significantly cut down their operational costs. Energy-efficient machinery leads to lower electricity bills, offering immediate financial savings and enhancing the long-term profitability of the enterprise.

The EB Ultra Series ball screw press brake is driven by an AC servomotor and ball screw drive mechanism. It maximises productivity with high-speed ram and high precision repeatability(0.001mm). This drive method is superior to all other electric/hydraulic performance while providing up 80% reduced energy consumption when compared with traditional hydraulic configurations.

2. Environmental responsibility

Enhanced operational speed and accuracy

Investing in energy-efficient technology showcases a commitment to environmental responsibility. Manufacturers can reduce their carbon footprint and contribute to a cleaner, more sustainable environment.

Combining energy efficiency with enhanced operational speed and accuracy. This blend of features ensures that the fabrication process is not only sustainable but also highly productive. Manufacturers benefit from both energy savings and increased production output, contributing to a more efficient and profitable operation.

1. Cost savings

3. Bottom-line benefit With tightening regulations related to energy usage and environmental impact, opting to purchase energy-efficient equipment may provide better access to grant funding. With a global push toward an ecofriendly attitude in manufacturing, and the unceasing march of increased manufacturing costs in Australia. Acquiring government assistance to enable the purchase of workshop machinery is a huge win for business owners.

The rise of energy efficiency in manufacturing The drive toward energy efficiency in manufacturing is fueled by several factors, including the need to reduce operational costs,

Conclusion In today's fast-paced industrial world, incorporating energy-efficient machinery is a fundamental step toward a sustainable future. The Accurl EB Ultra Press Brake serves as a prime example of how advanced technologies and innovative designs can revolutionise metal fabrication, reducing energy consumption and promoting environmental responsibility. As the manufacturing sector continues to evolve, embracing energy efficiency is not only an environmental imperative but also a strategic business decision that can lead to a more profitable and sustainable future. completemachinetools.com.au

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MATERIAL REMOVAL

TISCO big shot blast The biggest vertical shot blast machine ever built by Rösler goes to China. A perfect surface finish on up to 315,000 tons of stainless steel plates per year.

Stainless steel is one of the most important raw materials for many industries such as medical engineering, ship building, aerospace, etc. Accordingly, high volumes of stainless steel are used all over the world. To cope with the increasing demand, TISCO, one of the globally largest manufacturers of stainless steel, modernised the production line in its hot rolling mill for stainless steel plates. As partner in this challenging project Rösler built the biggest vertical shot blast machine in the company’s history.

As part of the China Baowu Steel Group Corporation Limited the Taiyuan Iron and Steel Group Co., Ltd., (TISCO), is one of the largest and most renowned suppliers of steel in the world. For a long time the company, located in Taiyuan in the Chinese province Shanxi, has specialised in the development and production of stainless steel products such as plates and sheets. Since 2020 a huge modernisation project is underway for this business division with the goal to update the production line in the hot rolling mill for stainless steel plates with state-of-the-art equipment, including a new shot blast and pickling system.

Once the project is completed, the entire line will run fully automatically. The technical specifications for the shot blast system, processing steel plates up to 4,100mm long, 160mm thick and with a maximum weight of 35 tons, were very detailed and strict; particularly with regard to the shot blasting results and the work piece handling. The challenge for the Rösler engineers was to design and build a machine that guarantees a high-quality, highprecision finish in the micrometre range and high throughput. With regard to size and production speed the new shot blast system dwarfs the equipment that the company has ever built in this field.

High feed rate and low surface roughness readings Some of the TISCO requirements were that the steel plates must pass through the shot blast machine at a speed of seven m/min, the surface roughness cannot exceed Ra = 4.0µm, and the surface finish must correspond to A/B Sa 2,5. To prevent even minimal damage on the work piece surface by the transport rollers, the customer demanded the plates to be transported through the

Directly in front of the shot blasting system the up to 160mm thick and 4,100mm long stainless steel plates are moved into a vertical position. They are then passing through the shot blast system and pickling line on special roller conveyors at a maximum speed of seven metres per minute.

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shot blast machine and the subsequent pickling system in vertical position. A challenge was that the plates are delivered horizontally and must be changed to vertical position before entering the shot blast machine.

Two machines combined into one system To meet the customer’s surface quality demands within the specified time frame the Rösler engineers developed an innovative equipment concept. It combines two identical shot blast machines into one system, where the stainless steel plates are passing through the two machines sequentially, and each machine utilises a different blast media. The individual machines are equipped with twelve Gamma 400G turbines with an installed power of 37kW per turbine. On each side of the blast chamber six turbines are mounted at an angle. This turbine arrangement ensures that the plates are evenly covered by the blast media across their entire width. The total blast media throughput per machine amounts to 12,000kg/minute – a huge quantity compared to the throughput of between 2,000 and 3,000kg in standard shot blast machines.

The high media throughput posed a particular challenge for the wear protection of the two machines. This challenge was met by fabricating the blast chamber from manganese steel and lining it with 10mm thick, easily replaceable, wear plates, also made from manganese steel.

For shot blasting operations, where a higher surface roughness is specified, each machine can be run separately. In such cases the transport speed of the steel plates is reduced to four metres per minute. To prevent media spillage, each machine is equipped with a high-performance blow-off system.

Extremely sturdy design facilitates maintenance The large size of the steel plates and their high weight demanded an extremely sturdy design of the two shot blast machines. For example, the maximum load per running metre amounts to four tons. The overall machine dimensions are also impressive: The entire system is 17 metres long and 14 metres high. It was placed

MATERIAL REMOVAL in a pit with a depth of 2.5 metres. The blast media cleaning system and media hopper were placed on the roof of each shot blast machine. For quick and easy maintenance the machines are equipped with four inspection platforms on different levels that can be easily reached by suitable stairways. This enhances the already impressive appearance of the shot blast system, designed for processing 315,000 tons of stainless steel plates.

Level 2 control system designed for fully automatic operation The production unit consisting of the two Rosler shot blast machines and the pickling line is equipped with a level 2 control system. This upper-level system provides all the data required for the process, for example, the plate type and the required surface roughness. The information also specifies whether a special plate type must pass through both shot blast machines or just one. This ensures that the required surface roughness and finish values are achieved without any manual intervention whatsoever.

Shipped to China in 21 containers The entire vertical shot blasting system was designed and built in Germany. It was shipped to China by sea in 21 containers. Rösler service engineers, some of them from Germany, installed the system at the customer’s location. Another challenge was that the installation had to take place during a time of strict Chinese travel restrictions and quarantine regulations. In addition, the installation had to be carefully coordinated with the service engineers of the company supplying the pickling line. “Because of the extraordinary size of the shot blast system, only after the installation at TISCO could we test the entire system,” Vasili Schaermann, global sales expert at Rösler Oberflächentechnik GmbH said. “Such a test was not possible during the production phase at our Untermerzbach plant in Germany. Fortunately, the commissioning at the customer location was successful. Actually, the entire project went very well.

Impressive size: The vertical shot blasting system is 14m high and is placed in a pit with a depth of 2.5m. Four inspection platforms with stairways enhance the impressive appearance of the equipment.

In the future we will build other vertical shot blast machines, and I would like to point out that we are pleased with the cooperation between TISCO and Rösler.” The customer was very satisfied with how the project was handled and the achieved shot blasting results. The customer’s employees were particularly impressed by the ability of the Rösler experts to fully satisfy the TISCO demands.

The big, sophisticated shot blasting system from Germany will certainly help TISCO to strengthen its position as one of the leading stainless manufacturers in the world. rosler.com

The rise of material removal robots Automated Solutions Australia is able to offer the full range of material removal robots from FANUC. In the dynamic landscape that is Australian manufacturing, the advent of material removal robots marks a significant leap forward for global competitiveness and sovereign capability. From cutting and grinding to deburring, polishing, sanding, and buffing, robots are transforming tasks while redefining workplace safety and efficiency. Manufacturers increasingly turn to robots for tasks that pose health risks to human workers. Robots minimise exposure to hazardous conditions, enhancing workplace safety in applications such as sanding, grinding, and cutting. In an era of skilled labour shortages, these robots offer a reliable solution, maintaining quality and consistency in the final product.

Companies like FANUC are at the forefront of this revolution with their LR Mate series, known for their compact design and versatility.

These robots can handle a range of part sizes and shapes, ensuring that there's a robot for virtually every deburring task. Similarly, robotic cutting systems have revolutionised precision and efficiency, significantly reducing operator errors and material waste.

On the polishing front, manufacturers employ robots to achieve custom finishes with unparalleled consistency, all without compromising on quality. Integrating robots in sanding processes accelerates the task, while having the added benefit of shielding workers from hazardous environments laden with dust and debris.

Technologies like FANUC Force Sensors and iRVision further

enhance the sophistication of these robots.

Force Sensors enable robots to detect and respond to the force exerted, allowing for precise deburring, grinding, and polishing. iRVision, on the other hand, provides real-time error detection, ensuring impeccable quality and consistency. Programmed correctly and designed with integrated parameter control, robots can be your best operator, on his best day, all day, every day. When you partner with an experienced system integrator like Automated Solutions Australia, expect a consistent, repeatable outcome, job to job, and day after day.

The future of material removal robotics The scope of material removal robots continues to expand, encompassing tasks like buffing, deflashing, degating, gouging, and drilling. With continuous technological advancements, robots are becoming indispensable in every manufacturing process, driving efficiency, safety, and innovation to unprecedented levels.

It’s not just about automating tasks; it's about opening new frontiers in manufacturing, where precision, safety, and efficiency go hand in hand with technological innovation. A robotic material removal system is an investment in the future for Australian manufacturers looking to shore up their manufacturing and compete on a global scale with precision, repeatable parts automatedsolutions.com.au

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MATERIAL REMOVAL

Grade GC4405 New steel turning Grade GC4405 for high feed roughing, is designed for high metal removal rates.

Cutting tool and tooling system specialist Sandvik Coromant has introduced a new grade in its new generation steel turning series.

Grade GC4405 is first choice for high metal removal rates in stable conditions, especially in harder steels. The possibility to machine dry in softer steels opens up for more sustainable machining.

Sandvik Coromant also recently introduced steel turning grades GC4425 and GC4415. The new generation grades have been refined in every aspect, delivering an average 25% increase in tool life compared to previous grades. “With the introduction of GC4405, we are complementing the steel turning grade chain within the high feed roughing area”, says Torbjörn Ågren, Product Application Specialist at Sandvik Coromant. “We strive to make it as easy as possible to choose and apply the correct grade to match the specific application.” Grade GC4425 delivers wear resistance, heat resistance and toughness in a wide application range, while grade GC4415 complements GC4425 with enhanced performance when more heat resistance is needed. Grade GC4405 should be applied as a high feed productivity optimizer with high metal removal rates in stable conditions where plastic deformation properties are demanding.

Among the features coming with the new grade is a new carbide substrate with optimised microstructure, which will reduce plastic deformation in high feed applications. The substantial increase in plastic deformation resistance has enabled a drastic expansion in the application range towards harder steels and higher productivity compared to existing grade GC4305. New grade GC4405 features second generation Inveio® technology coating, with this coating version designed specifically to combat crater wear common to P05 applications. What makes second generation Inveio different from the earlier generation is the alumina coating, where the crystals are lined up in an even more vertical orientation towards the top surface to improve wear resistance, bringing a more consistent quality and performance.

AMT DEC/JAN 2024

The new grade provides a considerable increase in productivity and tool life, particularly when machining steels above 300 HB. The grade is also suitable for machining softer steels — in this case without the need of coolant, which is a noteworthy opportunity from a sustainability point of view. Comprehensive tests conducted between existing GC4305 and next generation steel turning grade GC4405 indicate an increase in tool life ranging from 30% up to 130%, mainly a result of significantly improved plastic deformation and crater wear resistance.

Grade GC4405 is recommended for continuous roughing to semifinishing in stable conditions and long time in cut. It is suitable for high feed machining with medium, roughing or wiper geometries in harder steels above 300 HB or for high feed and/or high speed machining in softer steels below 300 HB. The grade should be applied in ISO application area P05 (P01–P10). It is optimized for P2.5 low-alloyed hardened steel, but also recommended for high productivity applications in low-alloyed P2.1 and unalloyed P1.2 steel. sandvik.coromant.com

Come Join Us! The Australian Manufacturing Technology Institute Limited (AMTIL) is the peak national body that represents the interests of manufacturing technology suppliers and users within the precision engineering and advanced manufacturing sector.

Whether you are a manufacturer, importer or distributor, or a general manufacturing technology company we have various membership offerings with which to help you and your business.

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Australian Manufacturing Technology Institute Limited Suite 10, 5 Corporate Boulevard Bayswater VIC, 3153 Australia T 03 9800 3666 F 03 9800 3436 info@amtil.com.au

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FORUM LAW

Exit Smart Report Planning ahead will help you to ‘exit smart’. Jeremy Raniti looks at the results of William Buck’s 2023 Exit Smart survey.

As part of William Buck’s 2023 Exit Smart survey, over 300 business owners and key decision-makers were asked a series of questions designed to evaluate their readiness for an exit. The results of this survey, which are detailed in William Buck’s fourth leading Exit Smart Report, show that the majority of respondents (more than 70%) plan to exit their business within the next decade, but that six in ten do not have an exit strategy. This article explores key stages in the exit planning process that can help business owners to maximise their after-sale proceeds, minimise tax on those proceeds and exit successfully on their terms.

Timing William Buck’s Exit Smart Report 2023 sheds light on the significance of timing in the exit planning process. For instance, it indicates that retirement is a key time-based driver that leads business owners to an exit, but it’s not the only one. Knowing when to commence the planning process and when to seek professional advice are critical to a successful exit. Those who wish to consider an IPO, for which corporate governance and financial reporting are key measures of success, also need to consider timing. And, when a business is facing distress, seeking professional advice as early as possible will help owners to turn their business around prior to exit.

Value Too often, exit plans are seen as an afterthought in the sale process.

This neglect leads to a discrepancy between the business owners’ perceived value and the market value of a business. Advisors can help both owners and C-suite management maximise the value of their business by developing a thorough and detailed plan. A Corporate Finance or Business Advisor will have expertise in assisting with and completing transactions, often including mergers and acquisitions, private equity buyouts and IPOs; and tend to have a wide range of industry contacts and a deep understanding of the sentiment among potential buyers.

AMT DEC/JAN 2024

Tax minimisation William Buck’s Exit Smart Report 2023 suggests that business owners often overlook the structure of their business when embarking on an exit. Nearly 59% of respondents revealed they had not considered the best ownership structure to maximise after-tax sale proceeds upon exit. This alarming statistic indicates that the majority of business owners risk losing a large portion of their sale proceeds to preventable income tax. Working alongside an advisor during the exit planning stage can help avoid such risks. An advisor can undertake an assessment of the current structure and proactively review potential strategies to ensure nothing is left to chance.

Post sale Exiting a business can be a difficult experience that encompasses joy, sadness, nostalgia and endless opportunities for the future.

Professional advisors understand the importance of this stage and aim to both safeguard the financial stability of these business owners and proactively assist them with their wealth creation plans.

Conclusion William Buck’s leading report clearly demonstrates that while many business owners are planning to sell their enterprise within the next decade, there is a significant lack of preparedness among them.

A lack of awareness on how to maximise the sale value of their enterprise, or even who would buy the venture, is setting many owners up for a less-than-optimal exit outcome. Maximising the after-sale proceeds, minimising the resulting tax impost and ensuring a seamless path through the sale process all happen best when guided or supported by professional advisors. Connect with William Buck experts to lay plans for an exit at an early stage – preferably several years out from an exit date. In our experience, it's never too early to undertake exit planning, with some of the most successful business owners having planned their exits when first establishing their business. williambuck.com

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FORUM CONTRACTS

Breaching contracts Strengthened unfair contract term laws: what does it mean for manufacturers? Julia Cameron talks straight.

Businesses using standard form contracts — such as trading terms and conditions and online click-through agreements that are not routinely negotiated — are at risk of breaching strengthened unfair contract term (UCTs) laws under the Australian Consumer Law (ACL) which came into force on 9 November 2023.

While the UCT regime has applied to standard form contracts since 2016, the reforms will, among other things, significantly broaden the scope of contracts to which the UCT laws apply and markedly increase the penalties for using or relying on unfair contract terms.

What is a standard form contract?

A standard form contract is one that is prepared by one party without the other party having an effective opportunity to negotiate its terms, or one that issued repetitively to multiple parties on a ‘take it or leave it’ basis. Many manufacturers and suppliers are likely to use trading terms and conditions which will be considered standard form contracts as these terms are typically not negotiated for each supply. A standard form contract can be either a consumer contract or a small business contract.

A consumer contract concerns the supply of goods, services or the sale or grant of interest in land wholly or predominantly for personal, domestic or household use or consumption where at least one party is an individual. A small business contract is where at least one party employs 100 or fewer persons or has an annual turnover of less than ten million dollars.

Prior to the recent changes, a small business contract was one which had an upfront price of less than $300,000 or a duration of more than 12 months and an upfront price of up to $1,000,000.

The new definition of small business contract will mean many more contracts will fall within that definition and become subject to the new laws.

What is an unfair contract term?

Key changes In addition to the expansion of the definition of ‘small business contract’, the key changes to the UCT are as follows: •

•

•

•

•

UCTs are now unlawful — it will be an offence to enter into a standard-form contract that contains an unfair term or seek to rely on an unfair term in a standard form contract; the definition of ‘standard form contract’ has been expanded to include contracts where the other party is provided with an opportunity to negotiate insignificant changes or to choose from a range of specified options; the Courts now have the power to impose pecuniary penalties of up to $2.5m (for individuals) and for companies, the greater of $50m; and if the Court can determine the value of the benefit obtained from the contravention — three times the value of the benefit derived from the contravention of the UCT; or if the Court cannot determine the value of the benefit — 30% of the company’s annual turnover for the 12-month period prior to the contravention.

A term is unfair if it satisfies the following three limbs:

Timing

•

The strengthened UCT laws will apply to standard form contracts entered into or varied from 9 November 2023. Existing contracts which are in place as at 9 November 2023 will remain subject to the old UCT regime.

it causes significant imbalance in the parties’ rights and obligations arising under the contract; and • is not reasonably necessary to protect the legitimate interests of the party advantaged by the term; and • it causes detriment (financial or otherwise) to a counterparty if it were to be applied or relied on.

This means each term which may potentially breach the UCT regime needs to be considered in the context of the contract and the circumstances of the contracting parties — there is not a ‘onesized fits all’ approach to determining if a clause is a UCT. However, the ACL does provide a number of non-exhaustive examples of UCTs. UCTs generally permit one party (usually the supplier of goods and/or services), but not the other (usually a consumer/small business) to: • • • • • •

avoid or limit their obligations under the contract (including under indemnity or limitation of liability clauses); terminate the contract; vary the contract terms; renew or not renew the contract; vary the price payable without termination from the counterparty; and unilaterally determine whether the contract has been breached or interpret its meaning.

For manufacturers and suppliers who sell their goods and services in accordance with a purchase order and invoicing practice, and on the supplier’s trading terms and conditions, this is likely to mean that all sales made from 9 November 2023 will be subject to the new UCT regime.

What do you need to do?

We have been working with clients across the manufacturing and related industries to identify their existing standard form contracts and to review, amend and improve their contracts to ensure compliance with the new reforms.

We also can carry out internal compliance training for businesses.

The seriousness of the penalties for non-compliance means businesses who use standard form contracts simply cannot afford to ignore these changes.

For more information on the UCTs regime and to discuss your requirements, please contact Julia Cameron, Partner – Corporate & Commercial, at Rigby Cooke on 03 9321 7807, or a member of our Corporate & Commercial team. rigbycooke.com.au

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FORUM BUDGETS

WA powering up Thriving innovation ecosystem key to scaling WA’s manufacturing ingenuity.

The manufacturing sector in Western Australia continues to evolve.

Once inextricably linked to the natural resources sector, the state’s manufacturing capability is now seen as an engine for diversifying the local economy and opening trade and investment opportunities.

High-growth opportunities have been identified in segments from value-added food production, battery and renewable energy, and critical minerals processing to medical devices and space technologies. That’s set to build on what’s already one of WA’s most valuable industries. In the latest figures from 2021-222, manufacturers contributed almost $19bn towards WA’s Gross State Product, up from $15.3bn the year before. In the same year, its workforce was nearly 90,000 strong and expanding.

Realising future growth and capturing diversification opportunities will rely on WA’s advanced manufacturing ecosystem. Encouragingly, the state has already emerged as a nexus for innovation, developing and producing high-tech products for a range of industries.

This enviable capability and growth potential are partly thanks to close collaboration between manufacturers, suppliers, industry stakeholders, research institutions, and public sector organisations.

Evidence of novel solutions and the commercialisation of innovative products can be found across the WA economy, says CommBank’s National Manager of Manufacturing, Maria Christina.

"Our research earlier this year showed that technology investment was the top strategic priority for manufacturers across the nation, and the sector in WA is a prime example," she said.

"Working alongside industry, and with the support of research institutions, we’re seeing WA manufacturers harnessing this investment to drive progress in areas from helping the energy transition to ensuring customers better manage their operations."

Homegrown manufacturing innovation Among the many WA-based manufacturers taking innovative products to the world, are Magellan Power and Roborigger. Both are examples of the power of collaboration across the manufacturing ecosystem and innovative approaches to problem-solving.

Masoud Abshar, Director at Magellan Power, says the manufacturer puts innovation at the heart of its strategy, constantly listening to customers and empowering its teams to develop new ideas. He says this has led to new products, from camera-based cloud detection equipment for solar energy to home and utility-scale energy storage systems.

Another example of homegrown innovation is Roborigger, a manufacturer reimagining lifting and logistics operations. The company’s flagship Roborigger unit is a remote-controlled robotic device that connects to a crane’s wire rope and holds the load in position. In 2021, Roborigger established its manufacturing facility in Wangara as it scaled up to meet local and global demand. The facility was opened by the WA Innovation and ICT Minister.

Roborigger founder Derick Markwell, says, "The spark for innovation doesn’t come when you’re hunting for it. It’s more about understanding a problem, demonstrating a workable technical solution with a captive market."

Collaboration drives innovation Both Magellan Power and Roborigger have developed strong internal research and development capabilities and have benefitted greatly from partnerships with local research institutions.

AMT DEC/JAN 2024

One such research institution as part of this includes Innovation Central Perth (ICP) – an industry and research collaboration centre led by partners, Cisco and Curtin University. Its vision is to bring together companies, researchers, and industry experts to advance digital transformation through an open ecosystem.

As a commercial enterprise, ICP is contracted by public and private sector organisations to identify, test, analyse, and deploy innovative technology. It is focused on original solutions through concept testing, prototype development, and integration analysis.

ICP, established in 2016, has refined their engagement model, leveraging student talent from disciplines like engineering, data science, and computer science. It works closely with customers, including manufacturers, to solve complex challenges through twoto four-month projects. ICP has established long-term relationships with companies, like Roborigger, who has engaged with the centre’s Summer Internship Program.

The internship was part of an effort to improve the internetconnected tracking software with Roborigger. The built-in software collects data from every lift, including time, weight, and the location of the lifted loads.

"I work with four universities in WA and have collaborated with them on various projects," Masoud says. "We gather ideas from collaborators, suppliers, teams, and customers and take them to universities to start a project. But instead of just asking them to create something, we work together to ensure successful results."

A bright future Recognising that this sector is a vital driver of economic growth, the WA Government aims to foster further innovation, create new avenues for product development and export markets, and unlock fresh opportunities through grants and funding schemes.

"It's an exciting time for the manufacturing industry in WA, with endless opportunities on the horizon," Maria Christina says. cba.com.au Disclaimer: Things you should know: This article is intended to provide general information of an educational nature only. It does not have regard to the financial situation or needs of any reader and must not be relied upon as financial product advice. You should consider seeking independent financial advice before making any decision based on this information. The information in this article and any opinions, conclusions or recommendations are reasonably held or made, based on the information available at the time of its publication but no representation or warranty, either expressed or implied, is made or provided as to the accuracy, reliability or completeness of any statement made in this article.

Commonwealth Bank of Australia ABN 48 123 123 124. AFSL and Australian Credit Licence 234945.

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FORUM FINANCE

Mandatory Sustainability Reporting What does MSR mean for manufacturers? Dylan Byrne, Partner, Business Services at BDO in Australia reports on the new paradigm of climate-related environmental reporting.

The drive for mandatory sustainability reporting is gaining momentum globally, including in Australia. The Australian Government’s latest Treasury Consultation Paper proposes a three-year implementation approach for large entities to prepare sustainability reports, including climate-related financial disclosures.

By 2027-2028, all large Australian entities - including large proprietary companies lodging financial reports with the Australian Securities and Investments Commission (ASIC) - are expected to be required to make sustainability-related financial disclosures. The anticipated timing for entities is based on the number of employees, value of assets, consolidated revenue, and requirements under the National Greenhouse and Energy Reporting Act 2007 (NGER Act), and grouped into the following timeframes: • Group 1 entities – 2024-2025 onwards • Group 2 entities – 2026-2027 onwards • Group 3 entities – 2027-2028 onwards.

However, small, and medium entities (SMEs) that do not lodge financial statements with ASIC are not necessarily exempt. This is because the Australian Government has assessed that companies already required to lodge financial statements are at a scale that warrants these extra disclosures.

Value chains Small- to medium-scale manufacturers may be indirectly caught up in sustainability reporting through their role in the supply chain. With most manufacturers selling their products to larger businesses, there is every chance those companies will seek to engage or pass on responsibility for carbon footprint reductions and other ESG (that is, environmental, social and governance matters) requirements to their supply chains.

Many large entities and groups have started publicising decarbonisation commitments such as ‘net zero by 2050’. To achieve these targets, they must ensure all suppliers, customers and service providers throughout the value chain have similar commitments. We are already seeing instances where businesses are given no choice but to measure their carbon footprint and prepare sustainability disclosures because customers demand it.

In many cases, assurance or verification of carbon footprints is also required. We have also seen large corporates imposing renewable energy targets on their suppliers.

If not already, ESG considerations (particularly environmental) will soon impact decision-making throughout the manufacturing supply chain. Australian manufacturers should be taking steps to demonstrate they are proactive in this space to maintain supply contracts and their position as an employer of choice for discerning potential employees.

Measuring a carbon footprint From a short-term, mandatory perspective, SMEs may be able to avoid measuring their carbon footprint, but doing so earlier than required may mean a more straightforward process with more positive outcomes. All organisations will need to reduce emissions through the value chain, which can only be assessed and communicated by measuring their carbon footprint.

An entity’s carbon footprint consists of: •

Scope 1 emissions – emissions created within a facility (under the control of the entity)

• •

Scope 2 emissions – from purchased electricity or steam Scope 3 emissions – indirect emissions from suppliers of goods and services (upstream activities) and customers (downstream activities).

The critical thing for manufacturers to remember is that their total emissions become the customers’ Scope 3 emissions. If these customers seek to reduce their Scope 3 emissions (which typically comprise a large chunk of their total emissions), manufacturers may be seen as an obvious choice for driving overall carbon reductions.

There are numerous ways of approaching a carbon footprint measurement, so making the right choices around designing the process, data capture, software selection, choosing the right emission factors, etc., is critical. Engaging with an expert who can talk you through the options and right approach for your business will lead to the best possible outcome.

Need help?

No matter the size of your business or where you are on your sustainability journey, BDO’s national team of sustainability experts can help with: • • • • •

Carbon footprint calculations or mandatory climate-related disclosures Carbon emission reduction strategies Sustainability reporting Developing your sustainability strategy Assurance over your carbon footprint or sustainability reporting.

bdo.com.au

AMT DEC/JAN 2024

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AMTIL INSIDE

Recent AMTIL activity As we finish off another year I am often asked – “so what has AMTIL been up to recently?” As a result, I started sending members a monthly update in dot form of the things we have been doing for our members each month.

I thought it might be appropriate to share this summary of activity over the past few months to give our readers a bit more enlightenment on what it is we get up to. So here is the summary of the past couple of months: In dot form, some of the activity for October and November included: •

•

•

•

•

We held our Annual General Meeting on the 26th October during which we had two new Directors appointed, so please join me in welcoming Johanna Boland from ANCA and Phil Bowles from Spee3D to our Board. The Board now has eight Directors with Annaliese Kloe (Headland Technology), Brigitte Stavar (Sheetmetal Machinery Australia), Mark Dobrich (John Hart), Pat Green (Automated Solutions Australia) Paul Philips (Benson Machines) and Peter Sutton (Sutton Tools) along with Johanna and Phil representing you as members.

Following the AGM we held a Board Meeting and the Board confirmed Brigitte Stavar as our President for another twelve months. Brigitte has been President for the past four years and has helped guide us through a very difficult period of COVID, loss of revenue due to show cancellations and a move to new premises which we purchased in September 2021. I am sure you will join me in thanking Brigitte for her continued efforts in this role.

We have sold 90% of the space available at AMW2024 in Sydney and there is not much left. So if you have any interest in exhibiting please email Anne Samuelsson at asamuelsson@ amtil.com.au We sent out the Oct/Nov issue of AMT magazine and uploaded it to our website at amtil.com.au/amt. Any interest in advertising can be directed to Nicholas Raftopoulos at nraftopoulos@amtil.com.au We have recently created a page on our website for AMTIL Member Events so if you have an event or activity coming up that you think we could help you promote, then please send it through to our Corporate Services Manager, Greg Chalker at gchalker@amtil.com.au for his consideration.

•

•

•

•

•

•

If you have been following the progress of our Skill Up & Placement Program you will know that we ran another pilot program in Western Sydney at Mt Druitt TAFE in November.

Greg has been in Sydney pulling this together that resulted in 11 people being trained as CNC operators and all of them back into the workforce through our Sydney members.

AMTIL signed as a Silver Sponsor for the Victorian Manufacturing Showcase that was held at Moonee Valley Racing Club on 21st November. Go to https://djsir.vic.gov.au/ about-us/news/victorian-manufacturing-showcase for more information.

We have had significant content being put through our social media platforms. If you don't already follow us on social media please have a look at our platforms on Facebook, LinkedIn, X and Instagram and follow us if you want to.

We held networking events in Brisbane on 23rd November and Adelaide on 30th November with many members joining us to celebrate the festive season.

We have confirmed our commitment to a new Additive Manufacturing Cooperative Research Centre bid that is being currently proposed to the Commonwealth. This is a huge opportunity for AMTIL members to take advantage of research grants that will be available through the CRC if it is successful in it’s application.

In my role as Chair of RMIT’s Centre for Additive Manufacturing (CAM), we held our annual meeting to hear what the CAM has achieved over the past twelve months. We were very pleased to hear the Centre is rated in the top 20 in the world for performance across some criteria within the tertiary system.

AMTIL is also celebrating 25 years of business in 2024, so please look out for lots of information on how we are going to celebrate.

We are also running a number of networking events and Christmas celebrations in December so please check them out at amtil.com. au/events/amtil.

May I take the opportunity to wish all of our readers a safe and prosperous festive season and I look forward to starting the New Year in good health and happiness.

Shane Infanti, CEO AMTIL

AMT DEC/JAN 2024

AMTIL HEADING INSIDE

Out West AMTIL tour of the Edith Cowan University Advanced Manufacturing Hub. About 30 WA-based AMTIL members joined up for an exclusive tour of the Edith Cowan University Advanced Manufacturing Hub. The is one of Western Australia's leading facilities in 3D printing technologies and advanced additive manufacturing.

ECU’s research and engineering expertise delivers innovative solutions, tackling the pressing challenges facing industry today.

The mission of the Advanced Manufacturing Hub here in Perth is to accelerate the adoption of Additive Manufacturing in the state. At ECU, there is a wide range of equipment and expertise to assist in the education around additive as well as traditional manufacturing, and advanced materials testing. The GE Additive Concept Laser

Metal 3D printer in the Hub is set to help this promise. The AMTIL tour included a guided-lab tour and an interesting presentation from Alex Rassau in the Electrical Engineering faculty. Rassau, Course Coordinator at School of Engineering, spoke about the advanced additive manufacturing technologies, and took us on a tour of manufacturing and motorsports workshops on the campus.

Stephanie Dirksz, the Manager of the Industry Development Unit, Dept of Jobs, Tourism, Science and Innovation, presented about the progress of the WA Government's Advanced Manufacturing scheme. ecu.edu.au

1382V4AMTIL

AMTIL gratefully acknowledges the support of its Corporate Partners.

AMTIL’s corporate partners offer a selection of products and services that will benefit our members in their business.

For any enquiries about our Corporate Partnerships, and how they can benefit you, contact Anne Samuelsson on 03 9800 3666 or email asamuelsson@amtil.com.au

Our Partners. Our Members.

Your Benefits.

amtil.com.au

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AMTIL INSIDE Take control of your entire business, from supply chain to sales, with Sage X3.

AMTIL AGM A great breakfast, and positive economic currents at the AMTIL AGM. The 2023 AMTIL AGM was in late October at the Riversdale Golf Club, a popular Melbourne venue for our association events. The occasion was well attended with a breakfast crowd of around 120, as always a great opportunity to touch base with industry mates.

Two new Directors were appointed to the AMTIL Board that morning. Welcome to Johanna Boland from ANCA and Phil Bowles from Spee3D, coming onto the Board. There are now eight Directors with Annaliese Kloe (Headland Technology), Brigitte Stavar (Sheetmetal Machinery Australia), Mark Dobrich (John Hart), Pat Green (Automated Solutions Australia) Paul Philips (Benson Machines) and Peter Sutton (Sutton Tools) along with Johanna and Phil now representing members.

Plaques were given out to companies with ten and twenty years of memberships: Ten Year plaques were presented to PLG Gearcutting Services, Brampton

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N3D NAGLE 3D - ADELAIDE Industrial Grade 3D Printing

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AMT DEC/JAN 2024

Sheetmetal, Ajay Engineering, JBO Engineering, Stahl Engineering, Whitelaw Engineering Machinery, Robert Bosch Australia and Melbourne Centre for Nanofabrication.

Twenty Year plaques were given out to Techni Waterjet, Sheetmetal Tooling Tech, Jenkins Bros and APT. The weather was glorious outside, and welcome positive financial results were in Shane’s address, thanks to a successful AMW2023 in Melbourne and the continued excellent showing each couple of months in the popular AMT magazine which you are holding.

The featured presenter was NAB economist Trent Nugent who delivered a no-holdsbarred address about the world’s financial health. His summary dug into the moves of various sectors of the Australian economy where the shifts and influences are felt deepest in our manufacturing industries. amtil.com.au

AMTIL INSIDE

New Members AMTIL would like to welcome the following companies who have signed up as new members of our association.

NANO DIMENSION AUSTRALIA PTY LTD

SUPERIOR SAWS PTY LTD

2.102/477 Pitt Street HAYMARKET, NSW 2000

138 Gipps Road SMITHFIELD, NSW 2164

nano-di.com

superiorsaws.com.au

NATURAL COOL AIR

SYSPRO AUSTRALASIA

6 Machinery Road YANDINA, QLD 4561

201 Kent Street SYDNEY, NSW 2000

naturalcoolair.com.au

au.syspro.com

OUTERSPACE DESIGN GROUP PTY LTD

TROAX SAFETY SYSTEMS

50 Duke Street ABBOTTSFORD, VIC 3067

Unit 17, 148 Kames Ruse Drive ROSEHILL, NSW 2142

outerspace.co

troax.com

Heading back to UniSC The AMTIL Advanced Manufacturing event was hosted at University of the Sunshine Coast Moreton Bay campus.

There were experts from various fields, backgrounds, and industries together at the USC Moreton Bay campus to share their unique perspectives, fostering a rich tapestry of ideas and insights. One of the key highlights was the incredible diversity of thought that permeated every discussion.

Kirsty Marks presented on behalf of City of Moreton Bay about the region's innovative manufacturing sector, and attendees were able to get a firsthand look at UniSC's impressive STEM facilities including the R&D technology and state of the art labs and equipment.

Collaboration was definitely at the heart of the event, as representatives from academia, industry, and government sectors, including a presentation by Department of Regional Development, Manufacturing and Water.

Attendees engaged in thought-provoking discussions, inspiring new approaches and solutions to industry challenges.

PACIFIC AUTOMATION

THUNDER LASER AUSTRALIA

45 Solomon Road JANDAKOT, WA 6164

3 Pipi Place MOUNTAIN CREEK, QLD 4557

pacificautomation.com.au

thunderlaser.com.au

PULSE LASER SYSTEMS

TS LOH PTY LTD

Unit 10, 39 Grice Street CLONTARF, QLD 4019

3/9 Nicole Close BAYSWATER NORTH, VIC 3153

pulselasersystems.com.au

visionmeasuringoceania.com.au

SBH SOLUTIONS

WORLD FIRST PTY LTD

3 Ballantyne Street MAGILL, SA 5072

Level 5, 261 George Street SYDNEY, NSW 2000

sbhsolutions.com.au

worldfirst.com

SSCUSTOM

ZEMBL

28 Palmaston Drive GREENVALE, VIC 3059

Level 5, 100 William Street SYDNEY, NSW 2000

sscustoms.com.au

zembl.com.au

The success of this event reinforces the importance of bringing together diverse voices, fostering innovation, and promoting sector collaboration. It's a testament to the bright future of advanced manufacturing in the Moreton Bay region and the role that organisations and institutions like AMTIL and University of the Sunshine Coast play in shaping it.

Thank you to the University of the Sunshine Coast team for their hospitality and insightful tour. usc.edu.au

AMT DEC/JAN 2024

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INDUSTRY CALENDAR During the COVID-19 pandemic, many industry events world-wide were postponed, rescheduled or cancelled. Readers are advised to check with all event organisers for the latest information. For the latest international travel advice, please visit smartraveller.gov.au For more events, please visit amtil.com.au/events INTERNATIONAL MANUFACTURING INDONESIA INDONESIA, Jakarta 6-9 December 2023

CCMT MACHINE TOOL FAIR CHINA, Pudong 8-12 April 2024

MMMM INDIA, New Delhi 29-31 August 2024

manufacturingindonesia.com

ccmtshow.com

mmmm-expo.com

SEMICON, JAPAN JAPAN, Tokyo 13-15 December 2023

MACH UK, Birmingham 15-19 April 2024

AMB GERMANY, Stuttgart 10-14 September 2024

semiconjapan.org

machexhibition.com

messe-stuttgart.de

2024

SIMTOS KOREA, Goyang 22-26 April 2024

BI-MU ITALY, Milan 9-12 October 2024

simtos.org

bimu.it

HANNOVER MESSE GERMANY, Hannover 22-26 April 2024

EUROBLECH 2024 GERMANY, Hanover 22-25 October 2024

hannovermesse.de

euroblech.com

AISTECH USA, Ohio 6-9 May 2024

JIMTOF 2024 JAPAN, Tokyo 5-10 November 2024

aist.org/conference-expositions/aistech

jimtof.org

FABTECH MEXICO, Nuevo Leon 7-9 May 2024

ADVANCED DESIGN & MANUFACTURING EXPO CANADA, Montreal 13-14 November 2024

STEELFAB UAE, Sharjah 8-11 January 2024 steelfabme.com

EUROGUSS GERMANY, Nurnberg 16-18 January 2024 euroguss.de/en

ALL ABOUT AUTOMATION GERMANY, Hamburg 17-18 January 2024 allaboutautomation.de

IMTEX FORMING INDIA, Bangalore 18-23 January 2024 imtex.in

SEMICON KOREA KOREA, Seoul 31 January-2 February 2024 semiconkorea.org

ATX WEST USA, Anaheim 6-8 February 2024 imengineeringwest.com

SIMODEC FRANCE, La Roche-Sur-Foron 4-8 March 2024 salon-simodec.com

ASIAMOLD CHINA, Guangzhou 4-6 March 2024 asiamold-china.cn.messefrankfurt.com

ALL ABOUT AUTOMATION GERMANY, Friedrichshafen 5-6 March 2024

mexico.fabtechexpo.com

NPE USA, Florida 6-10 May 2024 npe.org

3D PRINT CONGRESS & EXHIBITION FRANCE, Chassieu 4-6 June 2024 3dprint-exhibition-lyon.com

INTERTOOL AUSTRIA, Vienna 4-7 June 2024 intertool.at

ASSEMBLY & AUTOMATION TECNOLOGY BANKOK, Bitec 19-22 June 2024 assemblytechexpo.com

M-TECH JAPAN, Tokyo 19-21 June 2024 manufacturing-world.jp

allaboutautomation.de

SITL FRANCE, Paris 19-21 March 2024 sitl.eu

KONEPAJA FINLAND, Tampere 19-21 March 2024 konepajamessut.fi Euroguss

AMT DEC/JAN 2024

admmontreal.com

METEC INDIA INDIA, Maharashtra 27-29 November 2024 metec-india.com

2025 METEF ITALY, Bolgna 5-7 March 2025 metef.com

MACHINEERING BELGIUM, Brussels 26-28 March 2025 machineering.eu

ADVANCED ENGINEERING SWEDEN, Goteborg 2-3 April 2025 advancedengineeringgbg.se

INDUSTRY CALENDAR HEADING LOCAL

Advertiser Index

2024

from: contractors, architects, engineers, housebuilders, developers, government and construction professionals.

AUSTRALIAN MANUFACTURING WEEK (AMW) ICC SYDNEY, DARLING HARBOUR 17-19 APRIL 2024 Showcasing the latest innovations, technologies and equipment in the advanced manufacturing sector. New opportunities, meet and network with industry leaders and technology experts, under ONE roof at ONE show.

sydneybuildexpo.com

CEMAT AUSTRALIA MELBOURNE CONVENTION & EXHIBITION CENTRE 23-25 JULY 2024 Leading technology and service providers in intralogistics, robotics and automation, warehousing, supply chain management and materials handling. Showcasing innovation and best practices in a wide variety of settings and sectors including e-commerce manufacturing, food industry and resources.

australianmanufacturingweek.com.au

APPEX MELBOURNE CONVENTION & EXHIBITION CENTRE 12-15 MARCH 2024 Australasia’s Processing and Packaging Expo is an exhibition representing all sectors of the industry, including machinery, ancillary equipment, materials and packaging, food processing and industry services. A full range of all processing and packaging equipment and services under one roof.

cemat.com.au

AUSTRALIAN WASTE & RECYCLING EXPO ICC SYDNEY 24-25 JULY 2024 Showcasing of full circle innovative products and sustainable solutions to collect, process and recycle waste more smartly. Future critical areas include Machinery & Equipment, Software & Services, Bins, Vehicles, Food & Organics and more.

appex.com.au

AUSTRALIAN AUTO AFTERMARKET EXPO MELBOURNE CONVENTION & EXHIBITION CENTRE 11-13 APRIL 2024 ’The Workshop of the Future is Here’, debuting a range of fantastic new initiatives and features. Showcasing the latest vehicle repair and servicing equipment, parts, tools and accessories, new technology and trends, an Awards evening plus a comprehensive training and education program.

awre.com.au

LANDFORCES 2024 MELBOURNE CONVENTION & EXHIBITION CENTRE 11-13 SEPTEMBER 2024 A centrepiece regional exhibition, the opportunities for business engagement at Land Forces will be considerable. Hosting senior international military, defence, government, scientific and industry delegations from around the world, Defence professionals and trade visitors at all levels will be in attendance.

autoaftermarketexpo.com.au

SYDNEY BUILD EXPO ICC SYDNEY 1-2 MAY 2024 Showcasing all the latest opportunities in NSW and Australia. Connects all key players in the industry and attracts attendees

landforces.com.au

ys, SA 5032

Applied Machinery

15

Bilby 3D

39

Complete Machine Tools

9

ECI Solutions

57

Formero

99

Hare & Forbes

4,5

HG Farley Laserlab Aust

13

IM Group

75

IMTS

17

Industrial Laser

65

John Hart

7

Kaishan Adv

85

LAPP Australia

114

Laser Machine

61

Machinery Forum

OFC

MTI Qualos

51, 95

Nagle 3D

114

Okuma

11

Raymax

71

Rigby Cooke

101

Sage Business Solutions

114

Southwell Lifts & Hoists

114

William Buck

IBC

Zembi

81

e

Nicholas Raftopoulos: 0431 753 381

Insert

AEROSPACE & DEFENCE RENEWABLE ENERGY & CLEAN TECH STATE SPOTLIGHT: TASMANIA

stem

SOUTH WALES

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Call me now for a no-obligation chat about how AMTIL can help.

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SPOTLIGHT: NEW

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Sydney Head Office and Technical Centr e Unit 7/16 Lexing ton Dr, Bella Vista NSW 2153

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16/11/2023

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AUSTRALIA’S NO. 1 ADVANCED MANUFACTURING MAGAZINE

ADDITIVE MANUFACTURING INDUSTRY 4.0 MATERIALS HANDLING MOTORS & DRIVES CUTTING TOOLS FORMING & FABRICATION COMPRESSORS & AIR TECHNOLOGY

AMT DEC/JAN 2024

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HISTORY

Big wheels & little wheels – the story of UK-born Australian Sir Laurence John Hartnett (1898 – 1986) Australia’s “Father of the Holden” and much more

PART 57

PRESENTING TO THE COMMITTEE

When all is said and done, it comes down to the right person speaking up in the right place, at the right time.

S

loan sat back. “Goddam country,” I heard him mutter. I could feel my confidence fading. Already I could see the words “not approved” being scrawled across our submission. It’s now or never, win or lose, I told myself. So I went in hard.

“Gentlemen,” I said, “there is no doubt in my mind that if private enterprise does not take steps to produce an Australian car, the Government will participate in forming a company to do it. They have already indicated this, and they mean it.

“I think the Government will leave open its invitation to private enterprise for two or three months before making a decision.

I believe, too, that at least two concerns, apart from ourselves, will respond to the Government’s request. I recommend that General Motors-Holden undertake the manufacture of complete motor-vehicles in Australia, preferably with a low-list-price car which will appeal to the largest group of potential buyers.

“I’m not confident that a relatively high return on investment will be earned; certainly not in the first few years. I feel it would be optimistic to estimate a higher return than 9-12%. But I’m thoroughly confident that, technically, the organisation in Australia – with assistance from the United States, will be able effectively to undertake the work, producing a satisfactory product at a satisfactory cost.”

The committee digested all this without comment, so I went on immediately to the next----and most touchy-part of the proposal: the share structure.

“If ordinary shares in the enterprise were held entirely by General Motors in the U.S., it would, I feel, be acceptable to the Government and to the public, but our position would be far stronger if local capital were subscribed to participate in the Australian company. I say this because any company coming into open competition with us in this field, which had Australian or English capital, would have a stronger appeal to the public and Government.”

Then, briefly, I sketched the alternative courses open to GM-H if it were decided not to manufacture complete cars. There was no reason to believe that GM-H would close up if it didn't produce an Australian car. I felt the business would continue, but on a reduced sale compared with pre-war days and it would progressively contract over the years. But if the car project were

approved, I said, I could see no reason why GM-H plants could not continue to supply bodies, some components, chassis, sheet-metal pressings and the like for local assembly of chassis on similar lines to the practice we had followed in making bodies for competitive makes. The third course would be to sell the GM interests in Australia to local shareholders, and from then onwards arrange for a licence agreement and royalties, so that the local shareholder carried all the risks and General Motors would be assured of a steady income from the sale of advice, technique and knowhow.

Well, there it was. Laid right on the line.

And still no comment from the committee members. Alfred P. Sloan stared ahead thoughtfully. The other members doodled on their pads. No one spoke for a full minute. I wasn't happy about the atmosphere.

Then, to my relief, a friendly voice spoke up from the table. It was Charles E. Wilson, the president, who was later to become United States Secretary for Defence under Eisenhower.

“I’d like to interrupt you at this stage, Larry,” he said. “You’re talking about making a car. Which of the cars would you plan to make?” Wilson’s question side-tracked the committee’s thinking about Australian politics and brought them back sharply to a business they knew better, car-making. I was grateful to him. The ball was back in my court, and I took it on the run.

“Mr. Wilson,” I said, “I think a car must reflect the economics of the country. I think it must embody the local materials and their peculiarities. Everybody’s steel and iron are a little different, and everybody’s need is a little different.

“We can’t just pick up someone else’s design and say we’re going to make it.

The car for Australia has to be designed for

Australia’s needs. It must be a completely new car. That is essential. The design would reflect the characteristics of the indigenous raw materials, and importantly, it would reflect the volume, the extent and the grade of tooling.”

There was a pause while that sank in. Then Charles Wilson said, enthusiastically, “Say, that sounds like darned good sense to me. Whether we’d be able to do it or not, I don’t know, but it sure rings a bell with me.

We’re so damn crazy when we always want to take our economics and our technique and transplant them in a place where it has totally different circumstances.

“Here we have a Chevrolet set up and designed for two million or three million production and somebody thinks they can go and make fifty thousand of them. It’s crazy, from the bottom up. But what Larry Hartnett is saying is common sense. I’m all for it: if Larry’s project warrants a car being made down there, let’s set it up right from scratch.”

When a fellow like Charles Wilson talks in that vein you can feel his enthusiasm reaching out and infecting people around him. From that moment there was a swing my way. I could sense it. My confidence came back with a rush. But, underneath everything, I got a strong feeling I wasn’t very popular with them. I’m sure, thinking back, that somebody had spread stories about me in GM. I’m certain they had linked me very closely with the socialist aspect of the Labour Government, and had said I was the activating force behind Chifley’s determination to produce a car-if necessary, a Government car. They knew I was a friend of Chifley and Curtin, and I’m positive they’d been getting reports from Australia that “this fellow Hartnett and the socialists are all buddies together-watch him!”

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT DEC/JAN 2024

To be continued…

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STILL MADE IN JAPAN

Sydney Head Office and Technical Centre Unit 7/16 Lexington Dr, Bella Vista NSW 2153

Melbourne Office and Technical Centre Unit 1/3-4 Anzed Ct, Mulgrave VIC 3170

Auckland Office and Technical Centre Unit 2/67 Business Parade South, East Tamaki, Auckland 2013

Perth Service Centre Butler, WA 6036

Brisbane Service Centre Stafford Heights, QLD 4053

Adelaide Service Centre Lockleys, SA 5032