Industry Update Issue 109 August/September 2019 Victorian Edition by Industry Update

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Issue 109 August/September 2019

MANUFACTURING MAGAZINE

DUST DEVILS The current industry focus on the dangers of silica dust has more to do with creating awareness of the problem than it is to do with any new causal discovery. However, it is clearly an awareness campaign that is long overdue. The causal link between respirable silica dust particles and the disease known as silicosis has been understood for decades. Indeed, the US Department of Labor produced a shocking public information film as long ago as the 1930s. However, changes to both materials and machinery in the intervening time have meant that exposure to higher levels of silica dust have become commonplace in industries that have not hitherto had suitable protocols in place.

DEALING WITH THE DANGERS OF COMBUSTIBLE DUST P18

In particular, the use of composite stone for worktops, dry cut with high-speed power tools by workers often in smaller companies that have traditionally taken a “pragmatic” view of WH&S practices, has been exposing workers to levels of dust probably far in excess of even the current workplace exposure standard of 0.1 mg/m3 (eight hour time weighted average). And it has only been the identification of illness clusters of acute silicosis in such professions that

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has brought the problem into the spotlight.

CONFIDENCE IN OUR GREAT STATE p6

IU TURNS FOUR CORNERS IN 60 MINUTES

In truth, respirable silica dust poses a risk to workers in many areas outside the worktop cutting industry – from agriculture and mining to tunnelling and from construction to renovation. And these risks are just as pertinent to volunteers and DIYers as they are to professionals. While different materials produce different levels of silica dust, the health risks are all about the cumulative exposure. So a regular activity of, say, drilling holes in concrete floors could constitute a long-term exposure risk if suitable

Industry Update is expanding its video production portfolio with a new series of documentary videos, initially looking at some of the key safety issues affecting our industry. In the first two-part mini-series we’ve turned our attention to the key topic of workplace traffic management – looking at the measures Australian Continued page 4

Continued page 4

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• EDITORIAL

PUBLISHER SCOTT FILBY

EDITOR LAURENCE MARCHINI

WHY ARE WE WAITING?

ABSOLUTE BEACHFRONT

As a small business owner myself, I can fully sympathise with the problems of small businesses in keeping control of cashflow thanks to late payments. And if the results of the latest survey by business software company Xero are to be believed, the situation is getting worse. So it is great to see the Federal Government leading the way and committing to paying small business invoices within 20 days. This new policy covers any new contracts up to $1 million, and came into force on 1st July. However, that Xero survey is just the latest in a long line of reports showing that Australia’s larger enterprises are not playing fair by their smaller suppliers, and it concludes that small and medium businesses are losing access to as much as $7 billion a year thanks to this approach by the big end of town. Not only does this slow the growth of smaller companies – or in extreme cases cause their failure – it is counterproductive to the economy as a whole. Companies only grow by re-investing their profits, and they can’t do that until they get the money to which they are due. In this respect the arrogance of some of Australia’s largest enterprises (and household names) is breathtaking. When the Government announced its intention to

Over the past few days I’ve been looking at some of the good work done by the manufacturing community in supporting charitable initiatives, both at home and abroad. Many of the stories are deeply heart-warming, and we will be sharing them in the Community section of the magazine in the coming months.

speed up its own payments last year, it also revealed plans to develop an annual reporting framework requiring large businesses over $100 million in turnover to publish their payment information. However, earlier this year when the office of the Australian Small Business and Family Enterprise Ombudsman set out to conduct a review of payment times, a number of companies were “reluctant” to reveal their payment terms, claiming that revealing them publicly would impact their competitive positions.

Clearly, there is a great sense of community within the industry, but I do question whether it is universal. And the aspect that concerns me most is our commitment to the health of the planet. Heck, I’ll use the C word…. It’s the climate.

That review was submitted to the Minister for Small and Family Business in April, and should serve as ample cause for the government to press ahead with its plan to force large companies to publish their payment information.

Don’t get me wrong. I appreciate that energy costs are a serious problem for manufacturing industry – particularly an industry that had traditionally relied on the nation’s comparative advantage in producing low-cost coal-based power.

Of course, it would be preferable for all companies to appreciate the benefits to the economy as a whole of keeping the money circulating as quickly as possible.

But please… those days are gone. There is a reason why nobody has built any new coal-fired generation plant this century. The sums just don’t add up.

But sometimes it seems the market does need a little impetus from government to make it see the light. And now that the government has got its own house in order, it’s time for business to follow suit.

The technology has changed, and renewables are more economical. Yes, there are still problems to be resolved with grid stability, but with the pace of change we are seeing in storage technology, there is every reason to be

Pay up. You know it makes sense.

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I regularly bite my lip when I hear climate change deniers extol the cost effectiveness of coal-based generation. Worse still are those who say Australia’s actions are insignificant in the global scale of things. This “I’m all right Jack” attitude is exactly counter to the sense of community with which I began this article. So when I hear that the Australian Government is going to the Pacific Island Forum with an agenda to water down that organisation’s declaration on climate change I wonder how we can have the gall to front up in such a way. The undeniable sea level rises brought about by man-made climate change might even be improving property prices in Australia. In fact my own home only needs a one-meter rise to become absolute beachfront. But by then many islands and island nations at that meeting would simply cease to exist. So much for community.

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• NEWS

IU TURNS FOUR CORNERS IN 60 MINUTES

DUST DEVIL

Continued from cover

Continued from cover controls are not put in place to mitigate the risk. And, as Darren Gallagher, National Category Manager – Workplace Safety at safety supply specialist Blackwoods, is quick to point out, the solution does not begin and end with using a respirator. “There isn’t a single solution that covers all situations,” he says. “It really is a matter of following the principles of the hierarchy of controls as defined in the model WHS Regulations, and in this respect it is education that is crucially important.” That hierarchy of controls is important as it offers a step-by-step guide to minimising risks that between them will provide a total solution. And while some may seem obvious, it is clear from the sickness data now emerging that industry has not been following the guidelines to the letter. Briefly, the hierarchy of controls begins with substitution (of materials, where possible, for lower dust types), moves on to isolation of the hazard (keeping the workforce physically separated from the dust), and engineering controls (such as ventilation, water suppression or using tools with dust collection).

Should a risk still remain, administrative controls would include good housekeeping policies, shift rotations and modifying cutting sequences; and then, should a risk still remain, personal protective equipment (PPE), including appropriate respiratory equipment and work clothing that does not collect dust. And the regulations are clear in the assertion that more than one control will normally be required to adequately protect workers. There is clearly no one-size-fits-all solution to the problem, which is why it is essential to go through the hierarchy of controls for each situation. Similarly, when it comes to PPE, there is no single solution to the hazards of silica dust. Each activity will have its own requirements based on the risks presented. As Darren Gallagher puts it: “Whatever work you are doing, as an individual you should wear the appropriate PPE for that activity.” And that is the message that all industries have to get across to their employees. To paraphrase the current Safe Work publicity campaign, it’s a choice between a face mask now and an oxygen mask later.

companies are taking to keep pedestrians safe from motorised traffic on the shopfloor and in the warehouse.

shocking shortcomings. The two parts will be released on consecutive weeks in September.

This is an area of workplace safety where there is limited regulation, and with shocking statistics for workplace injuries (and, sadly, fatalities) caused by motorised traffic we question whether more guidance or regulation is necessary to make our workplaces safer.

You really won’t want to miss it!

The two-part documentary is hosted by Tim Webster, and exposes some

Future productions will look at other key aspects of workplace safety where regulations are either lacking or being wilfully disregarded. Please contact Industry Update if there are any issues you think we should investigate.

CONTENTS FROM THE EDITOR.......................... 2

MACHINERY.................................... 30

MATERIALS HANDLING................ 58

BUSINESS & FINANCE...................... 6

VEGA VIDEO ................................... 36

SAFETY.............................................. 63

INDUSTRY POLITICS......................10

COMPRESSORS & PNEUMATICS.41

Five trends in safety engineering....... 64

NEWS..................................................14

Innovation and attraction: finding ways with magnets....................................... 46

PRODUCTS...................................... 65

HYDRAULICS & FLUID CONTROL.48

COMMUNITY...................................72

Happy Birthday AMTIL......................15 CLEANING.........................................18 TEST & MEASUREMENT ................22

PUBLISHER SCOTT FILBY

ELECTRONEX PREVIEW............... 52 WASTE & ENVIRONMENT............ 54

PRODUCTION MANAGER JULIET NELSON

copy@industryupdate.com.au

lyn@industryupdate.com.au

ADVERTISING SALES DIRECTOR SCOTT FILBY

VIDEO EDITOR & PRODUCER CHARLIE LOUGHLIN

SUBSCRIPTION ASSISTANT MARK ZAKOSHANSKI info@industryupdate.com.au

OFFICE MANAGER NICOLE CHARLES

SUBSCRIPTION ASSISTANT KAITLYN OLIVER circ@industryupdate.com.au

NATIONAL SALES & MARKETING MANAGER GABRIEL BROOKS

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editor@industryupdate.com.au

EDITOR LAURENCE MARCHINI

ADVERTISING COORDINATOR JULIET NELSON copy@industryupdate.com.au

ASSISTANT EDITOR DAVID MORRIS

WEB DEVELOPER JINI M R

CREATIVE DIRECTOR MATTHEW LAM

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FINANCE & ACCOUNTS MICHELLE ALCOCK

FUN & GAMES.................................. 74

ACCOUNTS RECEIVABLE LYN SLIGAR

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INDUSTRY UPDATE VIDEO......... 68

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• BUSINESS & FINANCE

CONFIDENCE IN OUR GREAT STATE

By Andrew Eastwood

Manufacturing continues to play of an important part in Victoria’s economy. While the industry has seen changes over the years, with a shift from traditional manufacturing to more advanced techniques, it remains resilient. There has been much discussion about weak economic performance nationally and growing concerns in the global economy. Victoria is not immune from these developments. Moreover, the manufacturing industry is likely to be impacted by the increased uncertainty over ongoing global trade tensions. Nonetheless, I would like to focus on some of the positives we’re seeing in our great state. Victorian economic growth has slowed, but it has outperformed the national economy. Our Bank of Melbourne economics team is expecting this outperformance will continue. Victoria’s trump card is its solid rate of growth in population, which underpins relatively stronger growth in retail spending and economic activity. There have also been some recent signs of stabilisation in Melbourne’s housing market, where auction clearance rates lifted to 67% in June. Victorians are more upbeat than most Australians. Consumer sentiment,

according to the Westpac-Melbourne Institute, has been resilient in Victoria following the Federal election earlier in the year and recent tax cuts passed by parliament. These factors have had a positive impact on the mood of Victorians. In addition, business investment has been growing at a solid pace in Victoria. The big spending on infrastructure continues to be driven by the public sector. The Victorian State Government estimates a strong increase in public infrastructure spending over 2019-20 and reaching a peak in 2020-21. In addition, commercial construction activity remains solid. For Victoria’s manufacturing industry, areas linked to engineering construction should receive benefits from the huge amount of infrastructure spending in the state. In addition, the low Australian dollar should provide support to the sector, as it boosts exports by making them relatively cheaper than overseas goods. The weaker currency will be a key mitigating factor for Australia’s traded sector given the increasingly uncertain global trading environment. There’s no doubt that we have the right elements to continue to build a strong future in advanced manufacturing. As Victoria’s only bank with a dedicated, locally-based manufacturing team,

Bank of Melbourne has been a constant supporter of the industry. In this issue, we’re pleased to speak with another standout manufacturing champion, Phillip Rolls, about his company, RollsPack. Phillip shares his story of how they have become Australia’s largest flexible packaging manufacturing business and a global leader in innovation. The digital revolution kicked off a major change to the business, prompting RollsPack to pivot from industrial packaging to focus on ecommerce. It’s the drive to innovate that has kept their business thriving. You can read more about their journey on page 9.

At Bank of Melbourne, we’re in the business of manufacturing successful outcomes for our customers, and the Victorian economy. Get in touch via my details below, to find out how our expertise can help your business grow. Andrew leads the Bank of Melbourne Manufacturing Relationship Team of specialist industry bankers. He brings his experience from 28 years in banking to help support Victorian manufacturers. Bank of Melbourne 0402 970 792 www.bankofmelbourne. com.au/manufacturing

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You’re in manufacturing We have a banking expert for that - Andrew. Call Andrew Eastwood, Executive Manager on 0402 970 792 to find out how your business can benefit from our Manufacturing & Wholesale banking expertise.

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• BUSINESS & FINANCE

WHO NEEDS A WHISTLEBLOWER POLICY? On the face of it, the Treasury Laws Amendment (Enhancing Whistleblower Protections) Act 2019 looks like a win for honesty and openness in the conduct of Australian businesses.

Do you hear that your team are always busy? Is productivity improvement an issue for you? Have you ever considered setting up a team in another country but thought it’s too hard, risky or we aren’t big enough?

The new laws, which came into effect on 1st July 2019, provide enhanced protection for “eligible” whistleblowers that report wrongdoing in the workplace in companies of all sizes.

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They also require that all public companies and larger proprietary companies ($50 million turnover and 100+ employees) have a whistleblower policy that is available to all employees. Where the new laws will really have their impact is in encouraging employees to speak out about legal and/or ethical misconduct without fear of reprisal. And while much of the impetus for the reform has come from the financial services sector, it is just as relevant to industry, particularly in the fields of safety and environmental controls. Under the new act, just about all employees and their families will receive enhanced protection, allowing anonymous disclosure and providing immunity from civil, criminal, or administrative liability for protected disclosures.

Importantly, the new act removes the “good faith” disclosure requirement that previously removed protection if a disclosure was not motivated by “good faith”. And the protection provided has also been clarified to include dismissal, injury, disadvantageous change of working conditions, discrimination, harassment, damage to reputation, financial damage and victimisation of the whistleblower or anyone associated with them. The consequences for employers can be severe, with civil and/or criminal action for victimisation or breach of confidentiality. These penalties can be up to $1.05 million for an individual and up to $10.5 million for a company. There is also the provision for civil action against eligible employers that do not implement a whistleblower policy by 1st January 2020, with fines of up to $12,600.

MANUFACTURING EDGES BACK FROM THE BRINK Australian manufacturing rallied in July, with the Ai Group’s Performance of Manufacturing Index edging back into positive territory at 51.3 points, following June’s mild contraction. The improved performance comes despite sharp falls in both sales and production, but backed by improvements in new orders, exports and supplier deliveries. The ever-growing food and beverage sector continues to lead the growth (albeit slightly down to 59.2) and the building materials sector continues to defy the goslow in residential construction with a new high of 63.7. On the down side, the metals sector continues its serious contraction at 35.4 and the machinery and equipment sector is still below par at 48.8. Some of the underlying figures do seem to indicate that the industry is still struggling to stay ahead. Although the rate of growth of input prices is easing, at 66.3 that is still a worryingly high figure when

compared with a selling price index that is becalmed at 49.2. Meanwhile, wage growth is easing at 56.9, in spite of the 3 per cent increase in the minimum wage, which came into effect at the start of the month. Ai Group Chief Executive Innes Willox was optimistic in announcing the results, saying: “While production fell, export sales were stronger partly due to the downward drift in exchange rates over the first half of 2019 and partly due to strong overseas demand for food, beverages, pharmaceutical and cosmetic products. “Pressures on manufacturers’ margins continued in July in the face of weak domestic sales and selling prices even though the pace of increases in wages and other input costs eased. In encouraging pointers for the months ahead, both new orders and employment expanded in July,” he concluded.

www.integratedos.com 8

INDUSTRYUPDATE.COM.AU

AUGUST/SEPTEMBER 2019

BUSINESS & FINANCE •

AUSTRALIAN-GROWN PACKAGING PRODUCER ON THE INNOVATION FRONT FOOT customers are often more price-driven. That’s in contrast to the US, where customers are loyal to buying locally,” says Rolls. “If our customers are price-sensitive, we can produce in China with a longer lead time. If they need a fast turnaround, we can produce locally. Operating across several sites enables us to give our customers flexibility.”

Managing Director Phillip Rolls

Since starting out 35 years ago in a modest office with two desks and a heater in the middle of winter in Melbourne, Phillip Rolls has grown RollsPack to become Australia’s largest flexible packaging manufacturing business and a global leader in innovation.

Rolls says being open to overseas growth is important – as is the ability to adapt. “We’re now looking at the US and South America, but at heart we’re still an SME with our main operations in Australia,” he says. “We’re a privately owned company and we’ll stay that way because we need to constantly adapt to the market. “When I started the business there was only one plastics manufacturer in Australia. No one was looking after the smaller companies or industrial packaging. Back then 25 per cent of

“We take the environmental impact of our packaging products seriously,” says Rolls. “RollsPack encourages businesses to design more sustainable packaging and increase recycling. Our goal is to manufacture using 100 per cent recyclable materials by 2025, and for those products to return to the industry to produce things like injection moulding, bitumen mix, park benches and even flight runways.” It’s that drive to innovate and be adaptable that has kept the business thriving. And the industry agrees, with RollsPack taking home seven awards at last year’s Flexible Packaging and Label Makers Association Awards, including the coveted ‘Best in show’ accolade. “Innovation is my number one priority,” says Rolls. “I am constantly exploring how I can produce better quality printing and products. We can’t benchmark against ourselves – because we’re the only business of our kind in

Melbourne – they were receptive to providing the facilities we need to support our growth. The key is our personal relationship with our banker. With bigger banks you’re just a number; you’re no longer a company trying to employ people and contribute back to the economy.

Originally a plastic bag manufacturer, RollsPack’s first major client was Just Jeans, producing the iconic red, blue and white bag for the fashion brand. The business now manufactures food packaging, security and tamper-evident bags for banks and couriers, and specialises in retail and e-commerce packaging. The business is differentiated by its technology, with access to printing machinery that produces high-quality packaging that’s unique in Australia. “Food packaging uses different types of printing methods,” says RollsPack Managing Director Phillip Rolls. “The US and Europe use a particular printing style, and Asia uses another. We have both, giving us access to the world’s best photographic-quality printing.”

GDP was created by manufacturing in Australia – that’s down to 5-6 per cent today.”

Australia we have to look to our global peers and stay on top of industry trends.”

The digital revolution kicked off a change to the business. RollsPack left industrial packaging and focused on e-commerce.

Phillip Rolls says building a partnership with their local Bank of Melbourne Relationship Director has been crucial to ensuring the business continues to succeed and grow.

The company expanded its operations to New South Wales and New Zealand in 2009. In 2016 it opened in China to access the European, American and Chinese markets and help reduce costs for their Australian clients.

“Online shopping changed the domestic market,” says Rolls. “Bricks and mortar retail was dying. Everything went online and people wanted things ‘just in time’. At the core of our business is agility and adapting to the changing market.”

“We originally set up our Chinese operations to service the domestic market, but we found that our Australian

Those market changes include a direct focus on the environmental aspects of the business.

AUGUST/SEPTEMBER 2019

“We want to remain an Australianowned manufacturer, but it’s a competitive global market,” he says. “The costs to run our business in Australia are among the highest in the world, but we have to accept the challenge and continue to move forward. “That’s why we joined Bank of

“I want to deal with people, and people want to deal with us. My banker is a real person, not just a big building in the city. He listened to our needs and established a unique partnership, which has become so fundamental to our business. We’re so pleased with the way Bank of Melbourne provides banking services with modern thinking.” Working with business banking professionals who have a strong local knowledge of your industry can make the difference in the day-to-day running and the future of your business. RollsPack www.rollspack.com.au

Bank of Melbourne 0402 970 792 www.bankofmelbourne. com.au/manufacturing

INDUSTRYUPDATE.COM.AU

• INDUSTRY POLITICS

PREFABRICATION: BUILDING AN INDUSTRY FOR THE FUTURE

By Hon Karen Andrews MP

The increasing popularity of prefabricated building presents a great opportunity for Australian manufacturers. The sector represents between 3 and 5 per cent of Australia’s $150 billion construction industry but has considerable potential for growth. With the right investment, Australia’s prefabricated housing share could grow to 15 per cent by 2025. This would create up to 20,000 new jobs and add $30 billion to our economy.

Once established, this hub would support work on a wide range of buildings, including tiny houses, larger homes and offices. The hub would bring together the skills and knowledge of our building and manufacturing sectors to enable the Australian housing industry to compete on a global stage by providing smarter, more affordable, more sustainable construction solutions for all Australians.

The Government has provided assistance to prefabrication projects and is already investing in related research, having helped establish the Australian Research Council Training Centre for Advanced Manufacturing of Prefabricated Housing at the University of Melbourne. This centre has undertaken important research into prefabricated houses and other buildings. Industries and universities are already cooperating in the development of a training system. And we are building on that good work. In June I announced that up to $2 million would be allocated to the Advanced Manufacturing Growth Centre for a feasibility study and to develop a new collaborative hub for prefabricated buildings.

want to be a world leader in the field.

With the right approach, we could build an important new pillar to the Australian manufacturing sector. Australia has turned to prefabricated housing before, particularly after World War II when there was an acute shortage of housing and dwellings had to be built quickly. This housing was sourced from overseas, Sweden in particular, which produced wooden prefabricated components. Examples of these buildings still stand around Australia, including in a part of Darra in Brisbane around Kokoda Street, which used to be part

of the adjoining suburb of Wacol when the buildings housed military families. The Federal Government provided money for the states to import prefabricated housing and imported such housing on its own behalf. So history shows many Australians have embraced the prefabricated solution in the past and will do so again. But we don’t want to be an importer of prefabricated buildings any more. We want to build our own and we

The Advanced Manufacturing Growth Centre feasibility study I’ve announced will consider the best markets for us, and how to best develop our expertise. This support for prefabricated buildings is part of the Government’s wider commitment to Australia’s advanced manufacturing sector. This commitment is part of our plan to grow the economy and create 1.25 million new jobs over the next five years. With the right approach, we could build an important new pillar to the Australian manufacturing sector.

The Hon Karen Andrews MP is Minister for Industry, Science and Technology.

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• INDUSTRY BUSINESS &POLITICS FINANCE

KEEPING UPMANUFACTURING WITH GLOBAL DEMAND ADVANCED NEEDSTHE GREATEST CHALLENGE FOR MELBOURNE A STRONG PARTNERSHIP WITHMINING SUPPLY MANUFACTURER GOVERNMENT By Brendan O'Connor

From any historical distance you care to choose, we live in by far and away the most remarkable era of human innovation and technological advance humans have hitherto experienced.

As the new Shadow Minister for Industry and Employment, I want Australia to be a successful advanced manufacturing nation. At a time where the future of manufacturing is at the forefront of Australia’s consciousness, I am eager to work with industry to advance the debate on how to best

While this is an exciting time, the impacts of technological change on work, life and society brings its fair share of anxieties.

Strong investment in R&D allows all Australians share in the benefits of With more than 500 staff globally, new industries Duratray is the first Chilean enterprise to

It’s the responsibility of government to make sure that those profound impacts benefit workers across the economy. We are on the cusp of the new industrial revolution, Industry 4.0, and From its Melbourne headquarters, we have an obligation to understand Duratray – a leading supplier of trays forthe role of trucks manufacturing weway transition mining – is leadingasthe with to this new era, to support and growits innovative technology that has driven innovative and successful businesses. global expansion. Duratray was established in the 1970s. Since its purchase by current owners Conymet in 2001, it has grown its international footprint to 33 countries across five continents.

Duratray’s customers are seeing the difference in their bottom line, with payloads of up to 40 tonnes – 20 per cent prepare ourselves for the challenges that more than conventional steel body dump lay ahead for all of us. trucks. The company’s commitment to noise

reduction has won praise including a

finalist’s position in the 2017 Australian Mining Prospect awards, as well as

A family-run business – first by their late father and now by Melbourne-based Chilean Marcelo Medel and his two brothers – Duratray is making waves in Australia, Russia, Canada, the USA, Chile, South Africa and Europe. Despite the industry’s downturn, having the right support to grow the business means Duratray has more expansion plans afoot. “We are a leading manufacturer and exporter of dump bodies for haul trucks used in open cut mines and quarries,” says Marcelo Medel. “Our difference is in our suspended dump body solution. Instead of a steel base tray, we use lightweight rubber mats on heavy-duty fibrous suspension TM-Techman Cobots ropes that increase shock absorption and Zimmer Group Grippers and abrasion resistance.”

automation hardware

The patented tray reduces loading impact and dampens noise. It also reducesInventec Precision Parts Cleaning haul residue, known as carryback, that Solvents, Detergents and can adhere to the tray in certain weather Machinery Solutions commendation by the NSW Minerals conditions. Council. “The tray design optimises the mining www.onboardsolutions.com.au Duratray’s success on the international process. It has other benefi ts too: lower stage has also been recognised with a maintenance costs, increased capacity and Email : info@onboardsolutions.com Phone: +61 2 9695 1030 prestigious export accolade: the Governor payload, better safety and reliability, and less vehicle wear,” says Medel. of Victoria Export Awards 2010, in the

INDUSTRYUPDATE.COM.AU

Minerals, Energy, and Related Services category. Labor has always supported our The company’s plans to expand and manufacturing firms. innovate continue. The Duratray team is working with German manufacturer Incomprehensibly, at a time of great Kuhn to develop theglobal world’smanufacturing first 100 per challenges for the cent battery-operated dump truck. The industry, the Liberals have wiped their so-called ‘green truck’ is in trial in hands of responsibility; in factoperation they Switzerland. goaded the major car manufacturers to leave our shores. “This is a game changer for our industry,” says Medel. “Combined with the innovative technology of our suspended dump body tray, the electric vehicle will reduce carbon, noise and pollution while increasing productivity.”

establish itself in Australia.

“We’re very proud of our strong Labor understands that performance over the past twoadvanced decades, manufacturing has a bright futurethe in and our continued growth through Australia: it needs a strong partnership economic downturn,” says Marcelo Medel. with Government to hold its place in the global industry and to attract These days, the company’s greatest investment. challenge is keeping up with demand. “We’ve grown more than 300 per cent needs willing to overItthe past a3 government years, and have recently back them. Not one that says we can’t afford a manufacturing industry. If we invest in advanced manufacturing, Australia can be the best in the world. To do this we need to address the skills crisis facing this country, developing an appropriately skilled workforce to drive us into the new era of manufacturing. Recent research by the Ai Group has shown that 75 per cent of businesses are finding it difficult to recruit qualified Australian workers to fill vacancies. Under the Morrison Liberals, more than 150,000 apprentices and trainees have been lost, while $3 billion has been slashed from TAFE and training. This is holding Australia back. Labor is committed to retaining Australia’s position in the world as a leader in product development and automotive design. Our world class tertiary branches institutions, highly skilled and and St opened in Johannesburg innovative workforce, strong intellectual Petersburg. We’re in the fortunate position property laws and world class design, of having to increase production to meet engineering and testing facilities giveinus demand; we’re doing that by investing an edge over other countries, but we can bigger facilities in Australia and offshore. do more and we must do more or we risk missing Industry 4.0 boat. support, “Withthe Bank of Melbourne’s

Labor took a suite of policies to the election earlier this year that reflected Duratray Managing Director Marcelo Medel our commitment to supporting and growing our manufacturing industry. we’ve more than $5 in our Whileinvested individual policies willmillion be revisited Australian branches over the last three and reworked in consultation with years, including new Perthcommitment and Brisbane industry, the overriding facilities and a bigger facility in investment Melbourne that Labor made to increase set to open next year.” in research and development is a

commitment that we as a nation must do A partner for more than 12 years, Bank more than just aim for; we must realise. of Melbourne is key to the company’s success domestically and internationally. By investing in R&D, government provides resources is forour universities “Bank the of Melbourne biggest and research institutions to produce banking partner in Australia,” says Medel. results thatsupports inspire innovation, private “The bank us with finance, but it’s investment further research their strategicand point of view that weand really development. investment in value. Mining isStrong a dynamic environment R&D allows all Australians share in and if we take too long to act, we can the benefits of new industries, newtimes products, lose business. There have been good jobs and a higher standard of when we’ve needed Bank of Melbourne living. to support us within a 48-hour period and they’ve absolutely been there. Manufacturing is a significant employer of researchers, however “We often include our relationship under the current government spending with Bank of Melbourne in our proposals in R&D has fallen from 2.11 per to enhance our offer. It means wecent can of GDPstrategic in 2013/14 to 1.88 cent provide insight andper more in 2015/16.payment This is aterms trendtothat must attractive our clients.” be reversed if we are to take our Marcelo Medel saysinthat regardless of place as world leaders advanced the industry, Bank of Melbourne’s strategic manufacturing, be it in wine, food, approach can help businesses to thrive. electronics, defence, steel production and fabrication and more. “With economic conditions looking up, businesses need to respond to workers Labor values manufacturing opportunities,” he says. Bank of and businesses across “With the country. Melbourne, Duratray can offer customers things didn’twe even existed.ofIt’s Weweknow faceknow a number good for ourbut business good our challenges, Laborand is up for for it and customers.” I look forward to working with you to help us realise this ambition to secure Australia’s manufacturing future.

Bank of Melbourne 0402 970 792 Brendan O'Connor is Shadow www.bankofmelbourne. Minister for Industry and Employment. com.au/manufacturing

AUGUST/SEPTEMBER 2019

You can’t AUSTRALIA’S MANUFACTURING STAR manufacture success... CONTINUES TO RISE BUSINESS & FINANCE •

Introducing the NEW Nilfisk Scrubber Dryers Modern Design | Exceptional Performance

By Andrew Eastwood

As Victoria’s only bank with a dedicated manufacturing team, Bank of Melbourne showcased its support for the industry at last month’s National Manufacturing Week.

but you can fast track it.

Highlighting our expertise to the conference’s 11,000 delegates with an exhibition presence and panel discussion, we reaffirmed what we’ve known for years: that manufacturing is the most exciting sector of the Victorian economy. The conference theme, “Industrial Evolution”, focused on opportunities for businesses to capitalise on the sector’s transformation. Economically, Victorian business is comforted by the certainty a federal election result brings. Significant government infrastructure spending, low unemployment and strong population growth continue to underpin Victoria’s vibrant economy. Coupled with the projected 1.2% annual growth of the manufacturing industry nationally over the next 5 years, it’s time for manufacturing businesses to make the most of the opportunities ahead.

support manufacturers across a diverse range of topics including product value, market reach and resilience. Growth in service-based manufacturing: The move from traditional manufacturing towards service-based business models means a shift in thinking and establishing the right support network to help your business grow. Being competitive in an era of advanced manufacturing means thinking about how you make your product, not what you make.

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The following were my key takeaways from the week.

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Industrial Internet of Things: This exhibitor zone showcased machines embedded with sensors, switches or intelligent controls to make factories smarter and more efficient, reducing costs and improving workplace safety.

is helping manufacturers and distributors to operate more

Time is money – and today’s demand for cost efficiency and high standards requires a solution that is economical, flexible and eco-friendly. The Nilfisk BA 611 & BA 651 Walk Behind Scrubber Dryers, complete with the OneTouch™ control panel simplifies operations for greater ease of use. Designed for maximum performance, easy handling and low maintenance, providing greater versatility, up to 30% more productivity, unmatched reliability, extremely quiet operation and the most advanced ergonomics available.

Our team of experienced bankers supports manufacturers and wholesalers with solutions in managing cash flow, mitigating risk and funding capital investment. Get in touch to find out how our expertise can help your business grow.

efficiently, boost profitability,

It’s not the stuff of science fiction and become more successful.

– this type of technology has already

made its way into our smart, connected homes, with the Internet of Things changing the way we control our appliances.

See how to speed up Andrewsuccess: leads the Bank of Melbourne Manufacturing Relationship Team of Manufacturing Academy launch: specialist industry bankers. He brings his jcurvesolutions.com/success Technology is also changing the way we

experience from 28 years in banking to help access information and learning – the support Victorian manufacturers. meteoric rise of MOOCs (Massive Online Open Courses) from some of the world’s most prestigious educational institutions means that knowledge is now SOLUTION PROVIDER at everyone’s fingertips. Bank of Melbourne 0402 970 792 Offered by the Advanced www.bankofmelbourne. Manufacturing Growth Centre, the academy is a valuable online resource to com.au/manufacturing

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• NEWS

DANISH SUSTAINABILITY VALUES CLEAN UP IN BLACKTOWN

Danish Ambasador Tom Nerring, Nilfisk Pacific MD Michael Hansen and Councillor Stephen Bali, the Mayor of Blacktown City

Closer ties between Denmark and Australia were certainly the order of the day at the recent opening of the new Nilfisk Australia headquarters at Arndell Park in Sydney’s west. The ribbon cutting ceremony was a three-way affair between

Danish Ambasador Tom Nerring, Nilfisk Pacific MD Michael Hansen and Councillor Stephen Bali, the Mayor of Blacktown City. The new facility, which will act as a central hub for Nilfisk’s four other

warehouses around Australia (and a further two in New Zealand), covers a little over 2700m2. It combines warehousing with a fully equipped workshop and a mezzanine office level that has been laid out in Danish open-plan style. MD Michael Hansen was keen to point out that nobody (himself included) has their own office. There are breakout rooms for private meetings, but for the daily routine, the open-plan design reinforces the company ethos of “one team, one agenda”. The warehouse is an interesting one as it has to deal with both European and Australian pallet sizes, which has led to some degree of innovation in the racking design. And between the finished machines and the essential stocks of spare parts, it houses in excess of 25,000 different SKUs, and is currently receiving a container-load of stock every day. In addition to maintenance, the workshop is responsible for commissioning and customising the vast majority of the cleaning machines that arrive from Nilfisk’s factories. Speaking at the opening, Ambassador Nerring highlighted his nation’s emphasis on sustainability and adherence to the UN’s sustainability goals, which he said were not yet adhered to quite so closely

INDUSTRYUPDATE.COM.AU INDUSTRYUPDATE.COM.AU

in Australia. “Nilfisk has embraced those goals,” he said, “and has done so in a very clean way”. Michael Hansen added that Australia was viewed as a key market for Nilfisk – and for many other Danish companies – taking the view that “If we can get it to work in Australia we can get it to work anywhere, which is why Nilfisk releases its new models in Australia ahead of most of the world”. And in his former role as the former Trade Commissioner of Denmark to Australia and New Zealand, Hansen could confirm that other Danish household names including cookware giant Scanpan and jewellery manufacturer Pandora, take a similar view of the Australian market. For the local view, Councillor Bali highlighted the phenomenal growth of the City of Blacktown, with its population of 370,000, and an economy that has been growing at a rate of 4.6% for the last five years, now reaching $17.1 billion. ”Thank you for making Blacktown your home,” he said, “contributing to the fastest growing city in Australia.” Nilfisk 1300 556 710 www.nilfisk.com

AUGUST/SEPTEMBER 2019

NEWS •

HAPPY BIRTHDAY AMTIL

AMTIL (the Australian Manufacturing Technology Institute Limited) celebrated its 20th anniversary with a cocktail reception at the Sea Life Aquarium, Melbourne on 8th August. The event was attended by leaders from manufacturing businesses across Australia, as well as representatives from manufacturing technology suppliers, government and industry bodies, universities and research organisations. AMTIL CEO Shane Infanti, who has been with the association since the beginning, noted that this anniversary coincided with a strong resurgence in Australian manufacturing. “It’s great to be celebrating 20 years of AMTIL at such a positive time for our industry,” he said. “There’s been a lot of pessimism in recent years with the GFC and the car industry closures, but right now we’re just seeing exciting stuff going on all across the sector. So tonight’s event isn’t just about looking back on 20 years of AMTIL; it’s about looking forward to what I think is a very bright future for Australian manufacturing.” AMTIL came into being on 11th August 1999 as a result of the merger of the Institute of Machine Tools Australia and the Australian Machine Tool Association, and today has a membership of manufacturing companies and technology suppliers across every state and territory. Since its establishment, AMTIL has conducted a range of activities to support

AUGUST/SEPTEMBER 2019

the industry. It organises various industry events, most notably Austech, Australia’s premier advanced manufacturing technology exhibition. It produces a number of publications and reports, including the industry-leading AMT Magazine. Moreover, it is a partner organisation on government initiatives at both federal and state level, such as the Entrepreneurs’ Programme and the Additive Manufacturing Hub. Manufacturing in Australia has changed dramatically over the last 20 years, and AMTIL has changed and evolved with it. But according to Infanti, the need to support and promote the interests of the industry remain as important as ever. “Australian manufacturing needs to constantly adapt if it is to prosper and grow, and at AMTIL we’re committed to helping facilitate that,” he said. “This May we ran our most successful Austech exhibition to date. The AM Hub, which we launched last year, is proving to be a great success. And there are plenty more initiatives in the pipeline. We’re looking forward to supporting Australian manufacturing for many more years to come.” AMTIL 03 9800 3666 www.amtil.com.au

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• NEWS

MUSIC IN THE WORKPLACE? YOU NEED A LICENCE FOR THAT From 1st July 2019, companies have a single source for all their music licensing obligations. OneMusic Australia offers several different classes of licences, depending on the nature of the company applying. And while public venues – such as pubs, clubs, cafes etc – have separate requirements, workplaces such as manufacturing sites can be covered by the Workplace Music Use Licence Scheme, which charges an annual fee per full-timeequivalent employee in the first licence year. The minimum fee per annum is $220.00 including GST. That licence will cover any music played in the workplace for the benefit of employees, as well as at company events and in reception or front-of-office areas that are open to the public. It also covers copying music from legally obtained sources for use in the workplace.

Numerous studies have suggested that background music in the workplace can be a contributor to improved productivity – whether in an office environment, in the warehouse or on the shop floor. However, playing recorded or

broadcast music in the workplace requires licensing to comply with the requirements of the Copyright Act (1968), and the complex makeup of the music industry has meant that companies have needed to obtain licences from both APRA AMCOS (broadly covering the copyright of each

song) and from the PPCA (covering the copyright of the recordings of the songs).

It is important to note, though, that the workplace licence does not cover the use of music in telephone on-hold systems, as this requires a separate licence, also available via OneMusic Australia.

Fortunately, this complication has just been resolved with the launch of OneMusic Australia, a joint initiative of APRA AMCOS and the PPCA.

OneMusic Australia 1300 162 162 onemusic.com.au

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AUGUST/SEPTEMBER 2019

NEWS •

NEW PREMISES BOOST SUPPORT FOR QUEENSLAND INDUSTRY APS Industrial has relocated its Brisbane office to an all-new facility in Murarrie. The 1500m2 premises will boost the company’s ability to service the local Queensland market with increased local stockholding and additional office space to accommodate further technical support, product management and customer service personnel. “APS Industrial is now over 12 months old and in this time we’ve seen a significant uptake of our products and services in Queensland which is very pleasing. To cater for this growing customer base and product demand – both now and into the future, we have invested in a new branch location,” says David Hegarty, Managing Director of APS Industrial. “This significant increase in local stockholdings paired with our new national distribution centre in Melbourne ensures we are well placed to get the products to our valued customers quicker than ever before and that’s incredibly important to us.”

APS Industrial came into existence on 1st March 2018 as the master distribution partner for Siemens in Australia with other core national distribution agreements with Weidmüller, Rittal and Epcos. Since those initial launch agreements, the company has also secured national distribution agreements with Katko and Grace Engineered Products.

“From the outset of APS Industrial our focus was clear – partner with the world’s leading industrial manufacturers to bring the broadest portfolio in the industry to Australia and match that with exceptional customer service,” says Ernest Van Niekerk, State Manager – Queensland, APS Industrial. “There’s no question our Queensland team have lived up to those

core promises and this new move enables us to continue and build on this moving forward.” APS Industrial 1300 309 303 apsindustrial.com.au

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• CLEANING

DEALING WITH THE DANGERS OF DUST about dust issues,” he says. “It’s a difficult and complex issue, and unfortunately for some the reaction is to bury their heads in the sand. And it’s not helped by some poor advice out there in the market – it’s not malicious, it’s genuine misunderstanding of the hazards.” “Clearly, it is best to capture dust before it becomes airborne. Industrial vacuum cleaners have a role to play here, along with good housekeeping practices.” The choice of vacuum cleaner is important in this respect, as is its maintenance, keeping in mind that electrical and mechanical equipment frequently provides the ignition source for an explosion. Electrical arcs and sparks and overheated bearings must be avoided at all costs. The dangers of dust in the workplace are not limited to the health consequences of inhalation by the workforce. There are many instances in manufacturing industry where the dust produced – either as a by-product or as the end product itself – is potentially flammable.

The most violent explosions usually result from dust/air mixtures that are fuel rich. This means that the oxygen available in the air cannot burn all the dust, and partly burnt, glowing material often remains after the explosion. This can reignite if more air becomes available.

And while the flammability of dust (or powder) that has settled on the floor or other surface is of minor concern, should that dust become airborne in the form of a dust cloud, then there is a very real danger of a dust explosion.

The shape and size of the dust particles, and other factors, strongly affects the force of the explosion and the explosive limits. Only weak explosions are likely where the mean particle size of the dust exceeds 200 microns, or the moisture content exceeds 16%.

A dust explosion involves the rapid combustion of dust particles that releases energy and usually generates gaseous reaction products. While a mass of solid combustible material as a heap or pile will burn relatively slowly due to the limited surface area that is exposed to the oxygen in the air, if that same solid is in the form of a fine powder and it is suspended in air as a dust cloud, the result will be quite different. In this case the surface area exposed to the air is much larger, and if ignition occurs, the whole of the cloud may burn very rapidly, creating a dust explosion.

INDUSTRYUPDATE.COM.AU

Obviously, any explosion needs an ignition source, but these can be surprisingly commonplace, from an electric arc from a machine to an electrostatic discharge from something seemingly safe such as a conveyor roller. The list of flammable dusts and powders that can be found in manufacturing industry is surprisingly long. Dangerous substances range from obvious item like flour, sugar, and coal dust to pharmaceutical and complementary compounds and even some metals such as aluminium, magnesium, and titanium. Controlling dust in such manufacturing operations is not a

straightforward task. One option is to maintain a “damp” environment so that the dust is effectively “washed” out of the air. However, this is not practical in applications like flour milling (a sticky situation, indeed). In the majority of cases, the simplest form of dust control is to clean it up before it becomes a problem. And as any form of sweeping (whether manual or mechanised) comes with the risk of raising the dust into the atmosphere and creating a potentially flammable cloud, the safest solution for dust removal is a vacuum cleaner.

Like a number of models in the Nilfisk industrial vacuum cleaner range, the VHS110 is suitable for use in dust-laden atmospheres up to Ex Zone 22, the company also supplies several models suitable for the more stringent requirements of Zone 21. With its brushless motor, fully conductive construction and L-class antistatic star filter, the unit is designed from the ground up to remove the risk of ignition when used in environments prone to explosive dust/air mixtures.

However, not all vacuum cleaners are created equal, particularly when it comes to operating in dust-laden atmospheres.

The ultimate in safe vacuum cleaning comes from the Nilfisk Model CTT40 IECEx, a three-phase cleaner with full IECEx certification.

The Nilfisk Model VHS110 ATEX is an third-party-certified single-phase industrial vacuum cleaner suitable for use in Zone 22 Ex classified areas.

“In the end,” says Chris Callicott, “safety is all about minimising the risks posed by any dust in the workplace.”

Chris Callicott is Business Development Manager ANZ at Nilfisk, and he has spent many years in the industrial vacuum cleaner market. He feels that a great many companies fail to adequately address their issues with dust and powder in the workplace.

“Asbestos and silica are deadly, but they can take tens of years to kill you. Combustible dust can be instantaneous.”

“There’s a lot of complacency

Nilfisk 1300 556 710 www.nilfisk.com

AUGUST/SEPTEMBER 2019

CLEANING •

CLEANING STATION CUTS STATIC RISKS

Guardair has improved its Personnel Cleaning Station with the release of the NED (non-electrical discharge) version, available in Australia from Knight Pneumatics.

components, and so avoids the buildup of static charges. This makes it safe for use with combustible materials commonly found in manufacturing, chemical, and food processing facilities.

The Personnel Cleaning Station NED runs from a standard compressed air supply. It combines a high-efficiency pneumatic vacuum with a proprietary, on-demand air-agitator brush attachment that loosens and lifts particles airborne into the vacuum hose for transport to the container.

There is also a pre-drilled mounting plate for mounting the unit on vertical surfaces, and this incorporates an earthing lug that provides an extra degree of safety.

Importantly, the NED version is constructed from electrically conductive

Knight Pneumatics 03 9503 0550 www.knightpneumatics. com.au

CIP HEATERS CLEAN UP FOR F&B INDUSTRIES Efficient heating of clean-in-place (CIP) equipment is an integral part of quality control and maintaining product integrity in any food or beverage industry. Teralba Industries designs and manufactures a wide range of CIP heaters using Dimpleflo tubing, which greatly increases heat transfer coefficients, so these heaters are more compact and have a smaller footprint than conventional heat exchangers. As Dimpleflo CIP heaters are designed for high steam and water pressures, these Australian-made heat exchangers can handle line pressure steam up to a gauge pressure of 12bar. This means reduced installation costs, as a pressure reducing station is not required, unlike with plate heat exchangers. Customers who have been using Dimpleflo CIP for years often describe

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them as “bullet-proof”, because downtime and maintenance costs are virtually eliminated. Teralba Industries 02 4629 3000 www.teralba.com

INDUSTRYUPDATE.COM.AU

• CLEANING

SCRUBBERS PROVIDE VERSATILE CLEANING ON MOST FLOOR SURFACES uncompromising versatility on virtually any hard floor surface. The orbital head is rectangular for a superior edge-to-edge clean and can also clean baseboards and cove mouldings. A pad backer with hook and loop tape is designed to prevent the working pad from falling off during transportation or use, and the balanced rectangular orbital design allows for the compression of the pad to be maintained on uneven or textured floors.

The rectangular head provides superior edgeto-edge performance

Orbital technology is used across a range of industrial and commercial walk-behind scrubber dryers, and provides

Tennant’s T300 orbital scrubber is designed for thousands of oscillations per minute and has ten isolators to minimise vibration, ensuring operator comfort, maximised performance and machine durability. The orbital head draws less power overall and improves battery runtime up to 45 per cent compared with a traditional disk head, and pad life is extended. This translates into a lower cost

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Protoblast Company has been designing and manufacturing to suit Protoblast Company has been designing and manufacturing to suit customer’s needsand since 1975. Protoblast Company has individual been designing manufacturing to suit customer’s individual needs since 1975. customer’s individual needs since 1975. • Abrasive Recovery Systems • Airless Blast Machines Abrasive Recovery Systems Airless Machines • Section Blast Machines • Dust Collectors The best• way to prepare a surface for a •coating isBlast by using the abrasive • Section Blast Machines • Dust Collectors blasting process. Whether you need to blast castings, concrete blocks, The best way to prepare a surface for a coating is by using the abrasive screws, or steel work... Theblasting bestsurfboards way to prepare a surface for a coating is by using the abrasive process. Whether you need to blast castings, concrete blocks, blasting process. Whether you need to blast castings, concrete blocks, screws, surfboards or steel work... Protoblast has the experience screws, surfboards or steel work... to design andProtoblast supply equipment is fast, efficient, has the that experience to design improves your product and you Protoblast has the experience to design and supply equipment that is saves fast, efficient, money... year after year. andimproves supply equipment that is fast, efficient, your product and saves you improves product money...your year after year. and saves you money... year after year.

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The Tennant T300 walk-behind scrubber dryer

of ownership and increased productivity for businesses and facility managers. “Tennant’s three variable downpressure settings means operators can easily optimise down pressure at the touch of a button,” Tennant Australia Commercial Distribution Manager Tony Applin says. “There’s no need to add or remove heavy counter weights from the scrub head. This delivers our customers savings in terms of extended run times, which means better productivity per shift and safe WH&S operating conditions. “Orbital heads provide a deep daily clean and with the ability on our machines to change pad pressure they maximise your overall cleaning performance. Industries we find most suited to this type of cleaning are education, healthcare, retail and hospitality. Such facilities may have multiple floor types and need to maintain their image to a high standard on a daily basis.

addition the even larger T600 workhorse. All available with ec-H2O NanoClean and Iris intelligent insights software where customers require it.” In simple terms, the darker the colour of the pad, the more aggressive the cleaning will be. 3M’s blue cleaning pad is used for heavy-duty scrubbing, and removes dirt, spills and scuffs, leaving a clean, prepared surface. Its red cleaning pad is designed for everyday cleaning and light scrubbing to remove light soil, scuff marks and black heel marks. Its white polishing pad is used for light cleaning to help remove soil and soft scuff marks with minimal dulling of finish. A melamine pad is made of an open-cell polymeric foam that produces outstanding results when cleaning vinyl, terrazzo, tile, concrete and epoxy floors. It is effective at removing black marks and can restore tile and grout without using harsh chemicals.

“More and more facilities are using modern decorative tiles and natural stone for their flooring, which brings new challenges to cleaning regimes. And we’ve had great success with customers who have facilities with grout lines and non-slip surfaces.

Recently, in addition to scrubbing, there is a growing movement towards chemical-free floor stripping, and orbital dual technology is the perfect solution. The versatility of a dual-purpose machine is a great investment for any facility that wants to reduce its environmental impact and also save money in the long term.

“The current range is for our mid to large walk-behind scrubber dryers starting at the T300 moving into the larger T500 family and finally our latest

Tennant Australia 1800 226 843 au.tennantco.com

AUGUST/SEPTEMBER 2019

CLEANING •

POWERFUL PETROL PRESSURE CLEANERS TACKLE INDUSTRIAL GRADE CLEAN-UPS The problem, according to Spitwater NSW’s Milo Gajin, was the reduction ratio required. The Honda engine operates efficiently at around 3600rpm, while the pump runs best between 1000 and 1750rpm. So any rigid gearbox would be subjected to extreme loads, leading to high stresses, accelerated wear and probable early failure.

For many years in Australia, the name Spitwater has been synonymous with heavy-duty pressure cleaners. And the company’s latest flagship model reinforces that association while taking the company’s range to new levels of performance and rugged reliability. Spitwater produces a range of dieseland petrol-powered slow-speed coldwater pressure cleaners that are ideally suited to outdoor cleaning.

The new top of the range Model HP251/A is powered by a 13hp Honda industrial petrol engine coupled to a slowspeed Italian-made Interpump brass-head pump. However, rather than connect the engine and the pump in the conventional way via a gearbox, Spitwater’s engineering team took the brave decision to reimagine the linkage and opt for a belt drive instead.

In the new design, the engine and the pump crankshafts are each fitted with suitably sized pulleys that are linked using Spitwater’s own Oz-Tuff toothed, flexible, rubber belt, which provides a rugged and reliable transmission that reduces the stresses on both crankshafts. With the belt drive enclosed by a metal cover, the transmission is fully maintenance free. And in testing out the design, the engineering team was delighted to find that the belt drive was actually more efficient than a gearbox, saving as much as 3hp of the engine’s power (which translates directly to fuel savings). “It’s a very smart design,” says Gajin.

“But the beauty of it is that it has allowed us to bring together the best of both worlds: the Honda engine has legendary reliability and the Interpump really is the Rolls Royce of the pump world for this kind of application.” That highly praised pump has a brass head and solid ceramic pump pistons that are both self-lubricating and wearresistant, providing a reliable 15L/min water flow and a huge 250bar of pressure. Designed and built in Australia for Australian conditions, these rugged pressure cleaners have an all-steel construction and also feature a watercooling tank to stop the pump from overheating. There are four wheels with large pneumatic tyres to aid manoeuvrability. And there’s the peace of mind of a three-year Australia-wide warranty on the Honda engine. Spitwater 1800 172 005 www.spitwater.com.au

SUPERIOR PERFORMANCE. MORE POWER. CERTIFIED SAFETY.

WORK IN TOTAL SAFETY WITH NILFISK INDUSTRIAL VACUUMS Design, ease of use and flexibility make the Nilfisk Industrial Vacuum Range the most popular with companies where safety and hygiene is a must.

Nilfisk work closely with Industry Specialists and safety consultants to ensure the range is WHS compliant and certified. IECEx certified model available.

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AUGUST/SEPTEMBER 2019

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â&#x20AC;˘ TEST & MEASUREMENT

SENSOR APPLICATIONS IN ADVANCING ADDITIVE MANUFACTURING

Additive manufacturing, generally referred to as 3D printing, has become prominent in the manufacturing industry as it is a cost-effective and flexible manufacturing technique in comparison with traditional manufacturing processes. The technological advancement in additive manufacturing has revolutionised the manufacturing industry with its design-driven approach and rapid prototyping capabilities. The technology has proved to be beneficial to a wide range of industry sectors by offering distinguishing benefits such as reducing material usage and manufacturing automation. These allow for the manufacturing of highly complex structures at a higher production rate and improved production efficiency. The technology is highly utilised in series productions and by OEM suppliers to create distinctive profiles based on new and custom

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geometries, faster development cycles and the ability to meet sustainability goals. The medical industry has become the pioneer of this technology by adapting bioprinting for creating 3D printed organs from human cells. These organs will be utilised in medical research for the development of accurate, targeted and more personalised treatment solutions to treat patient-specific illnesses. It is also theoretically possible to create viable and fully-functioning organs from 3D printing; however, there is still a long way to go to achieve that breakthrough. In the transport and building industries, 3D printing offers an opportunity for cheaper and more efficient manufacturing methods compared with traditional manufacturing. 3D printing has been widely used in rapid prototyping applications as it is a

cost-effective solution in product testing. Recent developments in 3D printing have observed a need to expand into creating functional structures and components that are more specific and objective-driven, in order to drive more value to the business. Considering the rapid advances in additive manufacturing, it is undeniable that sensors should be implemented as part of the system to improve the customised products in terms of functionality, preciseness and quality. Specialising in sensors and instrumentation, Bestech Australia offers a wide selection of precise and high-performing displacement sensors from Micro-Epsilon for applications in additive manufacturing, such as laser sensors, laser profile scanners, inductive eddy-current displacement sensors and capacitive measurement systems.

These non-contact sensors are well-suited for a wide range of industrial measurement applications due to their ability to provide accurate and reliable results on different components or surfaces. They can also be easily integrated with existing industrial interfaces.

Surface contour / edge detection in laser cladding Laser cladding or laser metal deposition is a manufacturing technique of applying powder substances to modify and enhance the surfaces of an object. The powder is sprayed into the protective gas stream and melted with the help of a laser. This technique has been widely used in surface coating and the development of innovative alloy materials in advanced laboratories. Sensors are used to control the

AUGUST/SEPTEMBER 2019

TEST & MEASUREMENT â&#x20AC;˘

trajectory of the deposition tracks to ensure that the products are manufactured with the highest precision.

include the monitoring of small components, surface etching or embossment depth.

Laser profile scanners can detect the contour, profile and edges of an object with high accuracy. They can be used to determine the welding path by taking the profile before the deposition. The resulting profile is used to determine the guidance of the weld head.

triangulation sensors typically offer fast distance measurement up to 4kHz. This enables the system to readjust the process when errors are detected.

High-precision position monitoring Distance control of the print head

They can also be used to monitor the thickness of the coating during the deposition process. As the laser is used to metallurgically bond the coating material with the base material, certain imperfections may occur. Laser profile scanners typically have a high scanning resolution to reliably detect these anomalies during the deposition.

Quality monitoring and inspection Success in the manufacturing industry is all about quality and efficiency. A reliable monitoring system is needed to check the quality of printed products to ensure that they meet the reuqired standards. Blue laser scanner technology can be used for this monitoring application. The generated 3D images are compared with the CAD data in the computer, and a logic control can be used to accept or reject the products based on the comparison. Blue laser profile scanners have an operating wavelength near that of the ultraviolet range. Due to the short operating wavelength, the laser projected from the sensor does not penetrate the object deeply. Therefore, blue laser scanners offer higher resolution and better accuracy with conventional laser profile scanners. Examples of applications

AUGUST/SEPTEMBER 2019

Adjusting the distance of the print head is crucial in ensuring the quality of the final product in additive manufacturing. In 3D printing applications, the print head has to be positioned at an exact height for a flawless process. It is necessary to ensure that the print head is always positioned at the same height at all times. A noncontact laser triangulation sensor offers high precision and a highspeed measurement for this type of application. More importantly, laser sensors are typically small and compact, which makes them easy to be integrated with machinery. The sensors can also compensate for surface reflection and against different materials.

As an example, the exact height of the print head is crucial in the assembly of printed circuit boards, to enable smooth progress during printing, soldering and parts assembly. In addition, the laser sensor can also reliably detect the thickness of the glue bead, which is generally applied on the soldered circuit to protect it from damage. The head positioning also directly affects the final quality of the printed products. Laser

In selective laser sintering, a laser is used as a power source to solidify the powdered material into a compact form. During the process, the building platform is lowered with every melt cycle by a defined value which corresponds to the required print resolution. An inductive eddy current measurement system can be used to monitor the building platform to ensure that the print head is aligned in parallel.

Unlike laser-based displacement sensors, an eddy current sensor is more suitable for this type of application due to the environment. Eddy current sensors are robust and resistant to oil, dirt, dust and extreme environments such as high pressure or high temperature. They are also miniature in size, which makes them ideal to be integrated with industrial plants and machinery. Eddy current sensors are one of the most advanced non-contact technologies in the market for measuring displacement and position in an industrial environment due to their robustness, high precision and excellent frequency response. In another application, sensors are also needed to monitor the position of a squeegee blade, which is commonly used in a 3D printing

system to ensure repeatable and consistent printing quality. The blade moves over the powder bed and applies the next powder layer to the component design on the assembly space. It needs to be tilted at a precise angle in order to spread the material evenly on the building platform. Two synchronised, highresolution sensors at each end of the blade are needed to measure its exact tilt angle. Capacitive displacement sensors are recommended for monitoring the position of the blade as they can measure accurately with sub-nanometer resolutions. The sensors are connected to a multichannel controller, making it ideal for synchronous detection of multiple sensors for measuring at multiple locations. It also has a high-frequency response for dynamic and high-speed measurement, which is ideal for this type of measurement. This system is ideal to be used for long-term measurement in a clean environment.

Summary Although there is a wide range of precision sensors available in the market, there is no sensor that can be used in all measurement applications. Selection of a suitable sensor depends largely on the operating environment and the type of surface material to be measured. When applied correctly, the industry will reap the benefits of additive manufacturing, which will further accelerate growth in the field.

Bestech Australia 03 9540 5100 www.bestech.com.au

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• TEST & MEASUREMENT

THE ELECTRONICS TEST BENCH: BASIC, BETTER, BEST

By Rudy Ramos

electrical power conversion from AC to DC. Although SMPSs tend to generate highfrequency noise that can affect surrounding sensitive electronics, they are smaller, lighter and more efficient than linear power supplies so they generate less heat. A variable-voltage model with an upper range of 10A and 30V will provide enough current capacity to meet a variety of needs. Good examples include a B&K Precision 1747 dual-range DC power supply or the Global Specialties 1415 dual-output DC power supply.

Soldering station More often than not a basic electronic bench setup can prove to be sufficient for making most printed circuit board repairs.

Whether you are designing new products for a large corporation, tinkering with electronics as a hobby, or working somewhere in between, having the right test equipment for your needs is essential. Test benches are often seeded with equipment that’s been handed down from generation to generation (which is testament indeed to those manufacturers) or shared among multiple departments at a company. That said, the proper test equipment is not necessarily - nor even often - the most expensive or the most fully featured. Instead, the right test equipment depends on your level of electronics experience and testing needs. This article will examine five core pieces of test bench equipment, outline considerations for purchasing equipment that meets your needs, and explore how test bench equipment evolves as skills and requirements become more advanced. Multimeters are used to check continuity, resistance, voltage, and low levels of direct current (among other measurements). Power supplies are used as a reliable source of DC power for developing and testing circuits under a variety of conditions. Soldering stations are used to create circuits by connecting electronics components. Oscilloscopes are used to measure changes in electrical signals over time, which yields various data, including amplitude, frequency, rise time, distortion, and noise, among other parameters. Accessories are used to keep users safe and make testing easier.

The basic test bench The basic test bench is ideal for high school and college students, hobbyists, and tinkerers who dabble in an infinite number of possible

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electronics applications. For these enthusiasts, the right equipment should not only meet testing needs, but also be easy to use and not create obstacles that impede progress.

Multimeter The multimeter is the most basic tool on the electronic bench, so choosing one that meets your test needs, is accurate, and is easy to use is key. For a basic test bench, handheld digital multimeters (DMMs) offer several benefits: They provide portability and accuracy at an affordable price. They are easier to read, do not require calculating exact values, and have no moving parts that eventually wear and tear. They are more accurate than their analogue counterparts because they are free from parallax error. Aspects to consider when choosing a handheld DMM include: the resolution and number of display digits; the capability to measure true RMS (root mean square) voltage, which accurately measures pure and complex waveforms; and the capability to measure temperature. Suitable candidates for the basic test bench include Extech EX300 digital multimeters and B&K handheld digital multimeters.

Power supply If you plan to power up any maker board or want to provide power to your newly designed circuit, you need a reliable source of DC power for developing and testing circuits under a variety of conditions. For the basic test bench, we recommend a switch-mode DC power supply (SMPS), which uses a switching regulator to control the

A basic soldering station should include the power unit, soldering pencil, stand, and sponge. In choosing a soldering station for a basic test bench look for one with variable temperature control up to 450-550°C. This will cover most needs. Analogue temperature control is adequate for most bench soldering, but a digital soldering station provides extremely high-precision temperature control. The WES51 - 50W soldering workstation and WD 1002 - 95W soldering workstation (both from Apex Tool Group) are ideal for a basic test bench.

Oscilloscope Students, hobbyists, and tinkerers often find that a handheld digital multimeter is all they need for testing circuits. However, when these requirements begin to include troubleshooting, debugging, or diagnosing circuits or working with signals that involve buses, pulse signals, or fast circuits, then an oscilloscope might also be needed. An oscilloscope measures change in electrical signal over time; those measurements are displayed as different types of waveforms that yield various data, including amplitude, frequency, rise time, distortion, and noise, among other electrical parameters. Compared with other basic test bench equipment, oscilloscopes tend to be expensive, so you probably won’t invest in one until you need to troubleshoot (rather than just measure) circuits. In general, we recommend selecting a portable model, such as the SDO Nano V3 from Seeed Studio, which is a compact and easyto-use 32bit digital storage oscilloscope with a built-in signal generator.

Accessories Useful accessories for a basic test

bench include an electrostatic mat and a wrist strap, which earth you and prevent component damage due to electrostatic discharge. Additionally, hand tools such as wire cutters and strippers, crimpers, screwdrivers, and tweezers are all indispensable when testing electronic circuits.

Mid-range test benches Intermediate users might include educators, advancing students and hobbyists, as well as maintenance and repair professionals who build, troubleshoot, and fix electronics. In general, their test bench needs include more I/Os, higher powers, additional features, and products that are easy to set up, use, and monitor but that are robust enough to take care of the most demanding measurement needs. Mid-range test benches may also include equipment that is specific to an application or technology area.

Multimeters Mid-range multimeters will have: higher resolution and more display digits; dual displays; and the ability to measure frequency, period, statistics, histograms, and more. However, mid-range multimeters, such as Fluke’s Bench Digital Multimeter NIST W/ Data, should be calibrated at regular intervals, preferably annually.

Power supplies When choosing a power supply for a mid-level test bench, consider the types of tests you will be doing. For example, do you need constant current and voltage, variable current and voltage, or both? Do you need a programmable power supply for manually setting output? Do you need a linear power supply for signal processing, data acquisition, and control circuit testing? Do you need an uninterruptable power supply to help prevent interruptions in power? Do you need two separate power supplies to run both low voltage-low current and high voltage-high current tests? Good mid-range power supplies include the Global Specialties Bench Top Power Supply and the Triple Output Program DC Supply.

AUGUST/SEPTEMBER 2019

TEST & MEASUREMENT •

High-end oscilloscopes allow electrical design engineers to probe deep into their circuit design and conduct a detailed analysis of elusive electrical signals.

Soldering stations A mid-range soldering station has additional features and capabilities that enhance its performance and efficiency. These might include a graphic LC display, a fume extraction unit, solder tool recognition, heating plates, capability to update the station’s firmware, and automatic standby mode, just to name a few. The Apex Tool Group WT1 and WT1H are good examples of mid-range soldering stations.

Oscilloscope The biggest differences between basic and mid-range oscilloscopes are bandwidth and rise time (edge speeds). Whereas basic scopes have maximum bandwidths of less than 100MHz, mid-range models might have a maximum bandwidth of 500MHz. Improved rise time capabilities help users more accurately measure pulses and steps like those found in timing signals, where accurate rise time measurements are critical to their design requirements. The Teledyne LeCroy WaveSurfer 3000 and Tektronix MDO3000 mixed domain oscilloscope are good examples of mid-range oscilloscopes.

Accessories Useful accessories for the mid-range test bench might include the following. A solder fume extractor, like the Jonard Industries Soldering Fume Abs ESD, promotes health and safety by extracting lead-based solder fumes and smoke using either HEPA or activated carbon filtration. A ring magnifier lamp, such as the Luxo Corportation LED Magnifier Lamp makes small components easier to see and reduces fatigue. And a precision vice, like the PanaVise PCB Holder frees your hands from holding components while trying to work on them.

Top-end test benches Top-end test benches are used by design engineers, certified electronics professionals, technicians who guarantee their work, and electronics professionals working with standards. Test benches for this group tend to include equipment that’s both calibrated regularly and specialised to the application. Whereas we saw mid-range test equipment gain features, inputs, and outputs for high-volume and multiple uses, equipment for this group tend to have fewer, dedicated features with the highest precision available. Examples include: Teledyne LeCroy HDO 4000 Series scopes, Tektronix TSG4100A RF vector signal generators, Keithley 2260B programmable DC power supplies, Apex Tool Group soldering workstations, and the Keithley Model DMM7510 graphical sampling multimeter.

Conclusion Whether you are a seasoned engineer designing circuits for the latest applications or you are an electronics novice testing your first simple circuit design, you will have the best testing results and experiences when your test bench equipment matches your testing needs. Key test equipment includes multimeters, power supplies, soldering stations, oscilloscopes, and accessories. The specific capabilities and features of test bench equipment evolve from minimal capabilities at the fundamental level, multicapability and multi-function at the mid-range, and fewer, specific capabilities and functions at the high-end. In choosing test bench equipment, consider your current needs and budget, as well as how your needs may evolve over time.

Rudy Ramos is the project manager for the Technical Content Marketing team at Mouser Electronics.

AUGUST/SEPTEMBER 2019

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• TEST & MEASUREMENT

SMART SENSOR HAS THE ABILITY TO MONITOR MOTORS AND PUMPS Control Logic has a novel costefficient condition monitoring solution for induction motors and pumps. ABB’s Ability smart sensors enable preventive maintenance by accurately monitoring and analysing motor operating data to warn against failures before they happen. The Ability sensor comes with built-in Bluetooth 4.0 technology, and can easily be attached to any three-phase AC induction motor for quick configuration. The data from multiple smart sensors can be wirelessly collected using a smartphone app or an ABB gateway to securely upload data to the cloud. Parameters such as vibration and temperature are measured, analysed and converted into meaningful information, with the results available from a customer portal or via the ABB Ability smart sensor smartphone app. Simple ‘traffic light’ indicators give a quick overview of overall motor condition,

and further information comes in the form of maintenance advice via alarms, alerts and reminders on how to optimise

maintenance and save costs. Long-term data files are available in .csv format for further analysis.

VIBRATION MONITORING RANGE GOES GLOBAL

STATIONARY INDUSTRIAL SCANNERS AND VISION SYSTEMS

Wilcoxon Sensing Technologies has signed a global distribution agreement for Mouser Electronics to distribute its vibration monitoring products and sensing solutions. Now part of Amphenol, Wilcoxon has a long successful history in vibration monitoring dating back to the 1960s. “Wilcoxon Sensing Technologies is excited to extend its market reach through Mouser Electronics,” said Dr Christopher McLean, General Manager of Amphenol Piezo Technology Products overseeing Wilcoxon Sensing Technologies. “Mouser will play a valuable role in our global distribution strategy.”

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Control Logic 1800 557 705 www.controllogic.com.au

“Mouser is pleased to add this strong industry leader to our line card, and to deliver Wilcoxon’s newest, innovative products to our customers,” said Krystal Jackson, Vice President of Supplier Management at Mouser Electronics. “Design engineers now have easy access to Wilcoxon’s advanced components, backed by Mouser's unsurpassed customer service and best-in-class logistics. We’re looking forward to a very successful partnership.” The Wilcoxon product line available from Mouser includes a range of general-

purpose, hazardous-area certified, and HART-enabled sensors, plus intelligent vibration transmitters and cost-effective enclosures. Also from Mouser, Wilcoxon MachineryMate vibration meter kits feature a handheld vibration monitoring and analysis meter to help diagnose machinery faults such as misalignment, imbalance, and looseness. The meters come with full-colour, high-contrast OLED displays, 0 to +50°C operating temperature ranges, and rugged IP67 casings for harsh plant environments. Mouser Electronics +852 3756 4700 au.mouser.com

AUGUST/SEPTEMBER 2019

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• TEST & MEASUREMENT

SPINDLE MONITOR TO BOOST MACHINE TOOL PERFORMANCE AND RELIABILITY Schaeffler reckons that its new SpindleSense spindle monitoring system can make a significant contribution to machine tool uptime and performance. In most machine tools the main spindle is at the heart of the machine and largely defines the achievable cutting capacity, surface quality, and precision. In turn, the spindle bearing support is one of the most heavily loaded components because it must transmit machining forces precisely at very high speeds for long periods of time, and the risk of collisions can never be ruled out. It therefore comes as no surprise that the majority of machine tool downtimes can be traced back to defective spindles, particularly as a result of collisions and continuous, undetected overloads. In milling operations, for example, the combination of high radial loads, long tool protrusions, and high speeds leads to particularly high loads and unfavourable kinematic conditions on the spindle bearing in the vicinity of the tool. One reason why these loads occur is because to date operators have not had a suitable tool for measuring borderline loads on spindle bearings. Schaeffler reckons that the SpindleSense monitoring system is just the tool required. The system provides electronic

protection against continuous overload and collision damage. The sensor ring monitors any displacement of the spindle bearing with micrometre precision, and this data, in combination with Schaeffler’s expertise in rolling bearings, enables assessment of operating conditions. All the software and the required algorithms are integrated into the 16mm-wide sensor ring. No further components are required for the system. The system is locally functional and transmits an individual warning signal to the machine’s control system. The sensor technology is capable of signalling an overload at a digital output within 2ms. This allows serious subsequent damage to be minimised or even prevented through fast deactivation of the drive. It also provides long-term protection for machine tool spindles. Because SpindleSense immediately triggers a warning signal when an overload is detected, operators can adjust the machining program right after the first manufactured part and reduce the spindle load by using a new tool or modified cutting values, or by employing a more suitable tool type. The operator thus achieves lower and less frequent peak loads, and benefits from a longer spindle operating life with less machine tool downtime,

which ultimately means more production time and reduced repair costs. Two options are available for outputting the measured values. Variant C-A0 transmits alarm signals as soon as the individually defined limit values for the bearing load and kinematics are reached. Variant C-A1 outputs the measured radial and axial displacements including tilting via CANbus. Machine tool and spindle manufacturers can use these displacement values to develop analysis tools for optimising the utilisation of spindle capacity, for example by visualising the deflection collective measured by the sensor ring as a load collective. For the first time ever, the machine operator will have accurate data on how the spindle capacity in each machining process is being utilised and thus be able to adjust the machining process to optimise capacity utilisation and operating life for each machine: This means that harmful overloads are prevented despite maximum spindle loads. Safe operation in the limit range allows operators to increase their productivity and also to benefit from longer spindle operating life and less frequent machine downtimes. The measured displacements that are output via CANbus can also be

used for zero point compensation. This makes it possible to produce the same quality with larger cutting values or higher quality with unmodified cutting values. The monitoring of the maximum displacement can also be used for quality assurance. The first production-ready SRS sensor ring units – including radial and axial measuring ring with an inside diameter of 70mm – will be available to coincide with the major Hannover metalworking expo, EMO 2019 in September. Additional sizes with 80 and 100mm inside diameter will be available at the end of 2019. All units have a standard width of 16mm. The system includes an SST setup service tool, with which SpindleSense can be parameterised and put into operation. Schaeffler Australia 02 8977 1000 www.schaeffler.com.au

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• MACHINERY

FAMILY BUSINESS PUTS METAL TO THE SWORD

The Hartford Sword SW423 double-column machining centre features x-y-z travel of up to 4000 x 2300 x 1000mm

When Shane Cummins admits that the machines in his workshop “tend to get a bit of a rough time”, you had better believe him. Cummins Engineering specialises in some pretty heavy-duty drilling, machining, punching and cutting operations, with work for the mining sector as a major component.

The company began in 1998 in a shed in Shane Cummins’ backyard. Today, Cummins Engineering is still family owned, but now employs more than ten staff at its works in Wacol, Brisbane. The company now boasts six CNC machines working two shifts with the ability to process more than 1500 tonnes of cut, machined, punched and drilled steel a year.

So those machines are put to work on hard-wearing materials that by definition are difficult to drill. “But,” says Cummins, “we’re good at it.”

While the majority of the company’s work does come from the mining

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sector, there have also been significant contracts for structural steelwork, such as bases for wind turbines. However, Cummins does note that the mining sector in Queensland is currently in something of a lull while waiting for new projects to take off. “And for a small shop like us, it becomes noticeable.”

the continuing performance of the machines that has generated the repeat business for the Brisbane branch of the machinery supplier.

Nonetheless, Cummins is happy with the scale of his business, citing the greater efficiency of a smaller well trained team with access to an everexpanding array of CNC machinery. The latest addition to the Cummins stable is a Hartford Sword SW423 double-column machining centre, with x-y-z travel of up to 4000 x 2300 x 1000mm, chosen to fit the gap between the company’s existing smaller Hartford Tornado and Kappa machines and the huge Hartford Amazon. This continuation of the Hartford line is no coincidence. It was the local Hare & Forbes MachineryHouse that originally introduced Cummins to the Taiwanesemade Hartford range, and it has been

Shane Cummins programs the Sword

AUGUST/SEPTEMBER 2019

MACHINERY •

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The Doosan Puma lathe has expanded Cummins’ capabilities

Hartford is unique among which can amount to significant savings Taiwanese machinery builders. when you are working with materials like Not only is it the country’s largest Bisalloy and Hardox wear grades. machining centre manufacturer, it also Also new to the workshop, and again manufactures more than 90% of its on the advice of Hare & Forbes CNC components and completes all of its ith its extreme accuracy, speed and Division consistency of cut, combined with very low operating State Manager Jeff Matthews, assembly in-house. osts, the With new its Yawei HLF accuracy, fiber laserspeed isis the perfect take your business tovery the next level. extreme and consistency of cut, combined with low operating a Doosan Pumaway 4100 to CNC “They’re not the cheapest on the lathe that has added much needed costs, the new Yawei HLF fiber laser is the perfect way to take your business to the next level. by any the stretch,” says Cummins, turning of capabilities to the Cumminsup possibilities for companies ollar market for dollar, new HLF is in a league its own, opening “but they’re certainly among the Engineering portfolio. l across the laser sector; fromisstart-ups through to full production, 3-shift for companies Dollar for cutting dollar, the new HLF in a league of its own, opening up possibilities heaviest, and in our business that means all across the laser cutting sector; from start-ups through to full production, 3-shift nvironments. With four Hartford machines and stability and durability.” environments. Precision sheetmetal processing solutions. the Doosan Puma, all sourced from One feature common to the Hare & Forbescutting over the past 14 years, ith a quality German built Precitec auto-focus head, IPG laser source, SiemensPrecision sheetmetal processing solutions. Hartford range is and the heavy-duty With a quality built stress-relieved Precitec auto-focus head, IPG itlaser source, Siemens Shane Cummins is fully clearlycutting happy with 40DSL controller aGerman fabricated, annealed frame really is a cut above gearbox on the spindle drive –and rathera fabricated, the on-going support he receives from 840DSL controller stress-relieved fully annealed frame it really is a cut above e rest. than the the company. “It’s a rare event that I do thecurrent rest.vogue for direct-drive spindles. This, says Cummins, is a need to call them out,” he says, “but I major contributor to the reliability of can’t fault their speed of response.” the machines. And, he adds that those Fiber Lasers • Turret Punch Presses • Pressbrakes • Guillotines • Automation And for a small engineering works gearboxes are exceptionally durable. or more information: Fiber Lasers • Turret Punch Presses • Pressbrakes • Guillotines • Automation For more information: that relies on its machinery, that’s all: 03 9706 8066 Call: never 03 9706 “We’ve had8066 to replace so exactly what you want from a supplier. mail: sales@appliedmachinery.com.au sales@appliedmachinery.com.au much Email: as a gearbox bearing in 14 years,” sit: www.appliedmachinery.com.au Visit: www.appliedmachinery.com.au he says. Cummins Engineering Connect with us socially Connect with us socially The new generation Hartford Sword www.cumminsengineeringptyltd.com appliedmachinery.com.au is proving to be the star performer in appliedmachinery.com.au the workshop, with the latest design wei-FPC-1.indd 1 22/12/16 9:27 am APP054-Yawei-FPC-1.indd 1 22/12/16 9:27 am Hare & Forbes providing even higher rigidity. “That MachineryHouse means we can drive it faster and get 03 8066 9706 8066 sales@appliedmachinery.com.au Phone: Phone: 03 9706 Email:Email: sales@appliedmachinery.com.au www.machineryhouse. through the work quicker,” he says. It also means that the inserts last longer, com.au

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• MACHINERY

QUEENSLAND COMPONENT MAKER HAS 5-AXIS AMBITIONS

Eastgate Engineering MD Mick Bonanno and Operations Manager Peter Cleary

Nobody would ever accuse Mick Bonanno of a lack of ambition. Nor would he ever be found talking down the future of Australian manufacturing. The Managing Director of Brisbanebased Eastgate Engineering is hell bent on bringing his industry back onshore, and doing so by applying Europeanstyle values of quality and efficiency.

that we do, as well as taking some of the stress off the machinery.” Cleary’s point about the climate control benefitting the machinery is

an important one, with most of the company’s machines operating 16 hours a day.

Runs of up to 10,000 parts are not uncommon, and one customer relies on Eastgate for 15,000 parts per month.

Looking around Eastgate’s climatecontrolled workshop in the Brisbane suburb of Lytton, you cannot but be impressed by the cleanliness of the operation.

The company moved into its current custom-built facility at Lytton in December 2018, after a six-month wait for the power to be connected, and immediately set about equipping the workshop with more capacity and greatly increased capabilities.

The other thing that you notice is the temperature – a consistent 21°C, regardless of the Queensland climate outside – which is greatly appreciated by the 12-strong workforce. “The air conditioning is a real plus for the staff,” says Operations Manager Peter Cleary, “but it’s also important for maintaining the tolerances in the work

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Locally, Eastgate Engineering has

become well known and trusted for component manufacturing and other repetitive engineering covering a range of markets from transport and mining to automotive and electrical. And, countering trends, it isn’t only small niche needs that the company services.

The Doosan VC630/5AX five-axis machining centre

But that isn’t where the Eastgate growth story begins. Mick and Dianne Bonanno acquired the company in 2013. Mick was already familiar with the Doosan family of turning centres, having operated a Puma lathe at his

AUGUST/SEPTEMBER 2019

MACHINERY •

deal with a rapidly increasing skills void that they see as holding back manufacturing in Queensland. One saving grace for Eastgate though is that all its Doosan machines use a Fanuc controller, providing consistency of programming when moving from machine to machine. And Cleary is particularly fond of the conversational control features that make the CNC considerably easier to master. One thing is for sure, Eastgate Engineering does look after its machinery, with twice-yearly servicing for every machine, and this is where the company’s relationship with the local Hare & Forbes operation comes to the fore. “The service techs really know their stuff,” says Mick Bonanno, “and they’re on call for us pretty much 24/7 – not that we need them much.” Testimony to how well the machines are treated is that all seven Doosan machines look brand new. And if it wasn’t for a change of colour scheme in the last five years, a casual observer would not be able to tell which one was the first to be put into service.

Hare & Forbes technicians carry out twice-yearly servicing on all the machines

other Queensland-based engineering company. So when the time came to expand at Eastgate he called on Hare & Forbes MachineryHouse to check out the latest range. It was in 2014 that the first Doosan machine was installed at Eastgate Engineering – and it is still in full-time use, running 16 hours a day. Now, the new premises house no fewer than seven Doosan machines, the latest addition being a VC630/5AX five-axis machining centre. And Mick Bonanno is certain that this will not be the only machine of its type at Eastgate.

Peter Cleary bemoans the fact that there is no such thing as an apprenticeship course in CNC machining. “They do fitting and turning, but that’s not what we need,” he says, and so Cleary and Bonanno are lobbying hard to improve the training available to

Eastgate Engineering eastgate.net.au Hare & Forbes MachineryHouse www.machineryhouse.com.au

“We’re aiming to have more of these machines in the future,” he says, “with the intention to become the go-to place in Queensland for five-axis machining.” If that does happen, it will be down to the quality of the work that the 12-strong team at Eastgate are already performing. Thanks to the controlled working environment, the quality and condition of the machinery and the skills of the workforce, Peter Cleary proudly boasts that the team can “happily hold on to 5 micron tolerances”. Those same factors have also seen the company develop extensive experience in working with exotic materials. “There’s nothing we won’t touch,” boasts Cleary. This quality of production has seen Eastgate Engineering secure significant component manufacturing contracts in highly demanding markets, such as motorsport, defence and aerospace, which Mick Bonanno sees as a major growth area for Queensland with the state slated for the Australian Space Agency’s launch control centre. That focus on the space industry in Queensland has also seen Eastgate Engineering partnering with ASAN on the Live Fire rocket programme, which is providing a welcome boost to STEM training at schools around the state. In fact training in general is a major focus for the company, which is taking things into its own hands and beginning to develop its own apprenticeship programme.

6/32 Campbell Ave, Dee Why NSW 2099 www.serpent-dove.com.au industry update ad.indd 1

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VEGA TUTORIAL VIDEOS - PART SIX

SERIES 9 - PACTWARE ENVIRONMENT UNITES FIELD DEVICES AND COMMS ELEMENTS It used to be the case that every field instrument and sensor needed its own operating program. That was before the leading companies in industrial automation got together to formulate the Pactware operating environment.

a series of concise tutorials on the features of Pactware and how it provides a uniform environment for the setup and diagnostics of field devices and communications elements from different manufacturers. Individual videos address different aspects of Pactware, building into a complete picture of the capabilities of the software environment. These

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range from establishing simple pointto-point connections to networking using Ethernet and Profibus.

VEGA Australia 02 9542 6662 www.vega.com

The final video in the series shows how the expert diagnostics within Pactware can be leveraged to maintain the integrity of plant-wide networks, allowing faults to be located and rectified quickly, and minimising downtime.

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COMPRESSORS & PNEUMATICS •

EASY INSTALLATION FOR HOT TAP DIGITAL FLOWMETERS Measuring compressed air flows is the first step toward system optimisation by identifying areas of high compressed air use and leaks. And now Compressed Air Australia offers a range of digital flowmeters that can be installed on compressed air piping while it is still under pressure.

and hex wrenches. The Hot Tap feature is available on 2-8in (51203mm) flowmeters for fitting on schedule 40 iron pipe and Type L copper pipe. They are CE and RoHS compliant and can also be ordered for schedule 80 or 10S pipe.

By eliminating the need to isolate and remove pressure from the pipe, Exair Hot Tap digital flowmeters reduce installation time while maintaining safety. The flowmeters incorporate two valves that the measuring probes pass through. A sound muffler that also collects chips from the drilling process stops installation debris from entering the airstream and minimises noise exposure.

The meters display airflow values on a bright LED screen, with optional data logger to capture and manipulate the data, or with wireless capability to transmit the data securely over a wireless network. Airflow values are expressed in standard cubic feet per minute or cubic meters per hour.

Each meter ships with all the hardware and tools needed for installation including drill bit, drill guide, chip capturing muffler,

Compressed Air Australia 1300 787 688 www.caasafety.com.au

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AUGUST/SEPTEMBER 2019

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• COMPRESSORS & PNEUMATIC

ENERGY-SAVING COMPRESSORS WORK TO PIONEER PLASTICS RECYCLING IN AUSTRALIA

Harry Wang with a wall of plastic waste ready for recycling

The decision by China not to accept our plastics waste was always going to create difficulties within Australia where, it would seem, we are far behind in developing our own solutions to home born waste treatment problems. However at least one forward-thinking entrepreneur recognised it as a business opportunity.

specialised machinery from the USA that uses technology including robotics and laser identification. Precision compressed air jets sort the different types of plastic, and artificial intelligence is utilised to further refine the process.

Two large air compressors sourced from Southern Cross Compressors (Australia) were installed to provide the power to run these high-tech sorting and processing machines. AC Polymers chose the 110kW 2-stage compressors

Kevin Smith is Chief Operations Officer at AC Polymers. He says: “In keeping with our commitment to environmental sustainability, we also wanted compressors that gave us the required output and more but were highly efficient in minimising our energy costs. To date, we couldn’t be happier with their performance and our service contract with Southern Cross we expect will ensure a reliable supply of compressed air power for the plant now and in the future.”

With an insight into China’s new, strict waste processing policy changes in 2018 restricting the import of waste for recycling, local businessman, Harry Wang realised that there would be a huge demand for a specialised solution to Australia’s waste treatment problems. After some 18 months of exhaustive research and development, Wang, founder of an Australian financial company, invested $20 million including a $500,000 commitment from the state government and his personal resources in establishing a state of the art plant in Somerton, Victoria with an initial processing capability of 70,000 tonnes of plastic waste materials per year, equivalent to nearly half of all plastics recycled in Victoria. Prior to the recent opening of AC Polymers, most of Australia’s waste plastics were shipped overseas for processing to return to us as imported products. Harry Wang imported the very latest

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for the high-quality air they delivered with variable output on demand, as well as being extremely energy efficient and reliable. The compressors also come with an extended performance warranty and an exclusive lifetime warranty on the airend.

The process involves transforming large quantities of low-value contaminated mixed plastics from households, commercial and industrial waste into high-quality commodities that can go directly back into the manufacture of new products. This involves sorting and cleaning plastic by polymer type specific to customer requirements, with the end result being a high-quality plastic flake that can be sold and made into more plastic products. The KHE110VS.8.II is an energy efficient 2-stage compresssor

"The demand is huge and still growing," says Wang. "Most of our

AUGUST/SEPTEMBER 2019

COMPRESSORS & PNEUMATICS •

Plastic waste processing at AC Polymers

products will be sold locally in Australia. More than half of that will be in Victoria.” With new regulations, forcing manufacturers to use a percentage of recycled materials and costing more to use virgin materials, there is already a great demand for recycled, reusable raw plastic inputs and it is expected that need will continue to grow in the coming years. The business sources mixed plastics from materials recovery facilities. Much of the feedstock consists of plastic beverage containers as well as containers for cleaning products and foodstuffs. Unfortunately, while there is plenty of product available, much of the plastic that should be recycled is still going to landfill. Better education about what can be recycled and how it should be separated before being put out for collection would help make even more plastic available for reuse.

and plastic trays, followed by fencing, packaging, outdoor furniture, pipes and other construction materials and clothes. "As long as they are in the recycle system they can be recycled again," says Wang. "It really depends on the strength and the quality of the raw, virgin material, how many times you can recycle. The circle is endless." “We are big supporters of reducing plastic pollution as a first step, but while there is still plastic to be recycled we should be doing our best to capture what we can. We should treat plastic like gold. It is a precious resource that can be used in production again and again,” says Wang. The recycling plant will be powered by renewable energy produced from Goldwind Australia’s wind farm near Ballarat.

Once items are sorted and grouped according to their particular polymers, they are thoroughly washed then chopped into small plastic flakes that are sold on to manufacturers to make products.

Advanced Circular Polymers 1300 066 666 www.acpolymers.com.au

Most of the products made using the flakes are the same as those fed into the plant: water and soft drink bottles. The next biggest use is for food containers

Southern Cross Compressors 1300 098 901 www.southerncrossaircompressors.com.au

AUGUST/SEPTEMBER 2019

Plastic re-useable flakes created from recycled plastic waste

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• COMPRESSORS & PNEUMATIC

VACUUM TECHNOLOGY MEETS THE DIGITAL FACTORY Linking machines with information processing systems is the key driver of the Fourth Industrial Revolution. This new level of innovation is based on crosssystem communication, and so long as all devices contain the appropriate interfaces, it enables energy and process control as well as predictive maintenance. Schmalz has developed a range of components for vacuum automation that not only capture energy- and performancerelated data and deliver it in the cloud, but also monitor and analyse as well. Thanks to IO-Link and Industrial Ethernet interfaces, these smart field devices communicate continuously from the sensor and actuator level to the higher-level programmable logic controller and all the way to the control level. These communications are bidirectional: as well as transferring data about energy consumption or condition, the controller can also be used to change parameters and transfer them to the field device. In addition to an IO-Link and Industrial Ethernet interface, Schmalz’s intelligent vacuum components also contain a Near Field Communication (NFC) interface that enables short-range communications with mobile devices. The smartphone can be used to parameterise the component as well, using Schmalz’s specially developed ControlRoom app. And parameter changes that are performed via NFC can be transferred directly to the device or copied from one device to another.

An additional benefit of NFC is the ability to directly assign a single device to a smartphone. As the two devices are linked over a very short distance - a maximum of 20mm - the user can rest assured that no neighbouring devices are inadvertently parameterised.

From air flow to data flow One example from the Schmalz range is the SCPSi compact terminal, which consolidates up to 16 separate vacuum generators into a single compact unit with just one electrical connection and one compressed air connection. This enables both simultaneous and individual handling of different parts using only one system. The vacuum is generated with a venturi nozzle and recorded by a sensor. The user can read the precise vacuum value via the IO-Link process data or the generator display. The cyclical process data are also used to control the ejectors and receive the current information reported from the SCPSi. The IO-Link connection settings and parameters and the measurement and analysis data are likewise available to the user. Furthermore, the vacuum components’ diagnostic and prognostic functions gather information about the condition of the system and identify trends in performance and quality.

All this information is transferred to an external cloud, where it is processed and analysed, generating real added value. If the system identifies subtle changes or values that diverge from allowable tolerances, it quickly and clearly reports them to the user. For example, the system checks dynamic pressure and leakage for predictive maintenance assessments. Furthermore, condition-monitoring events are triggered if dynamic pressure values deviate, the evacuation times for ejectors exceed their limit values or sensor voltage is outside the working range. The energy-monitoring function oversees the energy consumption of the connected vacuum systems. Monitoring is based on the measured air consumption, including measurements of system pressure and nozzle size. The user can specify an externally recorded pressure value using the IO-Link process data. Using this value, the ejector can measure the air consumption in absolute terms and as a percentage. This range of functions allows the user to maintain system efficiency and availability.

Quick integration IO-Link provides additional benefits when integrating the compact terminal into the system environment. The IO Device Description file contains information about identification, device parameters, process and diagnostic data, and communication properties. Exchanging devices is also simplified as the IO-Link log provides an automated process for data transfer. When a device is swapped for a new one of the same type, the settings for the old device are automatically sent to the new device by the system master. The SCPSi compact terminal is part of a growing range of smart field devices from Schmalz. These include: the VSi electronic vacuum pressure switch, which monitors and measures underpressure and overpressure in automation and handling systems; the SNGi-AE special gripper; and the ECBPi electronic vacuum generator with IO-Link and NFC for the digital factory. Schmalz Australia 03 92158800 www.schmalz.com

PCA TM

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AUGUST/SEPTEMBER 2019

â&#x20AC;˘ SERPENT & DOVE - APPLIED MAGNETICS

INNOVATION AND ATTRACTION FINDING WAYS WITH MAGNETS

THE HEAVY LIFTING

A WELD OF DIFFERENCE

When it comes to magnets for lifting steel, the Italian manufacturer Tecnomagnete is acknowledged as a world leader in both permanent magnet and permanent-electro magnet technology. Distributed in Australia and New Zealand by Serpent & Dove, the Tecnomagnete permanent-electro lifting magnet range is particularly advanced in that the units only require electric power momentarily to energise or de-energise their permanent magnet cores.

It was as long ago as 1984 that Serpent & Dove coined the term Welders Magnetic Square to describe a welderâ&#x20AC;&#x2122;s magnetic clamp that had the approximate proportions of an engineer's square.

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The company still makes its own range of magnetic welding clamps as well as distributing the Mag-Mate range of switchable permanent magnetic welder's squares, ground clamps and pivoting angles in Australia.

AUGUST/SEPTEMBER 2019

SERPENT & DOVE - APPLIED MAGNETICS •

There is no disputing the attraction of magnets. There comes a time in everyone’s childhood when three key discoveries are made: here is a magical device that can be used for picking things up, opposites attract and like poles repel. These realisations will likely lead to hours of experimentation. In some cases they might lead to a thirst for more knowledge. One person for whom the magnet “bug” has not diminished is Ian Heard, cofounder and still going strong at Serpent & Dove - Applied Magnetics. And that enthusiasm has been passed on to Ian’s son, Adrian, who now handles the day-to-day running of the company. Ian Heard freely admits that in the early days following the founding of the company in 1984, it was his cofounder Rob Miner who was the practical brains of the operation. A fitter and turner by trade, it was Miner who was the enabler that allowed Serpent & Dove to start manufacturing its own magnetic products. And to this day the company still relies on one particular manufacturing

machine made by Rob Miner. However, following Miner’s untimely death in 2006, Adrian joined the company in 2009, and between them the father and son team have accumulated decades of experience in the application of both permanent magnets and electromagnets, and an impressive array of patents for their innovations. It was not always so. The company began by manufacturing its own range of small magnetic products such as welding clamps and other workholding products, which became commercially successful both in Australia and in export markets. However, when orders from overseas distributors suddenly dried up, Ian Heard discovered that the range had been reverse engineered and was being manufactured in China for prices he simply couldn’t match. This was a costly lesson to learn in terms of loss of sales. However, having learnt that lesson the hard way, Serpent & Dove set about protecting its key intellectual property with patents. And while certain key products are protected by international patents (in particular, the latest version

of the company’s pilot ladder magnet – see below), the company has focused on using the Australian innovation patent system. These relatively low-cost patents have proved themselves extremely useful to Serpent & Dove in discouraging potential copiers. They have also been used to demonstrate “prior use” when a successful copier has attempted to claim that the company was infringing on its own intellectual propertry. Today, when it comes to the heavy lifting a significant proportion of the company’s work is in consultancy, and much of this involves telling some home truths about exactly what can and cannot be done with magnets. “We get a lot of requests along the lines of ‘I’ve seen a magnet lifter down the road – can I have one just the same for my application’,” says Adrian Heard. “And when we find out that the application involves a completely different type of load, the customer is surprised that the solution required is considerably more complex. It’s all about fitting the right magnet to the job.”

Ian Heard agrees: “ It isn’t simply a matter of the mass that’s to be lifted. It isn’t a simple equation. The geometry is all important, and this is a difficult concept for many people to grasp.” “So we have to ask a lot of questions in order to really understand the application. And there are occasions where we have to tell people that their ideas simply won’t work. They may not like what they hear, but they do eventually appreciate our considered opinion.” “And we do miss out on jobs because we ask those questions,” adds Adrian, “but safety is paramount, and there is no way that we would want to supply a magnet that couldn’t handle the work, and couldn’t handle it safely.”

Serpent & Dove - Applied Magnetics 02 9971 7577 www.serpent-dove.com

AN AID TO MARITIME SAFETY

THE MAGIC WAND

Probably Serpent & Dove's most successful product of all time, the Yellow Mag pilot ladder magnet is used worldwide to secure the ladder to a ship’s hull that allows the marine pilot to get on board and guide the ship in to port.

Serpent & Dove invented and first produced the Wonder-Wand magnetic wand in the late 1980s, and has sold tens of thousands worldwide. Not surprisingly, this one of the company’s most copied designs. But the genuine Wonder-Wand wand remains the preferred clean-up tool around lathes and drills in industrial workshops.

The improved Yellow Mag II is 33% lighter in weight and requires 15% less effort to remove than the first-generation device while retaining the same clamping strength. So important is the Yellow Mag II to Serpent & Dove that the company has patented it in the Netherlands.

AUGUST/SEPTEMBER 2019

More recently, the company has expanded the concept with a specially developed large diameter version for recovering ferrous contamination from drilling fluids in the oil industry. By removing the swarf, the patented Claymore Ditch Magnet allows the drilling fluids to be re-used, reducing wear and tear and avoiding downtime.

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• FLUID CONTROL

CHOOSING THE RIGHT PERISTALTIC PUMP FOR INDUSTRIAL APPLICATIONS viscosities. Pressure: Not all peristaltic pumps are created equal. The better designs will enable pumps to be applied on applications with pressures to 15bar. This requires hoses rated to these pressures and rollers, rotors and other components designed for these high pressures. Manufacturers will detail which models are rated to these pressures and what the flow and speed limitations are. Suction conditions: Peristaltic pumps are capable of high suction lifts, but any peristaltic pump selected for a duty requiring a suction lift should have a pulsation dampener fitted. Also, if the viscosity exceeds 2000cPs, the suction line diameter should be increased. Another good “rule of thumb” is to keep the suction line as short as possible.

The basic principle of the peristaltic pump traces back to human “peristalsis” (a term referring to the alternating contraction and relaxation of muscles around a tube to force the contents through it). An elastomeric tube is squeezed along its length by rollers or shoes that pushes the fluid contained within. The tube’s restitution after squeezing produces a vacuum that draws fluid continuously into the tube. This creates a gentle pumping action that doesn’t cause any damage to the product.

cycle; flow; pressure; suction conditions; the correct hose (tube) for the pumped media; temperature limitations; cleaning requirements (CIP or SIP); the effect of possible contamination; and maintenance aspects. Duty cycle: It is important to consider

There are basically two types of peristaltic pumps: low-pressure low-flow pumps are commonly used in laboratories or for low-flow dosing or metering applications; and larger industrial-class pumps handle higher flows and can generate higher pressures. This article will concentrate on industrial pumps.

Selection criteria There are a number of parameters that need to be considered when selecting the right peristaltic pump for a particular application. These are: duty

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Typical hose materials include: • Natural isoprene for abrasive fluids or moderately aggressive fluids: This is the most common hose material and is often available with various pressure ratings. • Natural isoprene with substrate for food products: These hoses will have FDA approval numbers and be suitable for the transportation of food grade products. Should be able to sterilise with hot water and a diluted cleaning agent and also steam cleaning.

Contamination is avoided because the product is contained in the tube (the only pump part that comes in contact with the pumped fluid). The peristaltic pump is a very versatile pump. It is a self-priming, positive displacement pump, able to deliver relatively high pressure, pass solids and transport corrosive and abrasive media. But selecting the right one for the job is important.

Correct hose: Selecting the right hose material for an application is critical in achieving extended hose life, and also critical if hygiene is required for transporting food or pharmaceutical products.

A pump with a roller design does not need casing lubricant

the duty cycle when selecting a pump. If the pump has to operate on a continuous basis (for hours on end), the speed must be reduced to prevent a shortened hose life. Good manufacturers will have performance curves that detail what part of the pump curve can be treated as continuous duty and what part should only be used intermittently. Flow: Most performance curves are based on water-like substances and flooded suction. When dealing with more viscous fluids or high suction lifts, this will need to be factored into sizing the pump for the correct flow inclusive of de-rating speeds for these aspects. Good manufacturers will have de-rating charts for increased

• EPDM hoses are suitable for a wide range of chemicals. • NBR hoses are suitable for oils, greases, hydrocarbons and various solvents. • NBR for food products: These hoses will also have FDA approval numbers and are suitable for oils and fats. Should be able to sterilise with hot water and a diluted cleaning agent and also steam cleaning. • Hypalon hose is suitable for a range of concentrated acids and alkaline liquids. • Pharmed thermoplastic elastomer base polypropylene is a limited-use hose for liquid pharmaceutical products. Will have FDA approval numbers and should be capable of sterilisation with hot water. Temperature limitations: Good manufacturers will have temperature

The leak detector is wired back to the control panel

limitations in their hose selection guides. Ensure that operating temperatures do not exceed the temperature rating of the hose. Cleaning requirements: Where hoses need to be cleaned in place (CIP) or sterilised in place (SIP), the hose selection needs to allow for this. Also, it is useful if the pump rollers (or shoes) are easy to retract to allow full flushing of the hose. Automated retraction makes this process even simpler. Contamination: If product contamination is an issue, selecting a peristaltic pump with rollers instead of shoes is best. The pumps with shoes will need their casings to be full of lubricating fluid. When the hose starts to fail, the lubricating fluid may contaminate the product being pumped. Maintenance: A peristaltic pump does not require a lot of maintenance apart from hose changes. It is in this area that pumps with certain designs and certain features can save time and money. A pump with rollers does not have a casing full of lubricant, so does not need this oil drained and then refilled again after the hose change, and no clean-up of the mess. Early leak detection is another feature that reduces maintenance costs. This is only possible for pumps with the roller-onbearing design. Because casings are not filled with fluid, a simple “plunger-in-cup” designed leak detector can pick up hose failures early, minimising product loss and mess. A remotely operated retractable roller will also reduce maintenance costs by extending hose life. Between pumping cycles (over night, weekends, holiday periods), the roller can be retracted to remove pressure on the hose during these periods, greatly extending hose life. Hydro Innovations 02 9898 1800 www.hydroinnovations.com.au

AUGUST/SEPTEMBER 2019

HYDRAULICS AND FLUID CONTROL •

HYDRAULIC BOLT TENSIONERS FIT COMPACT FLANGES found in industries such as oil and gas, mining and energy, manufacturing and process engineering, liquids reticulation and bulk materials handling. Generating 30 per cent more load capacity than traditional tensioners and available in maximum capacities from 134 to 4650kN, HM-Series tensioners fit all standard flanges, including ANSI, API and Norsok L005 compact flanges. According to Enerpac Regional Bolting Leader, Andrew Marsh: “HydraMax bolt tensioners are fieldproven tools. HydraMax tensioners have been the most recognisable tensioner in Hydratight’s bolting portfolio for more than a decade and are now becoming an important element of the Enerpac range of controlled bolting solutions as Hydratight and Enerpac are merged to become a single company. Enerpac’s compact HM-Series HydraMax topside bolt tensioners promise powerful, swift and even performance over multiple-bolt joints in assembly

and maintenance operations. The HM hydraulic tensioners are designed to overcome the dimensional constraints and bolt load requirements of compact flanges

“This integrated range expansion will have major benefits for bolting customers, including the comprehensive national sales and service backup for which Enerpac

is widely respected – as well as access from the one convenient source, to the extensive Enerpac range of professional bolting technology, all with global standards of reliability, safety compliance and traceability,” says Marsh. Enerpac is also updating its GT-Series topside bolt tensioner range with a new GT7 tensioner. The seven GT load cells and bridges will cover bolts from 5/8 to 4in and M16 to M105. The GT range will also benefit from a captive socket system that will prevent the socket falling or being lost from the tool. GT-Series universal bolt tensioners (in capacities up to 3958.4kN at 1500bar) and HM HydraMax topside tensioners are particularly suitable where operators want to achieve known and accurate bolt loads across multiple applications, such as pipelines, flanges, base bolts and turbines. Enerpac 02 8717 7200 www.enerpac.com

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• HYDRAULICS AND FLUID CONTROL

HYDRAULIC ASSISTANCE POWERS UP TYRE HANDLER

The tyre handler has to deal with large tyres, including haul trucks and belly dumper trucks

“Not only is their quality secondto-none, but they’re highly responsive. If we need something – they’ll be there. They’ve never let us down,” said Rynne. The tyre-handler in action

Leading Queensland forklift company, Norlift, has received expert hydraulic engineering assistance from Hydraulink to actuate a new Rexroth joystick control for enhanced safety and efficiency of its Hyundai tyrehandling forklifts for Rio Tinto.

essentially like a robotic arm. It can pick up a wheel flat on the ground and raise it vertically, then tilt it left, right, forwards or backwards,” explains Rynne.

work with,” he said. Hydraulink Cairns – the branch responsible for this project – is one of the extensive Australasian Hydraulink network, which has more than 400

Norlift supplied Hyundai 160D7 forklifts, fitted with cascade tyre handlers, to Rio’s Weipa and Gove operations, which contribute the majority of the company’s 50 million tonnes of bauxite exported annually. Rio invested $2.6 billion in expanding its Weipa operations in 2015 – the single biggest investment in Far North Queensland at the time.

“It’s a great system. If you push left on the joystick, it responds left. It’s

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According to Hydraulink Cairns Co-owner, Brett O’Hara, Hydraulink prides itself on having a solutionsfocused approach and working to customer’s needs, rather than providing a one-size-fits all approach. “For this custom design, the pilot system was removed from the forklift and a full electronic control valve was fitted. It’s proportional, and allows infinite control,” he said. Greg Rynne was impressed with the result, and the engineering involved throughout the process. “What I really like about Hydraulink is that they take pride in all the bits. Most of the hoses, connectors and fittings are hidden away in this application, but Hydraulink still set it up with incredibly ‘neat’ engineering. Everything fits well and is easy to find and maintain,” he said.

“Rio wanted a tyre-handler with better ease-of-use and safer operation, so we worked with Rexroth and came up with a joystick solution, where the operator only has to move one joystick instead of the typical eight levers. Hydraulink installed all the hydraulics neatly and efficiently,” said Norlift Owner Greg Rynne. The tyre handler is used for tyre changing and maintenance on a huge range of mining, earthmoving, bulk handling and resources machinery, including haul trucks and belly dumper trucks.

Neat engineering

The custom designed hydraulics

“Hydraulink shares the same philosophy as us, whereby we are always attentive to detail, take pride in our work and strive for engineering excellence. It makes them a pleasure to

service points across the region, where it also provides service and back-up 24/7 to customers in industries where safety and uptime are vital.

“Rio is very happy with the tyrehandling forklifts. The enhanced ease-of-use was very well received by their operators, and the fact that it also enhanced safety – one of their top priorities – was a major asset.” Hydraulink 1300 36 37 34 www.hydraulink.com.au

AUGUST/SEPTEMBER 2019

HYDRAULICS AND FLUID CONTROL •

QUALITY COMPONENTS SET THE STANDARD FOR HYDRAULIC ASSEMBLIES In the high-stakes world of hydraulic machines, equipment, tools and systems, engineers demand extraordinary precision and repeatability in the complex interconnected workings of components. Quite literally in fluid power, there is little room for failure, as even simple leaks and seal failures can cascade into system-wide failure, potential downtime or even create safety issues for operators. For decades, Boker’s has been a trusted provider of washers, spacers and shims in pumps, motor assembly armatures, valves, hose assemblies, connectors, fittings and virtually every moving or sealed part in hydraulic applications and the mechanisms driven by them. Among the precision components vital to the hydraulics industry, Boker’s manufactures backup rings, washers and retainers designed to protect O-rings,

AUGUST/SEPTEMBER 2019

gaskets and seals from deforming or extruding under hydraulic pressure. These components are made to precise dimensional and thickness tolerances in a number of configurations and custom designs, including flat or contoured, in solid construction. Boker’s washers, custom profiles, spacers, shims and discs also provide stability, maintain integrity and reduce friction that allows vibrating, rotating or torqued parts strain relief under loads and pressurised operating conditions. Numerous specifications and characteristics for material hardness, durability, corrosion-resistance, fluid and chemical compatibility, temperature range, resilience, wear resistance and more come into play with hydraulic applications, and Boker’s is well-equipped to deliver custom engineered solutions.

Along with the millions of possibilities offered by the company’s extensive range of nonstandard washer sizes, OEMs and MROs alike rely on Boker’s for manufacturing of proprietary parts, custom shapes and specialised requirements. Boker’s has unique part and component fabrication experience in a

broad range of hydraulics applications from heavy-lifting equipment to off-road machinery and construction equipment and from suspension systems to hand tools. Boker’s +1 612 729 9365 bokers.com

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• ELECTRONEX PREVIEW

ELECTRONICS EXPO COMES OF AGE

Now in its tenth year, Electronex – The Electronics Design and Assembly Expo – will be held on the 11th and 12th September at the Melbourne Convention & Exhibition Centre. Billed as Australia’s only dedicated trade event for the electronics industry, the exhibition will run alongside the SMCBA Electronics Design & Manufacture Conference. Electronex alternates annually between Sydney and Melbourne, and has grown considerably since the 2017 event attracted more than 1000 electronics design professionals to the Melbourne Park Function Centre. The move to the MCEC has seen a record number of companies participating in this year’s event. With more than 100 companies represented at the expo and a technical conference plus free seminars on the show floor featuring leading international and local industry experts, this is a must-see event for decision makers, managers and engineers designing or manufacturing

WORKSHOPS TO DELIVER IN-DEPTH COVERAGE

products that use electronics. This year’s event will feature a host of new product releases as well as advanced manufacturing solutions as Australian companies move towards high-tech specialised manufacturing applications. Companies are sourcing more products and solutions from Australian-based suppliers as local manufacturers seek out specialist applications and recognise the expertise and quality control that is available from local suppliers. In addition to featuring a wide of range of electronic components, surface-mount and inspection equipment together with the latest test and measurement products and other ancillary products and services, companies can also discuss their specific requirements with contract manufacturers that can design and produce turnkey solutions for specific applications. Trade visitors can register for free online at www.electronex.com.au

Running alongside Electronex, the 2019 Surface Mount & Circuit Board Association (SMCBA) Electronics Design & Manufacture Conference will feature three two-day workshops covering: new product development and introduction; improving manufacturing yield and reliability; and PCB design. The new product development and introduction workshop will be presented by Martin O’Hara, the former National Strategy Manager for the UK’s Centre for Innovative Manufacturing in Ultra Precision Manufacturing Systems and Processes. It will cover from start to finish the processes and procedures for new product development and introduction. Jasbir Bath will conduct the six-part workshop on improving manufacturing yield and reliability. He has more than 25

years of experience in research, design, development and implementation in the areas of soldering, surface mount and packaging technologies. Bath has extensive knowledge of soldering technologies, and in 2012 was appointed as principal engineer within the IPC's assembly technology area. The workshop on PCB design will be a comprehensive two-day course covering many of the trade-offs that make PCB design ever more difficult. The presenter, Andy Kowalewski, has been a board designer for 39 years and has owned and operated a service bureau designing under contract both in Australia and overseas. Visit www.smcba.asn.au/conference for full conference details.

COBOTS IN THE SPOTLIGHT CONNECTIVITY FOR ALL DIMENSIONS at Electronex 2019. Further production aids on show will include Zimmer Group grippers – quick-change adapters for use in cobot applications.

which offers versatile solutions for the connection of several PCBs within a device. It includes shielded versions with a pitch of 0.8mm and unshielded versions with a pitch of 1.27mm.

Other highlights will feature Inventec Advanced Materials, including solder paste, cleaners and fluxes, together with the company’s environmentally friendly, user-safe co-solvent precision de-fluxing and precision parts cleaning solutions with live cleaning demonstrations. ONBoard Solutions will be showing off the innovative TM-Techman cobot solution with Hantas screwdriving tooling and screw feeder on Stand A7

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ONBoard Solutions 02 9695 1030 www.onboardsolutions.com Electronex Stand A7

Horizontal and vertical female and male connectors enable PCBs to be arranged in a mezzanine, coplanar or orthogonal layout. Both ranges include 12- to 80-position versions for currents up to 1.4A and voltages up to 500V AC. Phoenix Contact will feature the newly developed Finepitch series of robust board-to-board connectors,

Phoenix Contact 1300 786 411 www.phoenixcontact.com Electronex Stand D28

AUGUST/SEPTEMBER 2019

ELECTRONEX PREVIEW â&#x20AC;˘

TINY DC/DC CONVERTOR REPLACES INDUSTRIAL REGULATORS

TROUBLESHOOTING SOUND & VIBRATION PROBLEMS

POWER SUPPLIES AID DESIGN TESTING

Mikado is the latest addition to the Acoustic Camera range on show from HW Technologies, and is perfectly suited for troubleshooting sound and vibration problems.

Keysight Technologies will be showing a new series of single- and dual-output power supplies that deliver more usable power, bench friendly design with low background noise, small footprint and large display.

This mobile, wireless device is easy to use and efficient, and enables very flexible measuring positions and angles, allowing the quick and efficient identification of noise sources using acoustic signals. The exchangeable Li-ion battery and Surface Pro tablet make it completely autonomous. HW Technologies 02 9683 4008 www.hwtechnologies.com.au Electronex Stand B23

Keysight's E36200 series enables engineers to test their designs across multiple industries including automotive electronics, consumer goods, medical devices, power tools and industrial applications. Keysight Technologies Australia 1800 225 574 www.keysight.com Electronex Stand A6

SENSOR ENCLOSURES FOR THE IOT The 1551V miniature ventilated sensor enclosures on show from Hammond Electronics are designed to house sensors and small subsystems installed as part of IoT systems. They come in four sizes corresponding to the most commonly used PCB sizes and are available in black, grey and white. There are four PCB mounts moulded

into the base, ventilation slots on the vertical faces and mounting slots and a 15mm cable knock out in the base. A snapfit closure allows repeated opening and closing without tools. Melbourne Hammond Electronics 08 8240 2244 www.hammondmfg.com Electronex Stand C19

On show on the APS Industrial stand at Electronex, the Torex XC9267/68 is billed as the worldâ&#x20AC;&#x2122;s smallest 36V DC/DC convertor. The device can operate from 3.0 to 36.0V and deliver loads up to 600mA making it an ideal replacement for inefficient linear regulators used in many industrial applications. Housed in a tiny USP-6C package, measuring only 2.0 x 1.8 x 0.6mm, the XC9267/68 works with low-ESR ceramic capacitors and comes with a choice of two switching frequencies, adjustable soft start and a power good output..

Park Function Centre 11-12 September 2016 APS Industrial 1300 309 303 apsindustrial.com.au Electronex Stand A34

Design, Develop, Manufacture with the latest Solutions Showcasing new innovations in Electronics and Advanced Manufacturing

FREE

Registration Online

Melbourne Park Function Centre www.electronex.com.au 11-12 September 2016 Melbourne Exhibition Centre 11-12 September 2019 In association with

AUGUST/SEPTEMBER 2019

Organised by

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• WASTE AND ENVIRONMENT

Waste Expo Australia, the country’s largest and most comprehensive waste management and resource recovery conference and exhibition, has launched registrations for this year’s event, which will return to the Melbourne Convention and Exhibition Centre on 23rd and 24th October. Hosting more than 120 brands and featuring more than 100 speakers across three conference stages, it will be where the industry converges to revolutionise Australia’s waste management processes. This year’s Expo offers premium freeto-attend conference content across the Waste and Wastewater Summits, which cover seven streams attracting the largest gathering of waste management and resource recovery professionals in Australia.

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• Gran-Calibur Series Granulators • Complete recycling lines; tyres, e-waste, cable, plastic washingrecycling & drying. • Complete lines; tyres, e-waste, cable, plastic washing & drying.

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The Waste Summit, sponsored by Oceania Clean Energy Solutions, will cover six streams: resource recovery, waste-toenergy, collections, landfill and transfer stations, construction and demolition waste, and commercial and industrial waste. Key speakers will include Victorian Minister for Energy, Environment and Climate Change Lily D’Ambrosio, Victorian EPA CEO Dr Cathy Wilkinson and NSW EPA Acting Executive Director for Waste Strategy and Policy Dr Kar Mei Tang. Other national and statebased bodies will be represented, along with case study presentations from local governments. Leading off on the first day the Waste Summit, a panel will discuss the pressing issues surrounding Australia’s waste-toenergy sector. Panel member Demian Natakhan, Consulting Director of Melbourne energy consultancy Enhar, will discuss the status of landfill solar generation and propose that the final resting place for municipal waste may be the beginning of new energy generation. “Solar farming on former landfill sites offers a way to put otherwise unproductive land to a valuable use,” he says.

“Where landfill gas is already collected in sufficient quantities to fire power generation, solar can be added onto existing grid infrastructure. “In sites with lower landfill gas volumes, new solar generation with grid upgrades can unlock significant solar generation, avoiding the competition between solar farming and productive agricultural or industrial land.” The challenges and opportunities in wastewater treatment will be the focus of the Wastewater Summit, sponsored by EnviroConcepts. Waste Expo Australia Event Director, Cory McCarrick, says the event continues to grow, with more speakers and suppliers involved this year than ever before. “We have seen an increase in the total number of exhibitors this year to 120 and around 50 of these are exhibiting for the first time at Waste Expo Australia,” he says. Some of the key exhibitors this year include Bost Group, Cleanaway, Caterpillar, HSR Southern Cross, Tricon Equipment, Applied Machinery and Hitachi. “Add to this list our impressive line-up of speakers, there is no other waste event in Australia that gives you access to such thought-provoking content that address the major issues facing the industry coupled with the opportunities to be immersed among the key players and products for free.” Waste Expo Australia is colocated with All-Energy Australia, Energy Efficiency Expo and ISSA Cleaning and Hygiene Expo, forming the nation’s most significant showcase for the waste, recycling, wastewater, renewable energy, energy efficiency and cleaning industries. Registration gives access to all four events on Wednesday 23rd and Thursday 24th October from 9am to 5pm each day. Registration is available on the event website. Waste Expo Australia 02 9422 2955 www.wasteexpoaustralia.com.au

AUGUST/SEPTEMBER 2019

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• ENERGY EFFICIENCY

EXPO PUTS ENERGY MANAGEMENT AND COST EFFICIENCY IN FOCUS This October, Australian manufacturers will have the opportunity to learn how to reduce their energy costs and improve operational energy efficiency, with Melbourne to host the inaugural Energy Efficiency Expo alongside All-Energy Australia. Developed from a partnership between Reed Exhibitions and the Energy Efficiency Council, Australia’s peak body for energy efficiency, energy management and demand response, Energy Efficiency Expo offers an opportunity to learn how to take control of rising energy costs and improve energy productivity. For Australia’s $383.2 billion manufacturing industry, which employs over 791,000 Australians (according to IBISWorld, 2019), energy efficiency and rising energy costs are a significant operational issue, with the International Energy Agency finding the manufacturing sector is Australia’s second largest most intensive energy usage sector, at 28 per cent (2017). This challenge for Australian manufacturers is highlighted by the nation lagging behind many other OECD nations when it comes to energy efficiency spending, with the 2018 International Energy Efficiency Scorecard revealing Australia spends only $6.12 per capita on energy efficiency utilities compared to $24.54 by Canada, $24.47 by the UK and the $20.58 by the USA. Energy Efficiency Expo’s 2019 theme will be ‘Ensuring Australia’s energy future’, recognising the importance of innovative energy efficiency solutions in a transforming energy landscape. The exhibition will feature smart energy products and services

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to quickly drive down energy costs and improve energy productivity, while the conference will focus on ready and practical measures to manage price spikes in energy costs, from the industry’s leading experts on energy efficiency. Luke Menzel, Chief Executive Officer of the Energy Efficiency Council, says that the time is right for business and government to get across the latest developments in energy efficiency and how to manage rising energy bills. “As energy costs have skyrocketed, businesses and governments are looking to energy efficiency and energy management to take control of their energy costs,” says Menzel. “In turn, they are recognising that the available solutions are evolving quickly, and they need to be on top of the latest technology and service offerings. Energy Efficiency Expo will be a one-stop shop for them to get across all this, so they are in the best possible position to deal with transforming energy market and get on with their core business.” A complete speaker line-up will be announced shortly for Energy Efficiency Expo’s conference programme, with a dedicated session focused on energy management options for manufacturers to reduce their energy use, reduce inefficiencies in their systems and processes, cut their reliance on the grid, and take an active position in the energy system. The conference programme will kick-off with a joint opening plenary on day one in partnership with All-Energy Australia. Menzel says there will be a strong

focus on case studies that show how leading businesses and governments are approaching energy management. “Importantly, the conference programme will feature real-world case studies from businesses and governments that are ahead of the curve in adopting smart energy solutions, so that attendees can learn what is working for others and start taking action as quickly as possible.” With Australia’s manufacturing industry projected to achieve a growth rate of 1.2% over the next five years, to $405.8b billion in 2023-24 (IBISWorld 2019), these smart energy solutions and real energy efficiency applications are crucial for manufacturers in achieving this growth by reducing costs, while improving global competitiveness.

energy, the opportunity to learn about practical and ready-now measures to improve energy efficiency is one to take advantage of this October.” Energy Efficiency Expo’s exhibition will feature low-carbon and energy cost-reducing solutions, including energyefficient lighting, energy-management equipment and software, energy-efficient HVAC, thermal performance products, microgrid technology and water heating efficiency technology. Companies with a confirmed presence at Energy Efficiency Expo 2019 include Alinta Energy Geothermal, Beovista, Eco Light Up, Lightsource BP, National Carbon Bank of Australia, Omniflow Australia, Rexel Australia, Stiebel Eltron, T4E, Wattly and Wattwatchers.

Robby Clark, Exhibition Director at Reed Exhibitions Australia, explains that Energy Efficiency Expo will provide Australian organisations, particularly manufacturers, with the platform they require to tackle one of their largest current operational challenges.

Visitors to Energy Efficiency Expo will also have access to the colocated All-Energy Australia and Waste Expo Australia, offering visitors Australia’s most comprehensive opportunity to learn about renewable energy, energy efficiency and sustainable solutions.

“Energy Efficiency Expo will offer organisations access to the latest expert insights and leading solutions to evolve their energy management and reduce costs,” says Clark.

Energy Efficiency Expo will be held on 23rd and 24th October 2019 at the Melbourne Convention & Exhibition Centre. Visitor registration is available now online.

“With manufacturing one of Australia’s highest energy intensive sectors, consuming over 28% of the nation’s total

Energy Efficiency Expo www.energyefficiencyexpo.com.au

AUGUST/SEPTEMBER 2019

ENVIRONMENT •

RESEARCH ASSESSES CSG-LNG GREENHOUSE GAS EMISSIONS A report by CSIRO’s Gas Industry Social and Environmental Research Alliance (GISERA) assesses the whole-of-life greenhouse gas emissions associated with the coal seam gas to liquefied natural gas industry in Queensland and the relative climate benefits of using Queensland natural gas in place of thermal coal as fuel for the generation of electricity in Australia. A unique feature of the research is the use of commercial-in-confidence data from a CSG to LNG project in the Surat Basin in southern Queensland to provide for the first time accurate estimates of the whole-of-life greenhouse gas emissions associated with CSG-LNG operations in Australia. The report estimates that the greenhouse gas emissions associated with CSG production, compression, dehydration, water treatment and liquefaction represent 1.4 per cent of likely future production from this CSG-LNG project (576PJ per year). The primary activities in the CSG-LNG supply chain contributing to emissions in Australia are on-site electricity use for CSG

extraction and the combustion of natural gas for electricity for LNG production. Outside Australia, the primary activity contributing to emissions is the combustion of natural gas, which represents 83 per cent of total emissions when all processes are considered, from wellhead through liquefaction, shipping, regasification and combustion. Switching from black thermal coal to Queensland coal seam gas for electricity generation using high-efficiency closedcycle gas turbines in Australia - avoiding liquefaction, shipping and regasification - represents a potential reduction in greenhouse gas emissions of around 50 per cent. GISERA Director Dr Damian Barrett says the results of this latest research align with other studies completed by CSIRO and GISERA in Queensland and other parts of Australia to understand methane and other greenhouse gas emissions associated with unconventional onshore gas activities.

“These results are consistent with other CSIRO studies in this region which suggest that the fugitive emissions component of the total greenhouse gas emissions identified in this latest study are at the lower end of the scale,” he says. “The climate benefits of using natural gas in place of thermal coal for electricity generation are generally accepted when fugitive emissions are less than three per cent of total production. “Replacement of coal-fired power by gas-fired generation, renewables and other low-carbon technologies is part of CSIRO’s vision for Australia’s energy transition. “Results of this latest research underline the potential climate benefits of using gas

in place of coal to generate electricity, particularly when using high efficiency closed cycle gas turbines.” GISERA is a collaboration between CSIRO, commonwealth and state governments and industry established to undertake publicly reported independent research. The purpose of GISERA is for CSIRO to provide quality assured scientific research and information to communities living in gas development regions focusing on social and environmental topics. The governance structure for GISERA is designed to provide for and protect research independence and transparency of research outputs.

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CASTORS ARE OUTSTANDING IN THE (MAGNETIC) FIELD and 125mm sizes, in a simple swivel castor or as  a swivel castor with total locking. The solution also offers valuable advantages for RCN’s international business. Each country has its own regulations governing the use of products in an MRI environment, but fully metal-free products can be used worldwide without restriction, so extensive research into country-specific regulations is no longer necessary. As a bonus, RCN can use the Levina castor on equipment for other metalfree areas, such as research facilities or near to security gates at airports.

Stand and deliver Elsewhere in the medical world, infusion stands have their own specific operational and design requirements. In recent years, many hospitals in industrialised nations have modified their architecture and interior design to make patients’ treatment time more pleasant, especially young patients. Bright and spacious entrances and waiting areas, larger rooms, sound insulation and the use of bright, radiant colours create a pleasant atmosphere for children and their parents, to promote healing. A magnetic resonance imaging (MRI) machine generates highresolution images using strong electromagnetic fields, measured in Teslas. Machines up to 3T are currently standard in hospitals, but for greater accuracy of detail, machines generating even stronger magnetic fields are increasingly being used. As a result, any magnetic objects are prohibited in the vicinity of MRI units as they might pose a threat to staff and patients due to the enormous forces of attraction involved. RCN Medizin & Rehatechnik has been producing nursing aids for more than 30 years and now employs about 100 people in factories in Germany and the USA. It develops and manufactures a wide range of products for everyday care, including shower stools, walkers and wheelchairs, as well as products meeting the strict requirements for use near MRIs up to 3T. Standardised white plastic tubing is used to make infusion stands, transport chairs and couches, and nonmagnetic

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brass is used for mounting fixtures and ball bearings in castors. However, for examinations using MRI machines from 7T upwards, the approval requirements for furniture and equipment are more strict, and even brass is not allowed. Indeed, in some countries there are metal-detecting security gates on the hospitals’ MRI departments. As a result, RCN also manufactures products that do not contain any metal components at all. And in the case of mobile equipment, this places some stiff constraints on the castors used. Tente’s Levina scan castors are fully metal-free, and so have no residual magnetism, guaranteeing the highest level of safety. They have a higher loadbearing capacity than castors containing brass, carrying weights up to 80kg. For RCN’s applications, Tente has adapted the castor stems to fit the company’s standard  plastic tubes and the castors are secured with a plastic screw on the frame so that the stem cannot twist. They are available in 100

encouraging them to leave their hospital chairs or beds. They also meet the strict hygiene and safety requirements of hospitals, just like the infusion stands to which they are fixed. They are very easy to clean, and are available with various mounting options and treads for soft or hard floors. Furthermore, they guarantee stability on uneven surfaces and sloping floors and ensure that door and lift thresholds can be crossed effortlessly. They can be produced in one or different colours, and supplied lacquered or printed, as required. And even when children leave hospital, Smiles castors on toy containers, chests of drawers, chairs or beds can keep their smile going at home, too.

Tente Castors & Wheels 1300 836 831} www.tente.com.au

German company provita medical produces innovative products and solutions for a wide range of applications in the medical sector, and is regarded as a trusted original equipment manufacturer worldwide. It employs more than 100 people and has a tradition going back more than 45 years. One of its novel products is a colourful infusion stand for children, which is equipped with Smiles castors from Tente. One of the most important roles for an infusion stand is to help keep patients mobile, and the Smiles play a leading role here. They enable children to move about freely during an infusion, which has a positive effect on their wellbeing. The sooner patients are on their feet, and the more active they are, the sooner they will recover. Working with a provita medical designer, Tente created the castors especially to suit the colourful and lively world of children’s wards. Their playful design includes the lovable faces of a mouse, cow, aeroplane or bear, intriguing the young patients and

AUGUST/SEPTEMBER 2019

MATERIALS HANDLING â&#x20AC;˘

SORTING SYSTEMS OFFER A PRACTICAL ALTERNATIVE

The global logistics industry has developed an impressive array of hardware designed to automatically sort goods for a customer order or for a specific destination. The problem for Australian companies is that this hardware is almost inevitably imported and certainly expensive to source.

While the capabilities are impressive, it can be difficult for companies to justify the expense of these all-singing all-dancing systems. And thatâ&#x20AC;&#x2122;s why Adept offers a practical alternative. Based on current customer shipping data and always with potential for future growth, Adept combines

commercially available specialised sort components with purpose built Australian designed hardware. The result is a sorting system that can be supplied to the customer at a fraction of the cost of the offerings from overseas integrators. Adept can supply details of

installations with major customers sorting many different types and sizes of parcels on a daily basis. Adept Conveyor Technologies 02 9771 4655 adeptconveyor.com.au

Solve your space problem with an Altrac gantry crane NE ED MORE LIF T? I NV ER TED GAN T RY LOW CEIL IN GS? LOW HE ADR OOM GAN T RY CO R NER S ? CU R VED GANTRY

An inverted gantry crane allows safe lifting and changeover of tractor implements by just one person.

A low-headroom gantry maximises the very limited space inside a shipping container.

A curved gantry allows safe work flow moving heavy stone items in a circular building.

AUGUST/SEPTEMBER 2019

www.bomac.com.au/get-a-quote

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• MATERIALS HANDLING

FOUR-WHEELED CASTORS TRANSPORT A HEAVY LOAD

Heavy transportation and industrial automation specialist AVT Europe is based in Essen in northern Belgium. The company specialises in driverless heavyload transporters for the movement of

very large and very heavy items such as railway carriages and aircraft parts. These transporters are massive mobile platforms bristling with intelligent

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electronics. They can carry loads of up to 100t and are operated remotely. AVT’s transporter design combines load-bearing castors and separate drive wheels. The load-bearing castors are always in use, and the weight of the item being transported is distributed evenly using air cushions. The drive wheels are lowered automatically when needed, to help to set the transporters in motion.

polyurethane, which not only helps the handling characteristics but is also easy on the floor. “What convinced us was the durability of the special-purpose castors – and the know-how of our business partners at Tente,” says AVT Europe General Manager Maarten Van Looveren.

The transporter design called for small diameter castors that could handle loads up to 12 tonnes in motion and 20 tonnes while stationary.

involved in the manufacturing industry will look at this page.

High quality and durability were also key factors because the transporters would be supplied to high-profile industry leaders such as Daimler, Airbus and CERN (the nuclear research institute) – all organisations that need robust and reliable transport for extremely high-value goods. AVT also needed component parts that would allow it to supply the transporters with a two-year warranty and an operating life of 20 years. Tente’s answer to the design brief came in the form of its Omikron quadro special-purpose castors. The custombuilt design features four 400mm wheels, with two to the left and two to the right of the centre. This arrangement provides an increased load-carrying capacity and a lower load point, with improved distribution of the applied load. WHAT DO YOU WANT TO SELL THEM TODAY? Advertising in Industry Update’s magazine, website or product cards can generate leads at a fraction of the cost of other mediums. Contact Industry Update today • 02 9439 1288 • sales@industryupdate.com.au 22

The current CAB audited circulation of Industry Update magazine is 18,000 with a readership of 72,000. From this edition (April 2013) the circulation has increased to 19,000 with a readership of 76,000.

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The four-wheel castor can be steered very easily because of the counter-rotation of the wheels around the common centre point. This significantly reduces the rolling and pivoting resistance in comparison to a single-wheel castor. Another advantage is that all the running surfaces are

The sophisticated design of the Omikron castors combines extreme durability with very low rolling resistance. As a result, the transporters can be designed with smaller lower-cost drive systems, saving both cost and ongoing power consumption. Tente’s staff in Belgium are continuing to work closely with AVT, responding to the growth of the company and providing advice on future custom development projects. Tente Castors & Wheels 1300 836 831 www.tente.com.au

AUGUST/SEPTEMBER 2019

MATERIALS HANDLING •

LOW HEADROOM CRANE FITS INTO TIGHT SPACES are working in a space with standard office or garage ceilings, a low-headroom crane can make a huge impact on safety by reducing manual lifting.”

When an overseas customer approached Bomac to order a full container of Altrac and StrongBac, it occurred to them that the easiest way to store and access the rails would be to keep it in the container itself.

As seen in a previous issue of Industry Update, Bomac recently launched an inverted gantry crane, where the crosstravel rail sits above the long travel rails. This is ideal in settings with a ceiling higher than a garage but lower than a modern factory, such as older factory facilities and farm sheds. This inverted configuration maximises the lifting height of the hoist.

To facilitate this, Bomac designed a low-headroom gantry crane complete with a battery-operated electric chain hoist that the customer could install directly into the container. “This worked really for us,” said Thomas Merritt of Blast Control. “We can utilise all the limited space of the container and access the rails quickly and easily.”

The Case Studies section of the Bomac website includes further examples of low-headroom cranes, and others.

The low-headroom design allows for maximum use of vertical space without compromising the functionality of an Altrac gantry crane. “This style of crane has been used for many other applications where space is at a premium,” explained Tate McFarlane, Bomac Engineering Director. “When you

Bomac Engineering 03 9796 5300 www.bomac.com.au

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PLANNING MATERIALS HANDLING AHEAD SAVES TIME AND MONEY “You’d be surprised how often I come to a plant to quote a job and, after being shown the brand new state-of-theart multi-million-dollar facility with the latest and greatest machinery, am told that no one stopped to consider how items were going to be loaded into this great machinery,” says Tate McFarlane, Engineering Director at Bomac Engineering. “No one at the planning stage looked over the design of the facility and said ‘how are we going to get our items from A to B?’ Or they assumed that they would simply use a forklift or similar, only to realise the space being shared by people on foot and the vehicle will cause serious risk for injuries or accidents.” McFarlane reckons that one of the great things about Bomac’s Altrac rail system is that in most cases he can design a system that works

within the context of what’s already there. But that doesn’t always result in the most efficient workflow possible once it’s all up and running, especially when there is not much left in the budget by the time this problem is identified. If Bomac had been called in at the planning phase, the team could have worked with the company to utilise the space better to design and build the crane around the intended workflow to maximise efficiency. Money and time can also be saved on installation if the crane is being put into an empty plant instead of having to work around bulky machinery or storage racks. Once the crane is up, it is completely out of the way of the on-ground equipment so no further time delay or financial cost would be incurred by installing crane first, machinery second.

The right way: here’s one manufacturer that had Bomac design and install an end-to-end gantry crane into its brand new premises

“I urge anyone planning out a manufacturing, maintenance or even storage facility to first consider materials handling before looking at the more ‘exciting’ technology you’ll be implementing,” says McFarlane. “It may be that nothing is needed or you might be set up in a way that a forklift really is the best solution. But if you find that a crane would be best, it’s much easier to integrate it from the beginning than to try and retro-fit it at the last minute.”

Anyone thinking about moving, upgrading or building new facilities anywhere in Australia is welcome to contact the team at Bomac Engineering in advance to make sure lifting and shifting products won’t become a major headache when they should be celebrating their new facility instead. Bomac Engineering 03 9796 5300 www.bomac.com.au

ELECTRIC CHAIN HOIST RAISES SAFETY AND EFFICIENCY Available now from Global Track Australia, the EQS is the latest addition to the Kito range of electric chain hoists. The compact and lightweight hoist is rated at up to 1 tonne, and comes with an impressive range of efficiency and safety features at a very competitive price. Running from a single-phase supply, the Kito EQS features a dualspeed inverter with both an electronic overload protection device and a friction clutch to ensure operational safety. Of the safety features, the friction clutch protects the hoist body and load chain from breakage should the hoist be used on an abnormally heavy load or attempt to lift an anchored object. At the same time, the electronic overload limiter monitors the inverter and stops operation immediately in the event of an electrical overload.

Phone: 1300 836 831

sales.au@tente.com

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tente.com.au

There are also upper and lower limit switches that prevent any load from being raised too high or lowered too far.

The dual-speed inverter enables a productivity-enhancing high-speed no-load mode while the hoist is moved into position in addition to high and low speed modes when the hoist is in use. The hoist features an ergonomically designed pendant controller with simple pushbutton controls and a readily accessible emergency stop that disconnects motor power without cutting off the main power supply. Global Track Australia 03 5275 3252 www.globaltrackaustralia. com.au

AUGUST/SEPTEMBER 2019

SAFETY •

LIGHT CURTAINS AND GRIDS ARE SAFE FOR FOOD AND PHARMA

Control Logic has a new range of IP69K-rated safety light curtains and light grids from Schmersal that are suitable for use in hygiene-sensitive sectors including food, pharmaceuticals, meat and milk processing. The SLC/SLG 440 IP69K series safety devices can withstand frequent cleaning with water, alkali solutions, foam, hot steam or high-pressure jets. The locking caps are manufactured in stainless steel (V4A) as are the cable inlet and the fastening parts. Transparent protective tubes are made from polycarbonate to provide high resistance to cleaning agents, and these can withstand strong mechanical loads. If spray lances should accidentally strike the enclosure

during pressure washing or there is impact with the enclosure, the units will continue to work thanks to the robust protective tubes. As with the standard SLC440 safety light curtains, the SLC440 IP69K versions are available in lengths from 170 to 1920mm and with a choice of 14 or 30mm resolution. The safety light grids are available with two, three or four light beam grids. All SLC/SLG440 IP69K devices are suitable for use in safety circuits up to PLe (EN 13849) or SIL3 (IEC 61508). Control Logic 1800 557 705 www.controllogic.com.au

RACK PROTECTION IN ACTION IN MELBOURNE hand to provide professional and upfront product advice to suit companies’ individual requirements. Rack Armour will highlight why and how its products provide the best protection, even against continual impact, providing companies with a long-term solution.

With more than 10 years’ experience in protecting racking systems from forklift damage at some of Australia’s leading organisations, Rack Armour is again exhibiting at Safety in Action Melbourne, being held on the 10th and 11th September 2019. Visitors to the Rack Armour stand (D05) will see the full product range on display, and company staff will be on

AUGUST/SEPTEMBER 2019

Those who are unable to make it to the show can check out the company’s new website, launched earlier this year. Rack Armour is happy to answer enquiries and will provide no obligation quotes. With resellers throughout Australia, Rack Armour is available nationwide. Rack Armour 02 9722 0502 www.rackarmour.com.au

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• SAFETY

FIVE TRENDS IN SAFETY ENGINEERING The design and function of safety engineering is constantly evolving, and Treotham is keeping up with the trends with its Euchner safety products. In complex networked installations and machines, providing functional safety information about the door position and guard locking is often no longer sufficient. Comprehensive diagnostics data supplied via IO-Link and bus systems help with troubleshooting and give an insight into the status of the systems. Simple configuration measures, for example in the ProfiNet network, reduce the amount of wiring work. The safe signals are also sent via the bus. The Euchner MGB series from Treotham makes it easy to integrate the very latest safety engineering functions into existing networks.

Managing access rights Not only people need to be protected from the harm that machines

can cause. In addition, it is essential that the costly manufacturing process is not interrupted by unauthorised or accidental interventions. In this case, key-operated rotary switches and passwords no longer

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RACK ARMOUR IS THE SIMPLE SUPERIOR SOLUTION TO PALLET RACKING DAMAGE CAUSED BY FORKLIFTS. RACK ARMOUR WILL BE EXHIBITING AT SAFETY IN ACTION MELBOURNE 10th – 11th SEPTEMBER, STAND D05

Telephone: (02) 9722 0502 • www.rackarmour.com.au

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provide adequate safety. The solution is an electronic key system that manages access rights centrally. The Euchner EKS from Treotham can do that, and much more. For example, a time limit can be set and keys can be blocked if they are lost. Other options include different access levels for different machines and managing user groups. When safety systems are bypassed, there is generally a good reason for doing so. Often, certain tasks can be carried out only when a safety door is open, but this can be dangerous. Electronically coded actuators that are ‘married’ to the accompanying safety switch allow almost all types of tampering to be prevented. However, if the safety door has to be open for the work to go ahead, the risk can be reduced by limiting the axis movements and pressing an enabling switch, for example. To activate this safety function, Euchner has developed a procedure for safely selecting operating modes based on the electronic key adaptor for safe applications. Only employees with the appropriate training are given the personalised electronic key to allow them to carry out tasks involving an increased risk.

Personalising safety products All safety applications are different. For example, the emergency stop often has to be integrated into the doorlocking mechanism, and the request and acknowledgment buttons may need to be fitted directly to the safety door.

Treotham’s special extended variants for safety switches with guard locking meet many of these requirements. The new MGB2 Modular even allows users to make the functional modifications themselves. By plugging in function submodules, users can adapt the multifunctional gate box for specific applications. With more than 20 different submodules on offer, there are plenty of options available. In addition, new modules can be produced in small numbers to meet individual customers’ requirements. The wide range of variants and the options for personalisation make the systems more user-friendly, which in turn increases productivity. In the past the appearance of production machines was relatively unimportant when compared with their functions. However, in recent years developers have increasingly focused on the design of the machines, which is often regarded as a reflection of their high standard of quality. For safety engineering products, this may well mean that they need to be concealed in the machine cover, but it is essential that they continue to function without problems. Fortunately the high level of electronic integration that is now possible has enabled PCBs to be reduced in size. Innovative technologies allow products to be made smaller and smaller. The smallest Euchner RFID configurator from Treotham is the same size as a 6mm plastic dowel and is almost invisible once it has been installed in a door. Treotham Automation 1300 65 75 64 www.treotham.com.au

AUGUST/SEPTEMBER 2019

PRODUCTS •

JOB MANAGEMENT SOFTWARE KEEPS SERVICES RUNNING SMOOTHLY With after-sales service increasingly viewed as a key element in the manufacturing lifecycle, manufacturers are finding that managing the service function can present something of a headache or bottleneck. Attempting to run a service operation by traditional methods can be a time-consuming and inefficient process. One solution to this management dilemma comes in the form of Riyo, a made-for-mobile job management software suite developed by Sydneybased JCurve Solutions (ASX: JCS). The claims are impressive: the easyto-use software is said to offer instant scalability that responds to seasonal, industry and unexpected demand changes. And, not only is Riyo claimed to improve the customer experience, it offers companies the chance to increase revenue through upsell opportunities from existing service jobs. So, why is this revolutionary? Interestingly, Riyo was designed from the ground up to be easy to adopt. Described as “a mobile app without the app”, the software is entirely web browser based and created with mobile in mind – so it will run on any device that you care to name. And, because it’s a cloud-based solution, there are no requirements for local storage. And now, with almost 12 months of deployment in the field, JCS is finding that the software can make a real difference to industrial suppliers and equipment manufacturers, with pump companies and commercial kitchen equipment suppliers

among those to reap the benefits. And first among those benefits is productivity. “Ultimately,” says JCS Business Development Manager Pat Turner, “it’s about getting more jobs into a day.” And key to that is getting rid of the manual processes. It goes without saying that the days of the illegibly hand-written job sheets are gone. Instead, Riyo offers fully customisable forms that companies can adapt to their exact requirements.

Turner parallels the Riyo approach to the disruption brought to the taxi market by Uber. And many of the customerfacing aspects of the system do mirror the ride-sharing platform, starting with the customer version of the app. So, just as an Uber customer waiting for a ride can see where their driver is in real time, a customer can use Riyo to see exactly where their service tech is, and when they are likely to arrive – again in real time. Compare that to the traditional “old-school taxi” style of interaction where the customer has traditionally been given a timeslot along the lines of “between 2pm

and 4.30pm”, and it becomes apparent that Riyo is as much about customer satisfaction as it is about workforce management. Giving the customer an accessible, easy-to-use app is the key to this engagement. However, it goes way beyond that by including secure payment facilities in the package itself, making a significant improvement to cashflow for service operations that are working on ad-hoc or non-contracted jobs. In all, Riyo provides a single application that not only manages job bookings, it manages the resources for those jobs. This enables service operations to scale their businesses in line with demand. One important factor in the allencompassing aspect of Riyo is that – like JCS’ ERP business management solutions – it is entirely cloud based. And that has the added advantage of allowing the integration of the two software offerings, bringing enterprise resource management and job management together, leveraging the same cloud-based database. And for those that might be wary of trusting important corporate data to an unknown entity Riyo uses the Google Cloud Platform, with all the security that entails. Riyo 1800 528 783 www.riyo.io

AUGUST/SEPTEMBER 2019

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• PRODUCTS

CLEAN, SAFE, DETECTABLE POLYMER BEARINGS FOR FOOD CONTACT The detection of foreign bodies plays a major role in the production and packaging of food to ensure the perfect quality of the products and to prevent contamination, so igus has developed its tribologically optimised plain bearing material iglidur FC 180 (the FC stands for “Food Contact”). This new material is detectable visually by its blue colour as well as by metal detectors due to the inclusion of appropriate, food-compatible additives. In this way, broken pieces can be quickly detected and removed in the event of damage to the system. As a result, the purity of the product is secured and costly product recalls are prevented. It complies with the specifications of FDA and EU Regulation 10/2011 and can therefore be used in direct food contact.

“Its low moisture absorption and lubrication-free property are additional criteria that speak in favour of the optimum suitability of the material in applications in the food technology, beverage and packaging industries,” igus Head of Packaging Industry Management Lars Braun explains. In its spherical bearings range, igus has combined a housing made of igumid FC and a bearing made of iglidur FC180 in self-adjusting igubal bearings, which are approved for direct food contact. The excellent detectability of the materials has also been confirmed by Sesotec GmbH, the specialist for foreign body detection and manufacturer of metal detectors for the food industry. Fragments of 0.0139g (iglidur FC180) or 0.0157g (igumid FC) can be identified on a conveyor belt when passing through the

Sesotec’s Intuity metal detector. The new vibration dampening bearings are resistant to corrosion and media due to their polymer base, allowing them to withstand cleaning with water and many cleaning agents. As a result, equipment manufacturers and operators in the food industry can now quickly and easily equip their machines with a wide range of igus bearing solutions from

Treotham, while saving twice as much. This is because plastic plain bearings don’t have to be serviced and are much more cost effective to buy than solutions consisting of sealed stainless steel bearings with food-grade lubricants. Treotham Automation 1300 657 564 www.treotham.com.au

WELDING MACHINE RANGE CLAIMS NEW STANDARDS IN USABILITY AND QUALITY Designed to withstand demanding welding environments and high temperatures, the impressive, nextgeneration MasterTig range of welding machines from Kemppi claims new standards in usability, welding quality capability and power efficiency. The new machines have been designed with the professional welder very much in mind. The Weld Assist feature lets users set up 60 per cent faster to help increase productivity. Users simply select the material, thickness, joint type and welding position, then Weld Assist determines the best parameters for the task. It also provides recommendations for electrode size, filler wire, gas flow, groove type, pass profile and travel speed. Users can also weld up to 30 per cent faster, thanks to the Double Pulse function, which accelerates the travel speed in DC hand welding and mechanised applications. This not only allows welders to power through work, but also reduces distortion levels and delivers excellent weld appearance. It also reduces heat input by 20 per cent, helping to minimise welding costs. The new machines are also packed with high-technology features that enhance TIG welding. The MicroTack

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function lets users complete multiple, repetitive tacking on thin sheet applications quickly, without forgoing quality or the visual appearance of the weld. iTEC is engineered ignition technology, which ensures a reliable arc start every time and is particularly useful with long torch extensions for site welding or precise thin materials and low current applications. The Optima AC feature is a customised waveform that combines the best of the traditional sine and square forms, improving welding quality while reducing the noise level of AC TIG welding by 20 per cent. Other features include 99 memory channels, a weld time clock that lets users measure and record job data, and Auto Pulse. The machines are also highly energy efficient. Dynamic gas and water cooling ensure optimal temperature control and power efficiency. Depending on the welding power level and duration, the power source cooling fans moderate air flow and cooler motor run time between 15 seconds and 4 minutes to reduce electrical power consumption and localised noise levels. The new range also offers considerable choice. Users can select

models with power variants in 230 and 300A, and the modular design of the machines lets them tailor the MasterTig to their needs. They can choose from various control panels, wireless remote controls and transport cart options as well as personalise the screen saver by uploading their company logo or favourite image. Designed for AC and DC TIG welding as well as MMA welding, the machines are light and compact, making them easy to manoeuver. The transport units feature floor-level cylinder loading, removing the need for heavy lifting. The P45MT transport unit integrates an innovative pivoting cylinder plate for safe cylinder loading. Tough and robust, the MasterTig range is built from strong, energy-

absorbing, recyclable plastics. Their structure also incorporates impact bridges that protect the power source from everyday knocks. Compatible with the range is the new Flexlite TX torch range, featuring high-strength, flexible molded handles for increased comfort and reduced welder fatigue. Silicone rubber material in the handle makes a firm grip possible, and the innovative design reduces wrist loading, allowing the welder to concentrate on creating the perfect weld. Flexlite TX torches are available in alternative power classes and lengths. Kemppi Australia 02 8785 2000 www.kemppi.com

AUGUST/SEPTEMBER 2019

PRODUCTS •

PERMANENT MARKERS WON’T DRY OUT surface properties ink, and the tip is guaranteed not to dry out – even if the cap is left off for up to 24 hours. There are two types of pen: the SCA100 with a 1mm fine tip, and the SCA400 with a 4mm broad tip – both available with vibrant black, blue, red or green ink. There are few things in life more frustrating than finding that somebody has left the cap off your marker pen and the ink has dried out. But that won’t happen with the latest range of tough permanent markers from Pilot Pen. The high-quality Japanese-made markers use a newly developed controlled

The marker pens are equally at home in the office, the warehouse and on the factory floor, with true multi-surface marking abilities, including glass, metals and plastics. Pilot Pen Australia 1300 325 866 pilotpen.com.au

PORTABLE FANS CLEAR THE AIR

Complete Packaging Lines Technical Support

Spare Parts

Partnership Programs Maintenance

Training

Powder Handling

Proven turnkey systems for powder processing industries. Delivery to dispatch.

Bagging & Palletising

Fanquip has released a series of electric-powered portable industrial purging fans for heavy industries with power and volume capabilities equalling those achieved by their fixed-position equivalents. These lightweight units are supplied with 5m of heavy-duty flexible ducting, allowing them to be placed well away from an opening to allow a greater amount of fresh air for workers.

industry, as they can also be supplied with Ex rated motors for hazardous areas. Designed primarily as a replacement for trailer mounted units, Fanquip purging fans include a standard transportation frame for convenient fit and moveability.

The purging fans have a lightweight aluminium casing and can be set up for either blowing or extracting; therefore in situations where there is only one escape route all unwanted air is quickly and easily purged.

The fans in the series include diameters of 300 and 400mm, motor speeds of 2880rpm, motor powers of 1.1, 1.5 and 2.2kW, free air volumes of 1200, 2200 and 2500L/s, and voltages of single phase 240V and three phase 415V.

With industry subject to increasing fines for breaches of workplace health and safety laws relating to confined space ventilation in the workplace, Fanquip’s purging fans suit almost every

Fanquip 02 6578 8600 www.fanquip.com.au

AUGUST/SEPTEMBER 2019

Lifting Systems

Ergonomic solutions for manual handling tasks.

(03) 9457 8244

Call to speak to your local representative www.kockumsbulk.com.au

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Industry Update Video has been a huge success, with more than a million impressions and half a million YouTube views in one month alone during 2018. All our videos can be viewed on the Industry Update YouTube Channel and from the Industry Update Website. And now readers of Industry Update Magazine can check out the latest releases direct from this regular Video Update section. Just scan the QR codes on these pages with your mobile device of choice and you will be taken straight to the video. (Users of some older mobile devices may need to download a QR reader app.)

A-Safe - Rack Guard

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Applied Machinery - Genox eWaste Technology

Cigweld - Professional High Impact Welding Helmets

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• PRODUCTS

TECHNOLOGIES SAFEGUARD PRODUCTS, PACKAGING AND TRACEABILITY machine-readable code readers and one of the few machine vision camera vendors to also offer laser marking systems and to bring both capabilities into greater alignment.

CONNECTED PSUS RAISE RELIABILITY

The company is focusing on improving its optical character recognition and codereading tools, and has developed the new P-Series OCR, an ultracompact smart camera ideal for OCR print inspections on labels for the food industry, and the Advanced OCR vision software tool for very demanding applications with lowquality printed codes. “We’re developing tools that can read more challenging codes,” says Bradley Weber, Product Marketing Manager at Datalogic. “Many times characters are not clear black-on-white printing, and many times the print is not perfect or it’s on a varying background.”

The technologies used by Datalogic can be divided into five categories, depending on the type and function of the product data or production process: marking (laser markers), scanning (barcode readers and vision systems), writing and reading (readers and RFID tags), object and physical feature scanning (photoelectric sensors, smart cameras and vision systems).

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Datalogic products also detect and locate parts during the manufacturing process enabling the robot guidance and full automation of process (sensors, smart cameras and vision systems). In the food and beverage industry there are several requirements and types of barcodes, of which the most widespread is the OCR marking code. Datalogic has been known as a leader in image-based

Weber adds that Datalogic has also upgraded its pattern-finding tool to be on par with the best in the industry. “We looked at speed, accuracy, and repeatability,” he says. “We’re now the gold standard on all three, able to find objects with the same or better subpixel accuracy as any other player in the market.” For traditional barcodes, legible exclusively with barcode readers, Datalogic Matrix Series 2D imagers enable full traceability from the manufacturing plant to the warehouse. The same traditional barcode is used for logistics applications, including automated reading at the supermarket checkout. Also, the use of the QR code is increasing. It contains more information, in terms of marketing, and can be read by a smartphone or self-shopping device like the Joya Touch multipurpose retail device from Datalogic.

New from Omron, the S8VK-X series of power supplies incorporates EtherNet/IP and Modbus TCPcompatible communication together with monitoring software that allows users to centrally monitor and control multiple supplies. This facility enables predictive maintenance, maximising uptime and reducing overall maintenance costs. The free power supply monitoring tool can be operated simply by connecting the S8VK-X to a personal computer via an Ethernet cable. In addition to collectively displaying and saving data and displaying graphs, the software allows users to check the PSU status in real time on a derating chart and to simulate the effects of capacity changes. The PSUs include a power boost function (120% up to 120W, 150% for 240W and 480W) for applications that require higher startup currents.

The Joya Touch allows consumer applications such as self-shopping, queue busting and gift registry to be resident on the same device as operational applications such as shelf replenishment, inventory control, mark downs, price checks and more.

The S8VK-X series supplies are particularly compact, and can be mounted side-by-side in a panel using a specially designed DIN-rail mounting clip. Operating temperature range is a wide -40 to + 70°C, providing increased environmental resistance and a wide window for stable equipment operation.

Datalogic 03 9558 9299 www.datalogic.com

Omron 1300 766 766 www.omron.com.au

AUGUST/SEPTEMBER 2019

PRODUCTS •

TERMINAL RANGE COMES WITH A STRONG INDUSTRIAL PEDIGREE

Arlin Components & Hardware has expanded its electrical interconnection portfolio with the signing of an exclusive distribution agreement with Hoppy Industrial Co, a Taiwan-based manufacturer with a broad range of terminal blocks, fuse holders and other components principally designed for HVAC and refrigeration markets.

ANZ National Sales Manager Anil Garyali.

Hoppy also manufactures other components and subassemblies for the HVAC industry, including controllers and pumps, but it is the electrical distribution components that are most appealing to Arlin’s

“This is a great addition to the Arlin linecard, and one that I am looking forward to introducing to Australian and New Zealand OEMs, not just in the heating and cooling business, but also for

“Hoppy dominates the terminal market in the HVAC sector, supplying all the major manufacturers like Fujitsu, Daikin, Hitachi and Mitsubishi, so the product range clearly meets the industry’s highest quality standards,” says Garyali.

elevators, electric traction and other general low-power distribution applications.” The full range of Hoppy terminal blocks available now from Arlin includes: fixed-type terminal blocks with thermal fuses rated from 10 to 150A; modular terminal blocks from 10 to 1000A with a choice of terminal types; tab-type terminal blocks from 15 to 25A; “three-in-one” terminal blocks with wires, thermal fuses, relays, power cords etc; double-sided terminal blocks from 20 to 400A; rail-mounted terminal blocks from 10 to 1000A; and American-type

terminal blocks from 90 to 760A, featuring aluminium alloy terminals. Arlin Components & Hardware 1300 362 191 arlin.com.au

WIRELESS SENSORS IMPROVE TOXIC GAS SAFETY Emerson Automation Solutions has introduced two new Rosemount 628 gas sensors to measure carbon monoxide and oxygen depletion, alongside the existing sensor to monitor hydrogen sulphide. The sensors are used in the Rosemount 928 wireless gas monitor, which is a highly versatile platform for monitoring hazardous conditions in process plants, remote wellheads, pipelines, storage terminals and other facilities. It can be easily deployed using a WirelessHART network in areas considered too impractical or expensive for the installation of conventional wired infrastructure. Once monitors are integrated into the wireless network, users can simply check the status of the remote monitoring system gas levels.

AUGUST/SEPTEMBER 2019

To simplify installation and maintenance, the 928 has hot-swappable main components, including the power module and the 628 sensor. Both are intrinsically safe and can be replaced in the field in minutes without the need for tools. The sensor’s calibration information is stored within the sensor, not the transmitter, which allows users to calibrate the sensor in a non-hazardous location and take it to the field for quick exchanges with installed sensors. This further enhances workers’ safety by minimising their time spent in potentially hazardous locations. The first Rosemount sensor was designed for hydrogen sulphide detection, given the ubiquity of this gas in the process industries, and the monitors have been installed around the world for this

purpose. With the addition of the new sensors for carbon monoxide and oxygen depletion, these monitors can now be used for other applications, or additional monitors can be deployed. If and when process conditions change, monitors can be moved as necessary, as long as they are placed within the coverage area of the WirelessHART network. Carbon monoxide can be released by a variety of combustion processes, and concentrations above 1500 ppm are immediately dangerous to life and health. Processes able to consume oxygen can reduce atmospheric content in given areas, and any situation where oxygen drops below 19.5 per cent is also dangerous. In many cases, more than one condition may exist at a given time, compounding the hazard.

Emerson Automation Solutions 1300 55 3051 www.emerson.com

INDUSTRYUPDATE.COM.AU

• COMMUNITY

BLUE BOOTS INITIATIVE PASSES BEYOND $200,000 Perth workboot manufacturer Steel Blue is a proud supporting partner of mental health support service Beyond Blue. Steel Blue joined forces with Beyond Blue in 2014 to launch the Blue Boot initiative to make a difference to mental health in Australia, particularly among tradies. The Beyond Blue range of boots is a popular choice for mining, construction and road workers. The packaging includes a Beyond Blue brochure to educate wearers on mental health issues and how they can access the Beyond Blue Support Service. Since the second year of the initiative, Steel Blue has donated $10 from every pair of men’s and limited-edition women’s Blue Boots directly to Beyond Blue. More than 20,000 pairs of Blue Boots have been sold to date, and the amount raised and donated has just passed $200,000. This has allowed more than 4100 people in Australia to be helped by Beyond Blue’s support service, which provides counselling, practical advice, referrals and hope to people in need 24 hours a day, seven days a week,

more than 170,000 times a year, and which is entirely funded by donations. According to Steel Blue CEO Garry Johnson: “The core to our partnership with Beyond Blue is educating as many Australians as possible, especially tradies, on mental health issues and contributing to the 24/7 Beyond Blue Support Service. “Over the past five years, we have seen the Blue Boots form part of the uniform of Mental Health First Aid Officers in the mining and construction industries. They have also become a talking point to break the stigma around mental health. “Steel Blue is incredibly proud of this milestone, being able to support over 4100 people in Australia affected by anxiety, depression and suicide through our partnership with Beyond Blue.” This year alone, 65,000 people in Australia will attempt suicide, resulting in eight deaths every day, six of them men. Every day, 82 men call an ambulance due to suicidal thoughts or attempts.

Tough working conditions can contribute to increased risks of anxiety, depression and suicide. Workers in the construction industry are almost twice as likely to take their own lives than workers in other industries. “Steel Blue’s support helps Beyond Blue provide people across Australia with access to free, life-changing support, advice and information to help people achieve their best mental health,” Beyond Blue CEO Georgie Harman says. “It’s fantastic to have Steel Blue’s continuing support for our work in the community and smashing the stigma in their industry.” Steel Blue 08 9209 3322 www.steelblue.com

STAFF, CUSTOMERS AND PARTNERS INVOLVED IN CHARITY FUNDRAISING become involved in fundraising for registered charities in areas to which many of them have had first-hand exposure. In most cases, the company will match the funds raised dollar for dollar. Some of the charities the staff have supported in the past year year have included the Worlds Greatest Shave, Movember, Variety Children’s Charity and Australia’s Biggest Morning Tea.

Family-owned Australian company Hare & Forbes Machineryhouse has been supporting those in need for many years. Through the hard work and dedication of all the family members and the sound business practices of its management, Hare & Forbes has constantly been able to increase the funds allotted for charitable and humane purposes each year. Until recently this was a personal decision made by the directors and not shared openly with the staff. Then last year the directors decided that they should involve the staff, customers and business partners, with the hope of encouraging others to stand up and become involved. Hare & Forbes encourages its staff to

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The management and staff are also involved when a crisis or disaster affects Australians and immediate action is required. Last year, the worsening of the drought was felt throughout the county. The management and sales teams were touched by the plight of farmers and the loss of their stock, so they galvanised with a promotion involving customers and suppliers. With this promotion, they raised $5635 over and above the company’s normal contribution of $30,000 in June. This was distributed to Aussie Helpers, headed by Brian Egan, with which Hare & Forbes has been associated since its inception. Aussie Helpers are tireless, and the funds helped with the Buy a Bale promotion. When floods hit Townsville earlier this year, the effects of the loss and devastation on the faces of those affected also touched management and staff, so they decided

to dig a little deeper and donate $15,000 to a charity called GIVIT, which helps with supplying essentials such as bedding, furniture and clothing to families feeling the burden of replacing the simple things so often taken for granted. Many Hare & Forbes staff and their families have been touched by mental health issues or cancer, and so the company supports charities such as Beyond Blue and the Prostate Cancer Foundation of Australia. One staff member on a recent outback trip required the help of the Royal Flying Doctor Service when his mate suffered a heart attack on a remote cattle station, so he experienced the importance of this service first-hand.

DRIVE TO RAISE MORE FUNDS FOR CANCER RESEARCH

Applied Machinery Managing Director David Macdonald will shortly embark on a roadtrip with a difference in the company of long-time friend Ben Vercoe. The two codrivers will form Team Caddyshack for the Spring 2019 Shitbox Rally travelling from Melbourne to Townsville via Birdsville. And the only real “rule” of the event, it that they have to do it in a vehicle costing less than $1000 (hence the name of the rally). Shitbox Rally is now a biannual event dedicated to raising much-needed funds to support cancer research. By getting out and doing something unique, positive and proactive, it brings an element of fun and excitement to the formidable task of raising money to cure this heartbreaking disease. This year marks the tenth anniversary of the rally series, and the aim is for each rally to raise $2 million for the Cancer Council. (This Autumn’s run from Perth to Sydney actually raised more than $2.6 million.) The rally is not a race. Rather it’s an unpredictable adventure with participants travelling at their own pace in smaller groups. Vehicles often break down, but the spirit of the event is that “we never leave anyone behind”. And each night is spent camping beneath the stars and celebrating the day’s achievements. Since it’s inception the rally has been the largest fundraiser for the Cancer Council nationally.

The company’s donation committee meets regularly and has decided that rather than make smaller ad-hoc donations, it would try to make larger annual donations so that the chosen charities can purchase a larger piece of equipment or support a certain researcher in finding a cure to the many cancers that affect our community today.

All told, almost $20 million has been raised to date, supporting projects such as: a research study to develop a vaccine that protects against lymphoma cancers; a research trial to standardise international guidelines on melanoma removal; and a research grant to revolutionise the treatment of pancreatic cancer.

Hare & Forbes Machineryhouse 02 9890 9111 www.machineryhouse.com.au

Team Caddyshack has set itself a goal of $15,000. Industry Update readers can help them realise this goal by donating at https://2019spring. shitboxrally.com.au/caddyshack

AUGUST/SEPTEMBER 2019

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FORTHCOMING EVENTS

TEABREAK TRIVIA

SAFETY IN ACTION

AUSTRALIAN WASTE & RECYCLING EXPO

10-11 September 2019, Melbourne Convention & Exhibition Centre

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2 Which horse won the 2018 Melbourne Cup?

ELECTRONEX

CORROSION AND PREVENTION 2019

11-12 September 2019, Melbourne Convention & Exhibition Centre

24-27 November 2019, Crown Promenade, Melbourne

3 …. and which horse won the first running of the same race in 1861?

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4 Which rocker was born Farrokh Bulsara on 5th September 1946 at Stone Town in Zanzibar?

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23-24 October 2019, Melbourne Convention & Exhibition Centre

13-15 May 2020, Sydney Showground

5 Who was the lead engineer of the team that designed the Volkswagen Beetle?

www.energyefficiencyexpo.com.au WASTE EXPO AUSTRALIA 23-24 October 2019, Melbourne Convention & Exhibition Centre www.wasteexpoaustralia.com.au ALL ENERGY AUSTRALIA 23-24 October 2019, Melbourne Convention & Exhibition Centre www.all-energy.com.au ISSA CLEANING & HYGIENE EXPO 23-24 October 2019, Melbourne Convention & Exhibition Centre issacleaninghygieneexpo.com CEBIT AUSTRALIA 29-31 October 2019, Sydney International Convention Centre www.cebit.com.au

"In politics, if you want anything said, ask a man; if you want anything done, ask a woman." Margaret Thatcher "Hindsight can give you insights about what went wrong. But only faith, reason and bravery can propel you forward." Julia Gillard "There is no more terrible fate for a comedian than to be taken seriously." Barry Humphries 74

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What is the most abundant animal life form on earth?

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6 In test cricket, which side has won more Ashes series – England or Australia?

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7 Which is the most populous city in the world?

19-21 May 2020, Melbourne Convention & Exhibition Centre www.arbs.com.au WORKPLACE HEALTH & SAFETY SHOW 27-28 May 2020, Melbourne Convention & Exhibition Centre

8 Where in Australia is the Big Mosquito, dubbed Ozzie the Mozzie? 9 Which Australian invention of 1974 has indebted sports fans around the world to Gordon Withnall? 10 Is there a synonym for synonym?

LATERAL THINKING 1) 1. If you are paying and all tickets cost the same, is it cheaper to take one friend to the movies twice, or two friends to the movies at the same time? 2) In Bundaberg, Queensland you can’t take a photo of a child with a bottle of rum. Why not? 3) What was the Australian Prime Minister’s name 50 years ago?

www.whsshow.com.au FOODPRO 5-8 July 2020, Melbourne Convention & Exhibition Centre Foodproexh.com CEMAT AUSTRALIA 14-16 July 2020, Melbourne Convention & Exhibition Centre www.cemat.com.au

THEY SAID IT.. The best industry and political quotes of the past and present:

ANSWERS

Teabreak Trivia

1 Nematodes (worms), 2 Cross Counter, 3 Archer, 4 Freddy Mercury, 5 Ferdinand Porsche, 6 Australia (33 compared with England’s 32), 7 Shanghai, 8 Hexham NSW, 9 The Super Sopper, 10 Yes

Lateral Thinking

1. Taking two friends to the movies at the same time means you buy three tickets, so it’s cheaper than taking one friend twice, which means you buy four. 2. Because it’s impossible. You have to use a camera or mobile phone. 3. Scott Morrison, the same as it’s been all his life.

THERE’S SOMETHING IN THE AIR The days are getting longer, and the weather’s warming up. It’s time to celebrate Spring with Industry Update’s October issue.

The deadline for editorial submissions is Tuesday 17th September 2019.

We’ll be taking a closer look at the motive force behind Australian industry with our annual special feature on motors and drives.

Editorial copy and images should be sent to editorial@industryupdate.com.au.

Other special features include:

"Patriotism is supporting your country all the time, and your government when it deserves it." Mark Twain "If you want to be a millionaire, start with a billion dollars and launch a new airline." Richard Branson "Focusing your life solely on making a buck shows a certain poverty of ambition." Barack Obama "Friends, family, religion. These are the demons you must slay if you wish to succeed in business." Mr Burns

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