Industry Update February/March 2020 Issue 112 by Industry Update

AUSTRALIA'S LARGEST CIRCULATING MANUFACTURING MAGAZINE ®

Issue 112 February/March 2020

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MANUFACTURING MAGAZINE

IS IT TIME TO BRING MANUFACTURING BACK TO AUSTRALIA? The continuing coronavirus epidemic illustrates just how many global supply chains rely on China’s manufacturing. And with quarantine as the most reliable methodology for containment, those supply chains will remain broken for some time to come. Shortages of low-cost Chinese made products from facemasks to materials handling equipment are being felt worldwide, and Australia is not immune from the problem. And in areas such as electronics manufacturing where OEMs are running short of certain subassemblies that might only form a

small proportion of the end product by value, the cost of lost business is all the more acute.

Australia were reliant on Chinese components and their inventories were draining.

One Melbourne-based manufacturer told Industry Update that he could perceive an up-tick in demand for his Australian-made products because his competition, while assembling their products in

And a national distributor of Chinese made materials handling products told Industry Update that his company was down to two weeks’

RAISING THE ROOF ON NEW YORK'S NEW TRANSPORT HUB PAGE 10

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EDITOR LAURENCE MARCHINI

A WELCOME RETURN ON THE CARDS

IS IT SAFE?

Funny, isn’t it? All those things that online media were going to sentence to the spam folder of history, and they are still there. Daily newspapers, trade magazines, books… the list is almost endless.

Suffice to say, the print catalogues have returned.

One thing that has certainly changed in the digital age is the mail.

And now I’m delighted to announce that another printed communication is making a long-overdue comeback – and this too is by popular demand. Industry Update Manufacturing Product Cards will be mailed to our magazine circulation in May this year.

It really wasn’t that long ago that we would all receive a mailbox full of “snail mail” each day, both at home and at work. But how many letters do you receive now? I’d wager it was only a tiny fraction of days gone by.

For the benefit of those too young to remember them (because it is several years since we’ve produced them) product cards are individual postcard-sized promotions, mailed out in a pack of 28.

This got me thinking, and last year we revived the idea of actually printing our media kit and mailing it out to all our advertisers, rather than just posting it online and sending out a link via email.

These unique cards are designed to grab the reader’s attention immediately, guaranteeing maximum response.

The results were fascinating. People remembered receiving it. And they kept it for reference – which was exactly the object of the exercise. Just like Industry Update magazine, which arrives on the reader’s desk at work and is kept for future reading, physical mail is perceived as having a greater value than electronic communications that pop up in an in-box. And, as a sidebar to that, of late I have spoken with several companies who had thought they could avoid the cost and palaver of printing a physical catalogue only to find that customers complained that searching an online catalogue was nothing like having the real thing in their hands.

How much response? Well, past product card advertisers have reported hundreds of responses. And one, an advertiser producing safety glasses reported more than 1000 responses. Product cards are great for promoting new products, special offers or new services. They are particularly useful for communicating things like company name changes or changes of contact details as readers are likely to pin them up on a noticeboard. We still have a few vacancies in the next pack of Industry Update Manufacturing Product Cards that will be mailed in May. Your name could be on one.

It’s one of the most chilling lines from the movies of the 20th century. My namesake and hometown hero Sir Laurence Olivier repeatedly asked Dustin Hoffman “Is it safe?” while torturing him in a dentist’s chair in the movie classic Marathon Man. Hoffman’s character’s problem was that he didn’t know what “it” was. So how could he answer? The recent story that reminded me of this particular movie scene was one from the world of cybersecurity. And it’s a story that just goes to show that in today’s IoT world, that unsafe “it” could be almost anything. It seems that last year, hackers from Check Point Research (fortunately the “good guys”) found that there were vulnerabilities in the ZigBee wireless protocols used to control a very mundane object – a smart lightbulb. The lamp in question, the Philips Hue, offers users the ability to control not only the brightness but also the colour of the illumination from a wirelessly connected control bridge. The Check Point hackers went on to demonstrate that it would be relatively easy for a malicious actor to take control of one of these devices wirelessly from anything up to 100m away. Once in control of the lightbulb, they simulated a malfunction in the lamp while

injecting malicious code that could be used to take over the control bridge for the lighting network once the user had rebooted the lamp to clear the fault. Once the control bridge had been taken over, they could than target any connected computer network. This would give them the opportunity to inject malware, ransomware and any other form of mischief into computers that might later be connected to a work network, or even a control system. So could a compromised lightbulb shut down a production line? It hardly seems likely, but it is certainly possible. Needless to say, the Check Point team revealed their findings to the manufacturer of the lightbulbs, which closed the loophole and issued a firmware security patch that would be automatically uploaded to all devices in the field. While that particular vulnerability has been resolved, it does go to show exactly how a security weak point in any connected device – however insignificant – could be exploited to attack major IT and OT assets. With more and more devices joining the Internet of Things each day, we really should all be asking ourselves “Is it safe?”… just as soon as we can work out what “it” is.

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CONTENTS FROM THE EDITOR........................................... 4 INDUSTRY NEWS............................................. 10 INDUSTRY POLITICS.......................................14

INDUSTRY POLITICS

ADVERTISING SALES DIRECTOR SCOTT FILBY

scott@industryupdate.com.au

ADVERTISING SALES REP GLYN SMITH

glyn@industryupdate.com.au

EDITOR LAURENCE MARCHINI

editor@industryupdate.com.au

CREATIVE DIRECTOR MATTHEW LAM

Lapp Group Celebrates Australia....................... 18

production@industryupdate.com.au

BUSINESS & FINANCE.....................................20

copy@industryupdate.com.au

PRODUCTION MANAGER JULIET NELSON VIDEO EDITOR & PRODUCER

video@industryupdate.com.au

New HQ for Vega Australia................................ 24

OFFICE MANAGER NICOLE CHARLES

nicole@industryupdate.com.au

ADVERTISING COORDINATOR JULIET NELSON copy@industryupdate.com.au

A Brief History of Compressed Air..................... 28 MACHINERY..................................................... 30 MATERIALS HANDLING................................. 37 ROBOTICS & AUTOMATION........................ 44 AMX PREVIEW.................................................. 49

WHAT DOES 2020 HOLD FOR MANUFACTURING?

FOCUS ON MANUFACTURING IN SOUTH AUSTRALIA & THE NT...................... 52 100 Years of South Australian Engineering........ 54 WORKPLACE SAFETY.................................... 57

FUN & GAMES................................................... 70

INDUSTRYUPDATE.COM.AU

ACCOUNTS RECEIVABLE LYN SLIGAR

lyn@industryupdate.com.au

SUBSCRIPTION ASSISTANT MARK ZAKOSHANSKI info@industryupdate.com.au

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SILENCE IS GOLDEN IN PALLET HANDLING MANUFACTURING MAGAZINE

ARBS PREVIEW................................................ 62 COMMUNITY................................................... 68

FINANCE & ACCOUNTS MICHELLE ALCOCK

michelle@industryupdate.com.au

PRINTER OVATO

INDUSTRIAL DOORS & SECURITY..............60 PRODUCTS....................................................... 63

WEB DEVELOPER JINI M R

CIRCULATION ASSISTANT circ@industryupdate.com.au

ENVIRONMENT, ENERGY & WASTE MANAGEMENT..............................50

PUBLISHER SCOTT FILBY

scott@industryupdate.com.au

AMX PREVIEW

All material in this publication is copyright to the publisher and/or its contributors. No material may be reproduced in part or in whole without the written consent from the Publisher. It is a condition of purchase or acceptance of this magazine that the Publisher does not assume any responsibility or liability for any loss or damage which may result from any inaccuracy or omission on this publication or from the use of the information in this publication or from the use of the information and illustrations contained herein and the Publisher makes no warranties, express or implied, with respect to any of the material contained herein. Â© Copyright Industry Update Media Pty Ltd 2020 Circulation 19,242 as at September 2018 Readership 76,968 as at September 2018 ABN 25 083 502 783

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A radar beam focused like a laser! The future is 80 GHz: a new generation of radar level sensors

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NEWS

IS IT TIME TO BRING MANUFACTURING BACK TO AUSTRALIA?

Continued from cover worth of stock.

the manufacturing process labour intensive.

Interestingly, on the electronics front in particular analysts are speculating that some companies may be in a slightly better inventory position than they might otherwise have been thanks to stockpiling ahead of escalation in the China-USA trade war.

However, new designs increasingly use close to 100% surface mount components and pick-and-place machines now operate at 120,000 components per hour.

However, for the long term, companies are already beginning to diversify their supply chains, making them less dependent on China. And it is broadly accepted that this will make the global economy more robust and less vulnerable to such disruptions in the future. In Australia there have been calls for manufacturing to be brought back onshore. Serena Ross is General Manager of Australian contract electronics manufacturer Circuitwise. She says: “We know of a number of original equipment

And she contends that using such highly automated technology has now allowed Australia manufacturers to reach price parity with Asia.

manufacturers who are in a world of pain right now. “Companies that have offshored their printed circuit board assembly to China are experiencing uncertainty and long delays in product being shipped to them.” “Anyone offshoring their manufacturing knows there are challenges around communication, responsiveness,

unexplained price hikes and hidden costs. The current coronavirus crisis in China simply highlights the existing risks and challenges of offshoring electronics manufacturing anywhere in Asia.” Interestingly, Ross contends that the reason why Asia was historically cheaper was because old electronic designs had a lot of hand-placed components, which made

“Circuitwise recently won a manufacturing contract with Siemens against direct competition from a contract manufacturer in Asia,” says Ross. “Siemens’ procurement team analysed all the factors of manufacturing in Asia and found that Circuitwise delivered a lower overall price position over a three-year period. “When all the factors are taken into account, including the reliability and convenience of a local manufacturer, then the business case for manufacturing in Australia is compelling.”

IGNORANCE OF PRESSURE CLEANER STANDARDS IS NO EXCUSE

Continued from cover

years ago, with a view to improving the safety of use of high-pressure cleaning equipment throughout Australia and New Zealand. Where the standard differs from previous versions is in defining two classes of equipment based on the size and power of the unit – Class A and Class B – with different safety requirements for operators. While the operation of Class A

equipment is still subject to the need for proper training, the wearing of suitable PPE and the observation of the normal standards of OH&S behaviour, the requirements for Class B are considerably more stringent. Importantly, Class B machine operators need to be certified by a registered training organisation. Also, the standards say that there should be two operators per machine: one directing

the gun and the other standing by the emergency stop. While the standards are designed to acknowledge that the potential for damage is greater for a Class B pressure cleaner than for a Class A unit, it is the method of calculation of the output, and the dividing line between the two categories that have left some users of existing equipment in limbo, and potentially in breach of the requirements of the standard. The important metric is the product of the pressure (in bars) and the flow rate (in litres per minute), expressed in “bar litres”. And the crucial figure is 5600 bar litres: above that and you are in Class B. Where some users have been caught out is that because the rating is the product of the pressure and the flow, there are some high-flow units at relatively lower pressures that fall into Class B, while a unit with a lower flow and higher pressure would safely fit into Class A. One manufacturer that has seen this confusion in the marketplace is Aussie Pumps. According to Managing Director, Warwick Lorenz, “Many pressure cleaner operators using bigger machines, and by that I mean Class B, are in denial about the new safety standards. What’s even worse is that many of the suppliers of

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this type of equipment also are failing to communicate to the market the details of their product range that fall into the Class B classifications”, said Lorenz. Australian Pump Industries has run a campaign over the last few years to inform users of the need to be aware of the new safety standards. The company has turned the number of pages of engineering jargon into a simple one-page explanation that enables operators to understand the difference between the two classifications. The company has also moved swiftly to develop bigger machines that are classified as Class A so that even 5,000 psi pressure cleaners fall within the Class A category. “We seem to be the only ones who are really trying to educate operators about not only the dangers and safety aspects of using Class B pressure cleaners and jetters but also, the legal implications,” said Lorenz. “We hear horror stories about injuries that have been sustained using Class B machines, leading to litigation and major penalties”, he said. This has even led to some industrial users returning their high-pressure cleaners to Aussie Pumps to have a smaller pump fitted to enable the unit to fall back into Class A.

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NEWS

NEW PRESIDENT FOR AMTIL RAISING THE ROOF ON NEW YORK’S NEW competitive we need to become innovative, adaptive and flexible; embrace the latest TRANSPORT HUB technologies; and improve efficiencies, training and education to be the best we can be in the global economy. The AMTIL Board will focus on developing and supporting strong networks in helping businesses grow within the manufacturing sector.”

Brigitte Stavar is the new President of the Australian Manufacturing Technology Institute Limited (AMTIL). Having served on the AMTIL Board for the past 6 years, Stavar has spent more than 16 years as General Manager at Sheetmetal Machinery Australia. She succeeds Paul Fowler, Managing Director of Dimac Tooling, who has served as President since 2013. “I look forward to continuing the great work AMTIL is involved with, representing our members interests and supporting the current initiatives such as the AM Hub, Export Hub and the Entrepreneurs Programme,” said Stavar. “The Australian manufacturing industry is undergoing change and to remain

Stavar is joined on the AMTIL Board by Peter Sutton, Managing Director of Sutton Tools, who replaces Philip Xuereb, also of Sutton Tools, who is also standing down. AMTIL CEO Shane Infanti welcomed Stavar to her new role, saying: “She is a highly respected figure within the industry, with a wealth of experience and insight that will be of enormous benefit to AMTIL and to our members. “In addition I must thank Paul for the enormous contribution he has made over the last six years. AMTIL has made huge advances under his leadership. And I would like to also thank Philip, and welcome Peter onto the Board. I feel confident with Brigitte and the Board we have in place, we are in safe hands for the coming new decade.”

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The most striking feature of the building is its futuristic roof: it is made of glazed steel ribs soaring upwards in the shape of a V for more than 50m, and is modelled on the wings of a bird taking flight, according to Calatrava. To let in sunlight, the entire roof can be opened up to 10m in the middle so the bird is seemingly flapping its wings – an effect made possible by the Winkel bearings and U-profiles.

Built into the roof of the Transportation Hub, these components make up a robust and durable guide track system that handles the extreme loads during the opening and closing of the rib structure. Winkel delivered a total of 224 bearings with flange plates and 445m of U-profiles for the project. The bearings have a special anti-corrosion coating to protect them from the elements. “Of course we are proud to play our part in such a historic and innovative project,” says Winkel’s Bernd Rudolph. “The Winkel bearings in conjunction with the U-profiles are the ideal solution for this difficult task. They can withstand enormous static and dynamic loads, have a long service life and are easy to install and replace.” Winkel bearings are available in Australia from TEA Transmissions. TEA Transmissions 07 4129 2533 www.tea.net.au

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“Jon has a strong focus on establishing business partnerships and fostering customer relationships. He has a long history of creating highly engaged teams, which makes him a perfect fit with Industree Group’s people-centred culture.

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“With over 30 years’ experience and the majority of time spent in senior level national and international roles in the PPE industry, Jon will help guide Industree Group through our next growth and development phase.

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(L to R) Jon Fleming and Jason Stenning

NSW Central Coast native Jon Fleming has joined Industree Group as General Manager and Equity Shareholder. The appointment continues the company’s focus on employing high-quality Central Coast locals for the West Gosford business. Industree Group

currently employs 22 Central Coast based employees. According to Managing Director, Jason Stenning: “Industree Group prides itself on the high quality of our Central Coast team and Jon’s appointment adds significant business experience and

“I am personally very pleased that we have been able to attract someone of Jon’s calibre and look forward to working with him and our Executive Team as we continue the exceptional growth of our carbon neutral Central Coast business operations,” Stenning concluded. Industree Group 1800 276 872 www.industree.com.au

ELECTRONICS SHOW SWINGS BACK TO SYDNEY IN SEPTEMBER visitors and exhibitors with several regular exhibitors commenting that it was the best Electronex show they had ever been involved in. Electronex was first held in 2010 and has grown to become the pre-eminent trade event for companies that use electronics in manufacturing, assembly or servicing.

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Reflecting the growth of high-tech niche manufacturing in Australia, at the recent Melbourne Expo more 87% of visitors said that they had met new companies and 81% discovered new products and technologies they were not aware of, reinforcing the important role of exhibitions in sourcing new technology and solutions in a rapidly changing marketplace. Electronex – The Electronics Design & Assembly Expo and Conference will return to Rosehill Gardens in Sydney on 9th and 10th September 2020. The 2019 event was hailed as an outstanding success at the Melbourne Conference and Exhibition Centre, with attendance increased by more than 12% and a record number of exhibitors. In a

further endorsement for the growth of the electronics sector and the success of the event, 53% of visitors had not attended Electronex previously and over 90% were engineers, managers or involved in production or purchasing. Organiser, Australasian Exhibition and Events (AEE) said that the move to MCEC was well received by both

The Sydney Expo is now open for bookings, and the organiser reports that around 60% of the space had already been booked by late December 2019. Australasian Exhibitions & Events 03 9676 2133 www.electronex.com.au

FEBRUARY / MARCH 2020

NEWS

MELBOURNE HOSTS FIRST AUSTRALIAN PLANT OF THE FUTURE

Cutting the ribbon are Lynn Johnson (Senior Manager Process Engineering APAC), Geoff Boshell (Senior Director, Supply Chain APAC), Shayne Bennett (Derrimut Service Centre Manager) and Jake Weragoda (Senior Manager, Technical and Strategic Operations)

CHEP Australia has unveiled its “Plant of the Future” concept with the opening of its newly upgraded Derrimut Service Centre, one of four Australian service centres to be upgraded as part of a global plant automation strategy.

to the multi-platform site, which now includes timber pallets, plastic pallets, bins, containers, crates and automotive platforms. The new pallet equipment has the capability to condition up to 3 million pallets per year and was built locally in Bendigo, Victoria.

Speaking at the opening, Phillip Austin, President, CHEP Asia Pacific, said: “This is the first site of its kind for our region, and I am proud of the work our team has done to bring this together. This not only creates more local jobs, we’re also ready to further support the growing needs of our customers sustainably with more capability and greater efficiency.

Geoff Boshell, Senior Director Supply Chain, CHEP Asia Pacific, said: “Benefits of a multi-platform site, include it’s a one-stop-shop for CHEP customers. We have also expanded the size of our site to house more platforms onsite, ready for when our customers need it.”

“As the industry gears up to meet the Australian Government’s 2025 Sustainable Packaging Targets, customers are increasingly looking to make their supply chains more sustainable and more resilient. “The first ‘plant of the future’ site,Derrimut allow growers, producers and food manufacturers within the region to deliver life’s essentials more sustainably,” Austin concluded. Pallet equipment has been added

FEBRUARY / MARCH 2020

The 24,000m2 facility includes renewable energy technologies, including solar, which has already saved 220 tonnes of carbon emissions. There is also a new automated bin washer and an upgraded crate washer, both using 100% recycled water. All CHEP sites achieved zero product waste targets for timber and plastics in FY19, showcasing best practice product stewardship as part of the company’s circular, share and reuse model.

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INDUSTRY POLITICS HON KAREN ANDREWS MP

HELPING INNOVATIVE COMPANIES COMMERCIALISE THEIR PRODUCTS Right across our nation there are innovative manufacturers showcasing the best in Aussie ingenuity: businesses expanding their horizons through new technology, while offering practical hands-on job opportunities in seemingly traditional industries. A small Queensland company that has developed a range of innovative devices to help fight bushfires is a prime example of how great ideas can reap benefits locally while having an eye to international markets.

tanks from southeast Queensland businesses, and the tanks themselves are manufactured locally.

Jason wanted to create a way to accurately release water to the fire ground as soon as possible and came up with a retractable tank concept.

The chief designer and engineer is Helitak CEO Jason Schellaars, a helicopter fire-fighting pilot.

In January I had the pleasure of visiting Helitak’s factory in Noosaville on the Sunshine Coast to announce that the

company had been awarded $497,500 as part of our Government’s Accelerating Commercialisation grants programme. The grant will help Helitak commercialise a tank developed for Airbus Super Puma helicopters, bringing the project to international markets. It will also help secure the intellectual property rights, ensuring that the manufacture of component parts can remain in Australia. The Super Puma helicopter tank can fill with 4200 litres of water or fire retardant in less than 50 seconds and drop the entire load or lesser amounts of water or fire retardant as required. Helicopters can take off and land with Helitak Fire Tanks attached, and they are much safer in flying over urban areas than helicopters using the traditional bucket design. The value of such a device to Australia is obvious. This sort of technology could make a vital difference in fighting the sort of devastating bushfires that have ravaged large areas of eastern Australia. But the device also has strong demand in international markets.

It is the sort of company the Morrison Government is determined to support: a local business manufacturing a product that can help Australians, employ local people, source components locally, but also export to the world. Helitak Fire Fighting Equipment provides solutions to help fight fires, both here at home and overseas.

The Morrison Government is always looking to support innovative products from businesses with strong commercial and export prospects that provide local jobs and benefits.

Established in 2006, the manufacturer employs locals to build its inventions and its workforce is expected to grow from about 13 now to 50 by the end of the year.

These are businesses thinking big and outside the box, at the same time as creating opportunities for manufacturing workers and local supply chains.

Among Helitak’s inventions is a retractable underbelly water tank for helicopters that does not require modifications to the aircraft’s undercarriage.

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

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INDUSTRY POLITICS month of contraction. This result in January marked the lowest monthly result since 2015.

BRENDAN O'CONNOR

R&D IS CRUCIAL TO AUSTRALIA’S MANUFACTURING FUTURE Nostalgia hit a high note last month with the announcement by General Motors that they will “retire” the iconic Holden brand in Australia and New Zealand after 160 years. It was a shocking blow, but upon reflection can we really be surprised considering the policy direction of the last seven years? The day the former Treasurer, Joe Hockey, dared Holden to leave Australia in December 2013 is etched in my mind. A foolish, arrogant but deliberate move that played a significant role in the departure of local Holden car

manufacturing. The following day, as the then Shadow Employment Minister, I moved a censure motion against the government condemning their treatment of Australian manufacturers. Since then, it seems as though the government has determined that the more they ignore the issue of what is increasingly a struggling manufacturing industry, all the while talking up the future of the industry, the problem might just go away. Industry Minister Karen

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Andrews just last year highlighted her indifference to the challenges facing the automotive industry, claiming the end of the manufacturing is good for the country. Karen Andrews said the end of automotive manufacturing: “… is turning out to be a positive story. The outcomes we are seeing have defied all the doom-and-gloom predictions of 2013.” I’d like to be enlightened as to just how it is a positive story for the nearly 600 Australian design and engineering staff about to lose their jobs, the nearly 200 automotive dealers reeling from the decision and who may have to close their doors, and the nearly 6000 automotive dealership employees whose jobs are at risk?

The only plan the Morrison Government currently has is an R&D Bill before Parliament ripping almost $2 billion from innovative manufacturers and firms. Slashing this funding will see a decline in research and development at a time when manufacturing is contracting. History has shown us that any dollars invested in research and development are returned to the economy many times over. Supporting the car industry and manufacturing in Australia has significant flow on effects, developing a skill set that is critical for this 21st century. It will provide high paid, secure and highly skilled jobs. Australia’s manufacturers are facing challenges, and they need a government that is willing to listen to them and to back them. What they don’t need is a government that says Australia can’t afford a manufacturing industry. Despite these challenges, I am optimistic about the future of manufacturing in this country. We have shown in the past that we are

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The Prime Minister and the Industry Minister expressed their outrage that they were only given 15 minutes notice by General Motors of the company’s decision. Rather than focusing on their pride, the government’s primary concern should be directed to those left on the scrap heap because of this decision, and for the state of the industry. Manufacturing in general has been struggling. The Australian Industry Group Performance of Manufacturing Index (PMI) reported a third consecutive

an innovation nation and we can continue to be. Continuing to invest in research and development will help us realise a bright manufacturing future that will benefit all Australians. History shows us that when governments and business collaborate we can do great things.

Brendan O'Connor is Shadow Minister for Industry and Employment.

FEBRUARY / MARCH 2020

LAPP GROUP CELEBRATES AUSTRALIA

MORE PRODUCTS AND INCREASED SUPPORT UNDERPIN AUSTRALIAN EXPANSION the complementary Wago and Tosibox technologies, says Lapp Australia General Manager Simon Pullinger, who welcomed to Australia members of the entrepreneurial Lapp family, including Andreas Lapp, Chairman of the Board of Lapp Holdings. Pullinger says the expanded availability of 18,000 products online – with live real-time stock checking on the local and German HQ warehouses – will give customers greater access to products and rapid lead times for better planning of future-focused automation initiatives including those taking place locally as a result of Industry 4.0 digital integration.

The Lapp family and the Rayner family join with Lapp Asia-Pacific leaders and local Aboriginal Darug Elders in the warehouse at Lapp Australia

Lapp is expanding in Australia following the visit of its founding family to celebrate the success of the establishment of Lapp Australia.

Lapp Australia launched its HQ in at Eastern Creek, Sydney in 2018, and is set to expand its operations with additional account managers, for Western Australia and NSW, new product and technical

LAPP FAMILY VALUES In November 2019, three members of the entrepreneurial family Lapp arrived in Sydney to celebrate the success of the company’s Australian operation. Andreas Lapp (Chairman of the Board of Lapp Holding) and his nephews Matthias Lapp (Chief Executive Officer LA EMEA) and Alexander Lapp (Global Manager Digital & eBusiness) were in the harbour city to visit Lapp Australia and to host a gala event for customers and staff at the Sydney Opera House. Industry Update took the opportunity to interview the three family members to try to gain some insight into the workings of Lapp and how a German family owned company views the Australian market.

support appointments, and thousands more products available with short lead times nationally. It will also distribute via its eshop

IU: Can we start by looking at the family business model? Why is it that there are so many major German corporations still in family hands? Andreas: I think it is very much to do with European culture. But also to do with our tax laws. Especially in central Europe, there is the tradition to stay in the same area and even in the same house for generations. So if you start something good, it is for the next generation. You know you don’t own it and it is for the next generation to develop. This isn’t just with businesses… its with houses, properties … everything. It is tradition. Alexander: Also – and this is not unique to our family – but we think the family members are assets, not liabilities for the company. We are not only a family business, but also a business family.

Pictured at the Lapp Australia Gala Event are NSW Minister for Finance Damien Tudehope with Alexander, Andreas and Matthias Lapp

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IU: So this is part of the family values that you apply to the business, and that you have brought to Australia?

The global Lapp organisation – with 4650 employees and turnover exceeding Eur 1.2 billion (AU $1.95 billion) – established Lapp Australia two years ago to serve future-focused industries down under, including manufacturing and plant engineering (including automation, robotics and process engineering systems); electrical engineering systems and energy

Andreas: For us, Australia and New Zealand are countries in Asia-Pacific that carry our values. IU: One area where we tend to feel that Europe leads Australia is in environmental matters. Where is Lapp in this equation? Andreas: Lapp in Germany is CO2 neutral. Other companies like Siemens and Bosch want to be in the near future. We are already. For my father and founder of the company, Oscar Lapp, this was not just an environmental issue, but also a commercial one – to save money. For example, the waste heat from the cable-making process is used for heating the building during winter. And for both heating and cooling of our headquarters building we have geothermal energy. We have the biggest solar farm in Stuttgart on the roof of our logistics building. And this was also not just

FEBRUARY / MARCH 2020

LAPP GROUP CELEBRATES AUSTRALIA Australia) to view the success of the operation and confirm local demand for high performing German engineered products that meet local standards and compliance, says Pullinger. “The Lapp family has taken a deep personal interest in the expansion of Lapp Australia so as to offer local customers access to Lapp’s complete product range, including flexible power and control cables, multicore cables, Ethernet cables, solar cables, cable glands and industrial connectors used by key industries.” Alexander Lapp addresses the assembled staff

systems, including wind and solar green energy; machine building and machine tools; food and beverage; automotive, rail and mobility systems; intelligent buildings and infrastructure; and the resources industry, including mining and oil and gas process engineering. “The Lapp entrepreneurial family’s recent visit underlined their strong commitment to building further on the success of Lapp Australia, with enhanced supply of the world’s best quality product in key market sectors,” says Pullinger.

the company would provide $50,000 to bushfire relief, to help parts of NSW that are struggling with one of the worst bushfire seasons on record. Andreas Lapp’s nephews Matthias Lapp (Chief Executive Officer LA EMEA) and Alexander Lapp (Global Manager Digital & eBusiness) also attended the event and were optimistic about Australian industry and further growth in emerging markets.

The Lapp Sydney Opera House gala function for customers was addressed by Andreas Lapp, who announced that

The visit was an opportunity for the Lapp family – as the founders of the world's leading supplier of integrated solutions for cable and connection technology – as well as the Rayner family (joint venture partners in Lapp

environmental as we manufacture the cables for the panels and we wanted to see how they work.

Matthias: We can also produce our Skintop cable glands from recycled fishing nets.

It’s interesting because we have to give a warranty to our customers of anything up to 25 years. And at that time there was no solar product that had been in use for more than five years.

IU: Is this collective attitude across Germany?

So how can you give 25 years? That’s why we had to test it ourselves.

I know we can do a lot to mitigate climate change. And the good thing is that we as a company are involved in this.

Alexander: And we have a range of products that use 30% recycled materials in the plastics for our cables and connectors. For us, environment and family are the same thing. But environmental matters will become even more important. In the future, customers will not just check that you have ethical standards, for example not abusing the workforce, the importance of the environmental aspects of our products will increase. And we are ready for this.

FEBRUARY / MARCH 2020

Andreas: I would say that all of Europe is more aware than other areas of the world.

Renewable energy is a big area for us. And electric mobility. IU: That brings us to research and development. What is the next big thing? Andreas: Not high voltage but medium and low voltages…. What happens to cables when you use DC rather than AC? [as in server farms] You need different cables. So now we have tested and we can say to our customers that for this type of application (say a server farm) where you use DC if you use this particular

New appointments powering expansion in 2020 include: Stephanie Ansley as an additional NSW Account Manager; Scot Rundell as Western Australia Account Manager; Jeremy Lively as new Product Manager; and Chris Keating as an additional Technical Support Engineer. Lapp Australia’s expanding ranges will be exhibited at the Advanced Manufacturing Expo in Sydney from 13th to 15th May, where the company will present a one-stop shop for highly integrated, efficient and reliable systems which comply with the leading Australian, European and American compliance and quality standards. The family-owned Lapp organisation is renowned globally for its levels

cable you are safer. IU: And what about your staff? Do you suffer from skills shortages? Andreas: We don’t just need engineers to design things. In our factories and even in the warehouses we need very well educated people. So we have apprentices. There is an issue with demographics. In Central Europe we can easily find well educated people. But in the rest of the world, we train them ourselves. To support this we have set up centres of excellence in cable technology in institutions that suit us. [at polytechnic level] Matthias: For our apprentices, we take them from school. And we have a very healthy application ratio. For 25 places we have something like 12001300 applicants. There will be easily 2000 applicants to join the scheme next year. Alexander: We have many colleagues that started as apprentices

Customer Service Executive Indy Saggu receives the Lapp Australia Employee of the Year Award from Andreas Lapp

of quality, innovation and for its commitment to ethical values and service, qualities that it will bring to key Australian markets. The family’s investment in Australia is a strong vote of confidence in local industry as it increasingly moves into the global industrial automation market, which is forecast to grow to an annual worth of US $350 billion (AU $460 billion) by 2024. Lapp Australia 1800 931 559 www.lappaustralia.com.au

and have been with the company for 20 years or more. IU: With Germany’s growing population, has the balance changed? Andreas: When I did it 35 years back there were only two in the intake who were not of German origin. Today it is almost opposite: the majority do not have a German background. In fact we think that Stuttgart is one of the most multicultural cities in the world. We have 195 nations living in Stuttgart – that’s more than New York! IU: That’s something you share with Australia then. Andreas: As I said before Australia and New Zealand are certainly the countries in Asia that share our values. And more so. I think the attitude of the Australians is very much welcomed in Europe and in Germany in particular. The image of Australia is excellent. IU: Thank you gentlemen.

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BUSINESS AND FINANCE

WHY MOVE ERP TO MODERN ENTERPRISE MANAGEMENT?

By Anne-Marie Keogh

It’s all too easy to blame advancing technology as a major challenge for industries such as manufacturing and distribution, says Anne-Marie Keogh. But while technology can complicate business, it can also simplify it. In today’s reality, bewildering datarates demand that decisions are made at breakneck speed. Organisational silos begin to interfere with operational efficiencies, as individual business units incorporate tools and systems to meet their own specific needs. And the always-on mobile world demands that companies satisfy their customers as and when they demand it. Traditional accounting software and legacy enterprise resource planning (ERP) solutions are no longer good enough. ERP was originally developed to help manage basic finance and accounting tasks. But it has evolved into a system that automates, manages, and delivers greater visibility into administrative, operational, financial, HR, procurement, manufacturing, warehousing, sales and marketing, and customer service functions. The problem with this evolution is that companies have been left with ever-more complex systems that are neither flexible nor customisable. Because these legacy ERP systems were never designed to work effectively with realtime data, they can’t help provide the insight needed to make smart, timely decisions. And there is no way they will be able to cope as the global economy grows and intensifies.

Not only that, but also when a customer adopts old-school ERP, they often struggle to get support - particularly when they add on ad-hoc solutions to satisfy different business units. These add-ons often don’t integrate well with the original solution, which tends to obstruct business processes rather than streamline them. Mid-market enterprises are also finding that their management software isn’t able to align siloed departments and business processes. This leaves them with inconsistent data or an inability to find key information when they need it. In a recent survey, Aberdeen Group asked leading manufacturers what they looked for in a new enterprise management solution. 44% wanted streamlined and accelerated processes to improve efficiency

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and productivity; 38% wanted a modernised technology infrastructure; and 31% wanted improved interoperability and collaboration. Today’s forward-looking mid-market enterprises are demanding a new class of enterprise management solutions that can answer today’s challenges, streamline business processes, and improve collaboration – both within the business and across the supply chain. The “wish list” for a modern enterprise management solution includes: easy access to accurate company information and reports; full information about services, products, vendors, suppliers, customer orders and more; easy analysis of sales and planning information; easy collaboration between teams in different business groups; and the ability to support multiple languages,

currencies, companies, sites, and legislations. The system should provide: accurate realtime data intelligence; faster processing of core business functions such as procurement, inventory, sales, and customer service; and improved forecasting and simplified financial management in a single system. And it needs to have virtually unlimited capacity to scale for any size of enterprise operating anywhere in the world. Sage explores this concept further in a new eBook titled “Move Beyond ERP”, available from www.sage.com/en-au/cp/ enterprise-management/beyond-erp. Anne-Marie Keogh is with Sage Software Australia.

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FEBRUARY / MARCH 2020

Turn invoices into Turn invoices into Ka-chingvoices! Ka-chingvoices! Talk to a St.George specialist banker to find out how you Talk to a St.George specialist banker to find out how you could unlock the cash flow in unpaid invoices. could unlock the cash flow in unpaid invoices. Matthew Kelly Manufacturing & Wholesale Manufacturing & Wholesale

Head of Manufacturing & Wholesale Matthew Kelly 0412 265 197 Head of Manufacturing & Wholesale manufacturingwholesale@stgeorge.com.au 0412 265 197 manufacturingwholesale@stgeorge.com.au

Things you should know: Eligibility, credit criteria, fees, charges, T&Cs apply. Speak to a banker for full details. ÂŠSt.George Bank - A Division of Westpac Banking Corporation ABN 33 007 457 141 AFSL and Australian credit licence 233714. Things you should know: Eligibility, credit criteria, fees, charges, T&Cs apply. Speak to a banker for full details. ÂŠSt.George Bank - A Division of Westpac Banking Corporation ABN 33 007 457 141 AFSL and Australian credit licence 233714.

BUSINESS AND FINANCE

WHAT DOES 2020 HOLD FOR MANUFACTURING? Industry Update sat down with Matthew Kelly, EM Manufacturing and Wholesaling, St.George, to find out his views on the financial health of the manufacturing sector in 2020. IU: How do you view the general financial climate for the Australian manufacturing sector in 2020? MK: I believe 2020 will see the emergence of a new generation of Australian manufacturing, with a great opportunity for financial growth. New South Wales manufacturers alone produce almost 30 per cent of Australia’s total manufacturing output and generate about AU $33 billion in industry value (St.George Advanced Manufacturing Report).

MK: We’ve seen great excitement from local manufacturing companies when it comes to taking on new challenges and opportunities. The sector is far from fading with automation, artificial intelligence and pure inventiveness enabling new business models and processes that are transforming an industry, which already contributes AU $100 billion to Australia’s GDP (Australian Bureau of Statistics).

With new technology allowing both start-ups and well-established manufacturing companies to move their businesses into the future, we can only see the financial climate improving.

However, the industry can do more to create a compelling value proposition for the next generation aligned to what matters most to them when purchasing products. This could be through investing in innovative manufacturing techniques to reduce costs and further using sustainable materials.

However, a recent report reveals that two-fifths of Australian manufacturers are reporting being affected by the coronavirus (Roy Morgan), which poses a threat to the positive financial climate of the industry.

IU: Is there sufficient help available from governments and/or banks to help Australian manufacturers adapt to new technologies and markets?

IU: How do you think local companies are taking up the challenges and opportunities of advanced manufacturing?

MK: While the government does provide adequate support to Australian manufacturers, we at St.George have a commitment to investing in the future of the sector.

AUSTRALIAN TYRE RECYCLER EXPORTS PROCESS TO THE USA

diesel, jet fuel and other petroleum based products.

Australian tyre recycler Green Distillation Technologies has signed a deal to build its first plant in the USA in an agreement that will provide up to US$100 million of funding for the roll out of additional US plants subject to the successful operation of the first one. GDT’s Chief Operating Officer Trevor Bayley says that the deal comes as the result of a considerable amount of work to negotiate an effective and workable agreement in the light of numerous US enquiries about the company’s technology, which recycles end-of-life tyres into oil, carbon and steel.

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“The US, like most countries around the world, has a significant old tyre disposal problem and generates in excess of 250 million end-of-life tyres a year,” says Bayley. “In contrast, Australia reaches 25 million, but the number of old tyres are increasing fast in India and China and the world total is now in excess of one and a half billion a year. “In the light of this burgeoning environmental disposal problem our approach provides a recycling solution as we turn a problem into valuable and saleable materials. “For example, our oil has been described as light crude, which is low in sulphur and easy to refine into petrol,

“The carbon we produce is a high-grade product that has massive potential for sale as carbon, in the form of carbon black. This is one of the world’s most widely used chemical building blocks in many products ranging from tyres, plastics and paints, water filtration, printer’s ink, paint, electrodes, graphene, toothpaste and cosmetics including eyeliner, mascara, nail polish, eye shadow, blushes, rouge and lipstick,” says Bayley. Bayley went on to highlight the company’s domestic progress, which will see its processing plant at Warren in Western New South Wales reach full production in 12 months and the second facility in Toowoomba, South Queensland, reaching full operation in 18 months. The projected cost of these two facilities is $20 million. Green Distillation Technologies 03 9826 2335 www.gdtc6.com

FEBRUARY / MARCH 2020

BUSINESS AND FINANCE St.George has been working across the manufacturing sector to provide help and build capabilities for businesses to adapt to new technologies and markets. For example, the St.George Kick Start programme offers $100,000 in grants to support Australia’s brightest business ideas, across all industries, including manufacturing. The grants will allow businesses to invest in scaling up and embrace new technologies. Additionally, at St.George we are collaborating with scientist and engineer Professor Veena Sahajwalla from The University of New South Wales and the Advanced Manufacturing Growth Centre (AMGC) to help businesses unlock their potential and address pain points such as rising energy costs. IU: Finally, Matthew, will we see you in the Happy Dragon suit again this year? MK: Yes, I will be in the Happy Dragon suit again this year to raise money for three wonderful charities, The Royal Institute of Deaf and Blind, St Gabriel’s School for Autistic Children and Westmead Prenatal. It is a privilege to be able to assist in raising money for them and should you be interested in contributing or donating, please get in contact.

St.George Bank 0412 265 197 www.stgeorge.com.au/manufacturing

SOURCE PRODUCTS SHARE SOLUTIONS CONNECT @ARBS Visit Australia’s only international HVAC+R & building services trade exhibition, with the largest range of suppliers, products and solutions, all under one roof. Featuring the highly regarded Speaker Series, the new IBTech Insight Series and the celebrated ARBS Industry Awards, ARBS 2020 should not be missed.

FEBRUARY / MARCH 2020

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VEGA OPENING

HEADQUARTERS OPENING KEEPS VEGA AUSTRALIA IN THE SHIRE VEGA Australia has formally opened its new headquarters at Caringbah in the Sutherland Shire. The honour of cutting the ribbon fell to Gunter Kech, Managing Director from VEGA headquarters in Schiltach in Germany’s Black Forest. Speaking after the ceremony Kech said that cutting the ribbon was “an emotional thing to do” and stressed the importance of the new headquarters as being a place where “people like to work and people like to be successful – that’s the basis of growth”. The location of the new headquarters in no chance event. VEGA Australia Managing Director John Leadbetter chose the site in part for its proximity to the company’s previous location at Kirrawee, also in the Sutherland Shire, to minimise the disruption for the existing staff.

This was a point not lost on Cr Carmelo Pesce, Mayor of Sutherland Shire Council, who congratulated VEGA on its choice to remain in “the best part of Australia”, as he put it. For Leadbetter, the opening marked the end of a very long journey, spanning four and a half years. “But an enjoyable result in the end,” he said. He went on to acknowledge the work of the whole VEGA family in bringing the project to fruition, including the support he received from Germany. Vega Australia 02 9542 6662 www.vega.com

The theme of the opening event echoed the “Black Forest meets Australia” theme of the building design.

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VEGA Australia Managing Director John Leadbetter (left) invites guests to enter the new premises after VEGA MD Gunter Keck (right) cut the ribbon at the formal opening.

The new office has space for 36 staff (not to mention 32 parking bays, compared with the six at VEGA’s old Australian HQ at Kirrawee).

FEBRUARY / MARCH 2020

VEGA OPENING

Guests could view working demonstrations of VEGA’s world leading 80GHz radar sensor technology. The dedicated training centre has facilities for up to 32 people at a time to receive what John Leadbetter describes as “proper training – not death by PowerPoint”.

The new warehouse at Caringbah is twice the size of the old one and, as can be seen from the outside, has been designed with security very much in mind – which is significant as it can hold upwards of $4 million worth of stock.

FEBRUARY / MARCH 2020

Central to the new site is an outdoor area with five mature gum trees around which the admin block, warehouse and training centre have been built, providing a quiet oasis for staff to take a break.

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HISTORY

FROM THE HUMBLE BELLOWS TO TODAY’S ADVANCED AIR COMPRESSORS

A brief history of compressed air

First compressed air inventions

Air compressors have been used for hundreds of years to power an incredible array of different devices. Those who have experience in engineering, manufacturing and construction are especially aware of this, as these machines are responsible for a great deal of the power used in these industries.

Around 3000 BC, people began practicing metallurgy more regularly. To obtain the high temperatures required to melt metal, they needed a steady stream of oxygen to blow onto the fire. They somehow scraped along with rudimentary means until the invention of bellows around 1800 BC.

In mathematics, there are so-called “natural” numbers. They are named because they are self-evident, and the logical conclusion is that anyone with an inclination to look would inevitably discover them. If ever such a machine existed, it would be the air compressor. Its invention was as inevitable as the discovery of pi. Largely, this is because we have our very own air compressors built into our bodies — our lungs. We use our lungs’ compressing qualities whenever we blow on a struggling fire to supply it with oxygen, blow the dust off a surface or try to fill up a balloon. Prehistoric humans may not have known the exact mechanics of what was happening in their chest cavities — specifically, their diaphragms pressing upward on the lungs and creating pressure — but they understood the results.

The Three-Stage Compressor

John Smeaton's waterwheel.. 1762

Bellows.. an early form of air compressor

Bellows went through different designs, but are most commonly made of a flexible bag placed between two inflexible boards. Typically, these two boards are hinged together at one end, and they are then pumped together and apart to create alternating high and low pressure inside the bag. The result, of course, is a steady stream of air out the nozzle.

The invention of air compressors

Our lungs can act as an air compressor

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It was the Industrial Revolution that saw the rethinking of bellows. In 1762, the inventor John Smeaton found a way to rig a water wheel to power a blowing cylinder. Smeaton enjoyed a brief run of success with his invention — but as is the case with revolutions, more change was soon to come. A few years later, just as his country

was entrenched in losing the American Revolution, Englishman John Wilkinson’s hydraulic blowing machine came to prominence. It was this hydraulic blowing machine that became the inspiration for modern air compressors. It was no surprise that the idea caught on, as during this period air compression was making its way to many different industries. Far from just heating blacksmiths’ fires, the air compressor was now in use in metal mines, fabrication plants and in underground work areas where ventilation was needed.

A plant in Wales used compressed air to power its workings in the 1820s. This gave rise to the idea that this might be even more effective than steam power, which was the height of technology of the day. The very same 1857 rail tunnel that used air compressors for ventilation also used them for power. This came in the form of pneumatic drills, which both the French and Italian teams used to blast through rock inside the tunnel. Also known as a jackhammer, a pneumatic drill uses compressed air to power the up and down motion of its hammer.

In 1857, a rail system was installed between Italy and France that bore an eight-mile tunnel full of workers. Because oxygen can quickly get used up in such environments, air compressors were responsible for moving air into the tunnel. It was half a century earlier that air compressors appeared as more than just a way to move air — it also dawned on people they could transport energy. Much like the forthcoming era of electricity, this period saw a host of inventors exploiting compressed air’s other abilities.

Early portable compressor

FEBRUARY / MARCH 2020

HISTORY

The future of compressed air in Australia and around the world

Viktor Popp's Compressor Plant 1888

First air compressor plant In 1888, the engineer Viktor Popp — an unpromising name for a man specialising in high-pressure air systems — introduced the first compressor plant to Europe. This plant went from producing 1500kW to 12 times that amount just three years later. At that time, it seemed compressed air was heading toward a very different kind of future. The 1900s and the road to modern air compressors As debates over whether compressed air would render electricity obsolete in Europe raged in Paris, the entire world seemed to be gearing up for its adoption. And while compressed air never did replace electricity, it did come to dominate in other areas. The twentieth century saw the air compressor go from a large, bulky engine that clanked and hissed to the sleek devices used today.

The uses of compressed air today Today’s air compressor works by taking air from the surrounding atmosphere and compressing it to high pressures through the use of a drive motor or engine. The air that has been compressed is collected in a tank either as an integral part of the device or as an auxiliary holding and distribution chamber, where it awaits usage by tools or machinery. To activate tools and machinery, the air compressor’s air receiver is connected a reticulation system and then on to the device. As the apparatus discharges air pressure to perform its particular task, the compressor sends more air through the pipework to compensate. This rate of air usage will vary per application and will dictate what size compressor is needed to perform its job. Matching the pressure requirements of your devices with the air pressure provided by a compressor is extremely important both in performance and source energy requirements. Air compressors have withstood the test of time, and we find more uses all the time. Today, air compressors are core components of engineering, mining, mechanical work, factory assembly lines, construction, transportation and more.

FEBRUARY / MARCH 2020

To address the constant rise in energy costs - a serious threat to air compressor and equipment manufacturers and suppliers - dramatically higher compressor efficiency levels must be achieved to maintain compressed air as a viable industrial power source immediately and well into the future. Innovations in motor efficiency and new technology are now creating machines that cost far less to run for the relative air power output. Kaishan Australia (formally Southern Cross Compressors) now leads the Australian market in energy-efficient compressors using advanced technologies. As one of the world’s largest designers and manufacturers of industrial air compressors, the global Kaishan group, has been at the forefront in research and development of ever evolving technologies in compressor engineering that have achieved energy savings beyond that required to satisfy their customers around the world. While rotary screw compressors remain the bastion of high-output industrial compressed air systems, Kaishan has developed its latest rotary screw machines to integrate with newly developed efficiency technologies that revolutionise the industry. The flagship of the Kaishan offering for heavy industry applications is the PMV range of two-stage rotary screw air compressors using permanent-magnet variable-frequency technology. With PMV, when air demand decreases, the machine’s output and motor electric current declines as well. After any extended period of zero demand the machine will idle and shut off, saving energy and reducing operating costs. However, immediately on demand for air, the compressor will automatically restart. This gives the air compressor the ability to adjust air output ranging from zero to 100 per cent, ensuring maximum operational efficiency. The Kaishan range of advanced air compressors has evolved to be a benchmark in providing sustainable compressed air power at the lowest possible cost. From small, quiet, compact workshop models to the revolutionary range of permanent-magnet variablefrequency rotary screw compressors, Kaishan has combined advanced global technology with engineering excellence to produce the most efficient range of energy-saving compressors available in Australia today. Kaishan Australia 1300 098 901 www.kaishan.com.au

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MACHINERY FAMILY BUSINESS FINDS BENEFITS FROM SINGLE MACHINERY SUPPLIER and massively expanded the company’s cutting capabilities. The Yawei fibre laser has a number of clear benefits: “We have found that the fibre laser is consistent and the speed and accuracy of cutting is brilliant,” says Amal. The advantages of the machine have already had a direct impact on the service provided by KNS. “Our lead times have greatly improved as a result of having the machine,” says Kamal. “We feel that we have taken back control of certain elements of our business,” he adds. Staff have also found the machine easy to use: “We’ve had the machine for 3-4 months now and our staff are very happy with its ease of use and the way in which it operates,” says Amal.

KNS Metals is one of Victoria’s fastest growing family owned and operated sheet-metal companies. The company was founded in 2014 by Kamal Singh, who had been working in the sheet-metal industry for over 30 years, together with his wife and two sons. Eldest son Amal is now General Manager of the company. In 2014 Kamal Singh spotted an opportunity in the marketplace and with extensive experience believed that it was the right time to go it alone. The business has grown rapidly over the past several years and it now operates with around 10-15 staff. KNS Metals specialises in custom programming and design fabrication for both commercial and residential customers. Commercial is the backbone of the company, which provides 95% of the business, while residential makes up the remainder. Their other services include CNC turret punching, laser cutting, pressbrake bending and welding. KNS operates Australia-wide but most of the clients with which it deals directly are based in Victoria. Kamal and Amal believe that their business has been successful due to their knowledge of the industry and outstanding customer service. While working in the business, Amal has also been completing his electrical engineering degree. The

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knowledge he has gained from this has been beneficial in enhancing the company’s overall expertise.

we were back working on Monday, that’s how much of a help they were,” Kamal explains.

“Our past experience as well as our critical and logical thinking helped a lot; and with this knowledge we can give customers great lead times and great quality products,” says Kamal.

Furthermore, the subsequent service and backup KNS received from Applied has cemented the relationship between the two companies. “We have a great working relationship with Applied and we are certain that will continue into the future,” says Amal.

Most of the company’s work comes through word-of-mouth. As such KNS Metals has never had much need to advertise, however the company is now expanding into social media. Kamal first encountered Applied Machinery when he purchased an Amada AE-2510 turret punch. When the company required another new machine, Applied Machinery was the first port of call. “We had dealt with Applied previously so it was only natural for us to do business with them again,” Kamal explains. “We were looking for the right machine and after discussion with Applied found that the Yawei pressbrake they offered was just what we were after.” Applied Machinery helped KNS Metals to set up the machine when it was delivered and this vital help impressed the company. “When we moved to our new factory, Applied came in after-hours and helped us set up over just one weekend,” says Amal. ”We packed-up on Friday and

The new pressbrake has had a big impact on the company. “We are very pleased with how the machine’s gone so far,” Kamal says. “We will likely get a second one as we anticipate further growth in part thanks to the effect the pressbrake has had,” he adds. KNS had previously been outsourcing a number of jobs due to a limitation on laser-cutting resources. However, it soon became apparent that it needed its own in-house laser-cutter that would be able to perform high-quality precision cuts. KNS went to Applied again and after reviewing Yawei’s extensive range of fibre lasers purchased an HLF15303kW model - Amal and Kamal were particularly impressed with the machine’s quality components, such as the Siemens controller. Importantly, this purchase allowed many of those previously outsourced jobs to come back in-house

The company is also reassured that Applied is always on hand to assist. “Occasionally, when we require additional assistance and technical guidance with the fibre laser, Applied has been available to help us right away; we are grateful for that support,” he adds. “Laser cutting has become a big part of our business in recent times so the machine was a vital purchase. We are already booked out for the next 6 months because of the work we are now able to perform with the Yawei,” Kamal explains. Much like the pressbrake, the success of the fibre laser has also meant that a second machine is likely to come at some point in the future. Amal and Kamal would like to keep on growing and expanding the company’s customer base. “We are very happy with our growth over the past few years and in the short-term we will probably purchase another Yawei guillotine and turret punch press,” says Kamal. Their growth and success in such a short time has meant KNS Metals will probably have to upscale yet again: “We will probably move to larger premises because we realise our current factory is not as big as what we wanted!” they conclude. Applied Machinery 03 9706 8066 www.appliedmachinery. com.au

FEBRUARY / MARCH 2020

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MACHINERY

DRILL BIT MAKER HAMMERS HOME THE IMPORTANCE OF SUPPORT

is currently making. “But there’s more to come,” he says alluding to future product developments. The drill bits are manufactured from an alloy steel, perhaps surprisingly a material that originates from the aerospace sector. The barstock (and in some cases forgings) is pretty easy to mill in its raw state, but becomes considerably harder after heat treatment. While the Western Australian mining industry has become synonymous with boom and bust cycles of investment, one multinational company serving the sector is increasing its local manufacturing output to satisfy WA miners' continuing demands for drill bits. With its headquarters in Shannon, Ireland, Mincon Group manufactures on a truly global scale. This includes operations in South Africa, the USA, Canada and Australia. The company’s growth over the past five years has been spectacular, with multiple acquisitions worldwide. However, it maintains a philosophy of keeping full control over every crucial step of the manufacturing process, for each product in its range. This approach allows it to meet local demand and adapt to customer requirements. The Mincon Rockdrills manufacturing facility in the Perth suburb of Welshpool is part of the global Mincon organisation that spans five continents, producing almost everything for drilling rock "from the drill rig downwards". The Perth facility has specialised in hammer drill bits for the exploration market for some years, and is still the company's centre of excellence in that market. More recently, though, it has expanded into the production of the physically larger production drill bits demanded by iron ore miners who are in full production. And in doing so, it has begun to manufacture products in Australia that have previously been imported from Mincon Rockdrills USA.

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This expansion has coincided with a change to the makeup of the machine shop at Welshpool. A reduction in the level of support provided by the company's previous preferred machine supplier led the Mincon team to investigate alternative suppliers. And with other manufacturing operations within the group favouring the Doosan brand of CNC machine tools, the decision was made to investigate the Korean machine maker’s range, available throughout Australia from Hare & Forbes Machineryhouse. Mincon Australia Group Technical Manager Carl Blundell explains: “You can’t manufacture on this scale without proper back-up. “Our Shannon headquarters machine shop gets great service from the local Doosan agent, and so do our colleagues at Mincon Rockdrills USA.

“Hare & Forbes supports our machines locally from its Perth office, so we don’t have to wait for support if something does go wrong. And that keeps our downtime to a minimum.”

However, Carl Blundell confirms that the Doosan mills have more than enough power to deal with the semi-finished heattreated drill bits.

The first arrival was a Doosan DNM6700 vertical machining centre with a rotary table. This was followed swiftly by a large horizontal machining centre. The Doosan NHM8000 has twin rotary tables on each pallet.

One feature of all the Doosan machines at all the Mincon facilities worldwide is the use of the same Fanuc CNC controller, which provides a uniform programming and control environment that makes it easy for operators to master multiple machines.

The latest additions to the machine shop have been: a Doosan Puma 5100LYC horizontal turning centre with extra-large 275mm spindle bore, a pneumatic chuck and a 1000psi coolant system; and Doosan Puma 3100XLY CNC lathe with programmable steady rest and a similar 1000psi coolant system. Blundell admits that the extra-large bore on the Puma 5100LYC is something of an “overkill” for the bits that Mincon

So does the company share programs between manufacturing operations? Unfortunately, the answer is no, even when a design like a production drill bit moves from the USA to Australia. “That would be an ideal situation,” says Carl Blundell ruefully, “but the products are not identical – the Americans are Imperial, but we of course are metric!” Overall, the four Doosan machines have proved their worth at Mincon Australia. Carl Blundell describes them a “value for money and proven to do the job.” But it is the support from Hare & Forbes that is the deal-clincher, and the true reason why, as Blundell says, “any future machine purchases are likely to come from the same source.” Mincon Rockdrills www.mincon.com Hare & Forbes Machineryhouse www.machineryhouse.com.au

FEBRUARY / MARCH 2020

MACHINERY

EXPERIENCE COUNTS IN SURFACE PREPARATION AND FINISHING A family-owned Australian manufacturer is thriving in outer Eastern Melbourne and doing so by embracing many of the concepts of advanced manufacturing within a traditional market. W Granowski has been a pioneer in surface preparation and finishing technologies, and supplies abrasive blast cleaning and peening equipment, degreasing equipment and associated parts and consumables for a wide range of industrial applications. For a company that is just about to celebrate its 92nd birthday, it certainly has a wealth of experience to fall back on. However, there is one part of the company’s reputation that is occasionally overlooked. “People tend to forget that we are actually equipment designers and builders,” says Managing Director Caitlin Granowski. “Which is odd considering we’ve been designing and manufacturing our equipment here in Melbourne for more than 90 years.” As a company, Granowski prides itself on creating robust innovative engineering solutions and today accomplishes this with the use of advanced engineering techniques such as digital manufacturing, robotics, optimisation analysis and design for manufacture.

“It’s always an exciting time when a customer presents us with a challenging application,” says Caitlin Granowski. “It might be that they want to turn a 6m-high blast machine into a containerised ‘appliance’. Or they want to precision-blast an exotic material such as carbon fibre. We’re currently working on a delicate deburring application for lightweight satellite parts. As an engineering company, we thrive on these design challenges.” The company works with its customers so that its equipment can be delivered interface-ready so to be easily integrated into the user’s production flow – whether the interfaces are for control, data acquisition, work handling or robotics. Ultimately, though, it is experience that Caitlin Granowski considers to be the company’s greatest strength. “Over decades, we’ve designed and manufactured thousands of machines, across virtually every industry segment, for both the domestic and overseas markets,” she says, adding “and with 95% of our customers providing repeat business we pride ourselves on the quality of our equipment and the level of customer satisfaction and service.” It helps that the company is technology agnostic, producing both wet and dry air blast cabinets, air and airless

MAGNETIC TOOLS BRING PLATES TOGETHER FOR WELDING When butt-joining steel plate, getting the surfaces properly aligned for welding can be a problem. The traditional method involves temporarily welding a fulcrum arch to one of the plates and inserting a bar to lever the plate to a level position. After welding, the arch has to be broken or ground off and the surface refinished. Mag-Mate Mag-Pry sheet aligning tools reduce this time-consuming procedure to a matter of seconds by holding the plates in perfect alignment at the flick of a switch (as shown in this video). (https://www.youtube.com/ watch?v=tGXpUrK90Rc) Available in two different sizes, each Mag-Pry device combines a strong pry bar with a powerful on/off permanent magnet clamp and its own fulcrum point to enable effortless and time-saving alignment of butt-joined steel.

FEBRUARY / MARCH 2020

This airblast equipment for blasting the surface of carbon fibre wheels incorporates a robotic arm

(wheel) blast equipment and degreasing machines. This means that it can approach a customer’s surface preparation application without preconceptions and produce the most suitable integrated solution for each requirement.

solve a specific problem, and encompass the full spectrum of surface preparations from fettling, deburring and descaling to polishing, etching, peening and degreasing.

These solutions evolve from the WG range of custom-built blast and degreasing systems, all of which are manufactured to

W Granowski 03 9729 4333 www.granowski.com.au

Your Stamping & Washer Specialists REQUEST YOUR FREE STAMPINGS & WASHERS CATALOGUE & CALENDAR!

3D-Printed Prototypes Available These alignment tools, available in Australia from Serpent & Dove, are suitable for all plate and seam work, including under foot, on vertical surfaces and even overhead.

bokers.com +16127299365 sales@bokers.com

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

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WATERJET CUTTING The JEKRAN XM series Waterjet is rich with technology but at the same time extremely user friendly, The X-MW series machines are equipped with many standard features such as built-in material databases, variable soft piercing function for brittle materials, auto garnet delivery system and laser light sheet positioning assistance to name a few. The powerhouse of the X-MW machine is the German built direct drive pump which outputs 3,800bar / 55,000psi at 100% duty cycle whilst maintaining unrivalled energy savings. These machines are manufactured in Europe and are unbelievably good value.

The heart of the system is the highly advanced German built variable speed direct drive pump, creating up to 3800bar / 55000psi pressure at 100% duty cycle using the standard 0.35mm orifice. The pump boasts a unique filtering system making it suitable for tap water quality saving you money on additional reverse osmosis equipment and maintenance costs.

Bulk Garnet Delivery System

Equipped with a PLC controlled automatic bulk garnet feeding system the machine utilises unique technology which allows you to fill the bulk hopper without stopping the cutting process, combined with a garnet low-level sensor maximum production efficiency is achieved. The hopper capacity is 80L / 180kg.

Available from

www.machineryhouse.com.au Specifications & Prices are subject to change without notification. All prices exclude GST and valid until 16-03-20

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The CNCThe controller CNC controller is a 15â&#x20AC;? Industrial is a 15â&#x20AC;? Industrial Touch panel Touch which panelhas which been has been ergonomically ergonomically designed designed for usersfor inusers both standing in both standing and sitting andpositions. sitting positions. Using large Using icon large based iconintuitive based intuitive CNC software, CNC software, most operators most operators can be can be well conversant well conversant in using in the using machine the machine with a single with aday single of training. day of training. The CNCThe andCNC accompanying and accompanying offline software offline software accept DXF, accept SVG, DXF, HPGL, SVG, HPGL, Vector files Vector as well filesas asG-Code well as G-Code files. Auto files. nesting Auto nesting of parts of can parts be achieved can be achieved or material for material sheet utilisation. sheet utilisation.

EnergyEnergy Efficiency Efficiency

The variable The variable speed directly speed directly driven pumps driven on pumps the X-MW on theseries X-MW series distinguish distinguish themselves themselves in comparison in comparison to intensifier to intensifier pumps with pumps a with a much higher muchdegree higher of degree powerofefficiency power efficiency of up toof 30% up more to 30% efficient more efficient than intensifier than intensifier pumps. pumps.

Material Material Database Database

The material The material database database makes the makes machine the machine suitablesuitable for any user. for any user. Cutting parameters Cutting parameters are all stored are allinstored the CNC in the andCNC loaded and accordingly. loaded accordingly. This means Thisthat means correct that parameters correct parameters and cutting and configuration cutting configuration is alwaysis always set and set an optimum and an optimum cut is guaranteed. cut is guaranteed.

Frame Frame / Chassis / Chassis

The chassis The is chassis fully welded is fully to welded to improveimprove strengthstrength and rigidity, and rigidity, making making the whole thecomposition whole composition robust. This robust. is especially This is especially important important after prolonged after prolonged cutting times cutting when times heat when canheat can distort the distort construction. the construction.

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MACHINERY

MORE OF THE SAME AS FABRICATOR EXPANDS MANUFACTURING OPERATIONS

that Stan Vasilopoulos sees his company’s future moving towards the mass production side of the business, producing higher volume runs to support other fabricators in the region. And with the addition of his engineering graduate son to the team, the company will have even more resources at its hands to take on ever more ambitious fabrication and manufacturing projects.

A Melbourne company founded almost 30 years ago by a fitter and turner working at Mistral Fans is developing an impressive reputation for its fabrication and manufacturing work. Any Steel Fabrication specialises in custom work in both mild and stainless steel, delivering everything from one-off specials to larger-scale manufacturing jobs. Today, Any Steel Fabrication operates with a team of between 14 and 17 skilled operatives, boasting well over 50 years of experience between them. Stan Vasilopoulos first struck out on his own in 1988, leaving Mistral Fans and purchasing a small lathe and a mill-drill from Hare & Forbes. He set up the machines in his father’s garage and set about manufacturing pulleys for gymnasium equipment.

4-metre 160-tonne CNC press brake that is still in use today. And like all members of the Baykal press brake range, that machine is based on a rigid monoblock steel frame, which guarantees minimal deflection under load for repeatable accurate bending. Today, the workshop at Any Steel Fabrication in Campbellfield features an array of Baykal CNC presses with capacities up to 300 tonnes (including that original unit with an upgraded CNC unit). There is also a Baykal guillotine, and – in pride of place – a Baykal BPS1503 X 170XPR CNC plasma machine. That plasma machine combines a highly rigid table typical of the Baykal product line with the industry standard Hypertherm plasma unit. And it has allowed Any Steel to take control back over more of its production by removing

the need to send cutting work out to subcontractors. “When you buy any machine, you have to know that you have the backup to rely on, and buying Baykal equipment from Hare & Forbes I’m confident that I’ll get the support I need,” he says. “All the Baykal machines have been very reliable. There’s been the odd minor issue, but these have all been sorted out very quickly. That’s why I’m comfortable in continuing to source Baykal machines from Hare & Forbes.” The next arrival is likely to be a fourth Baykal CNC press brake, the largest of all, with a 6-metre bed and 400 tonne capacity. With such a large investment in machinery, it is probably no surprise

Going forward, the biggest problem for Any Steel Fabrication appears to be lack of space. With the company’s ambitious expansion programme and the acquisition of still more Baykal machine tools, the premises in Campbellfield are starting to fill with equipment after only two years in occupation. But that is just the sort of problem that most other companies would love to have. For Stan Vasilopoulos, it’s evidence of success. Any Steel Fabrication anysteel.com.au Hare & Forbes Machineryhouse www.machineryhouse.com.au

Vasilopoulos is keen to make the point that he paid cash for those first two machines from Hare & Forbes; and also that the mill-drill is still in use to this day. After seven years working out his father’s back yard, Vasilopoulos moved his operations into a small unit in Thomastown, which he still owns, and Any Steel Fabrication was born. While Vasilopoulos has continued to source his machinery from Hare & Forbes, there has been another common factor over more recent years: a reliance on the Turkish made Baykal brand of machine tools. The first Baykal machine was purchased from Hare & Forbes in 2007, a

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FEBRUARY / MARCH 2020

MATERIALS HANDLING WALL STORAGE SYSTEM AVAILABLE ONLINE BAC Systems has added a new e-commerce section to its website to allow speedy access to its highly acclaimed BAC Wall Rack wall-mounted toolboard system. Billed as the ideal way to organise a workshop, the basic BAC Wall Rack system comes with hooks and brackets for hanging tools, but it also accommodates a wide range of accessories, including plug-in toolbars for socket sets, drill bits and the like. All the addons are securely mounted on the BAC Wall Rack using the system’s novel combination of square holes and round holes. There are five basic types of steel panels, all locally made from Australian steel, and all plastic mouldings are made from ABS recyclable plastics. BAC Systems has put together a

number of cost-effective BAC Wall Rack starter kits to help users get their workshops organised. These kits combine the basic panels and supports with a selection of toolholders – in fact everything needed to organise a workshop. Individual panels, partitions and accessories are also available to enable custom installations that provide highdensity bespoke storage on any wall. Full installation instructions are provided on the BAC Systems website. “Whether it’s for your workplace or your garage, this product - though small and simple - can transform your tool storage,” says Bob Griffin of BAC Systems. “We wanted to make it easy for the customer to purchase this product,

because we think it’s a real winner – hence, the e-commerce system was made available.”

Australia-wide (subject to a minimum order of $30).

The BAC Wall Rack kits and components are available now from the BAC Systems website, with free delivery

BAC Systems 02 9832 2777 www.bacsystems.com.au

Solve your space problem with an Altrac gantry crane N EED MO RE LI F T ? I NV E RT E D G A N T RY LO W CEI LI NG S ? LO W HE A DR O OM GAN TR Y CORN ERS ? CU R V E D GA NT R Y

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.

FEBRUARY / MARCH 2020

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

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MATERIALS HANDLING

COGGED V-BELT IN DRIVE FOR MACHINERY DUTIES Available now from Optibelt Australia, the Super XE-Power Pro is a revolutionary range of EPDM cogged V-belts for use in a wide range of machinery from compressors and pumps to lathes and CNC machine tools. The design of the belt features a novel moulded cogged profile that greatly improves durability, flexibility and power transmission over previous generations of belts. And the high-modulus polyester cords used in the construction of the belt resist stretching, making the V-belt fully maintenance free. This reduces downtime, improves drive efficiency, and increases belt power capacity by up to 20% over other high-performance cogged V-belts. The new tooth shape allows the Super XE-Power Pro to be used on pulleys with extremely small diameters, making it suitable use in smaller machines. And, unlike

competing products, the belt is also suitable for back bend idlers, which enables its use in ultra-compact drive units. The combination of the lowstretch cords used in conjunction with a tooth form optimised for dynamic loads gives the Super XE-Power Pro extremely high power handling capabilities. And the inclusion of an innovative red cushion compound gives a perfect adhesion for tension cords and high load capacity. The EPDM transverse-fibre-laden compound gives the belt a wide operational temperature range from -40 to +120Â°C, and it runs extremely quietly and smoothly - even at high speeds. Optibelt Australia 03 8791 2700 www.optibelt.com

A fully integrated system or a basic component â&#x20AC;&#x201C; YOU choose from a single supplier.

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Adept has been supplying the materials handling industry with innovative and Bespoke designs for many years. Warehouse order fulfilment systems. Freight and courier parcel handling systems. E-commerce - Scope and range to satisfy and support most e-commerce companies. Faster Deliveries - Not subject to long lead times. Faster deliveries than all industry peers. Systems can be up and running before others get theirs off the boat. Flexibility - We provide solutions from a basic component to full system analysis, design and implementation. Long Term Support - Will always have availability of spares no matter how old the design may be.

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FEBRUARY / MARCH 2020

MATERIALS HANDLING

GETTING TO GRIPS WITH BULK BAGS

GET HEAVY LOADS MOVING EFFORTLESSLY WITH THE

TENTE E-DRIVE FLEX

STARTING ASSISTANCE SYSTEM

As more companies look to reduce their packaging and transportation costs, bulk bags are becoming widely used as a cost effective, efficient and eco-friendly solution for storing, transporting and discharging bulk materials. When fully loaded, the size and weight of these bulk bags create a problem for safe and productive handling in the workplace. The issue is finding cost effective equipment that is safe and practical for basic handling applications. East West Engineering has now extended its range of bulk bag handling equipment to include a range of bulk bag stands, each suiting a variety of applications. The extensive range allows greater use of bulk bags in the workplace for general-purpose waste collection, as well as storing, filling and dispensing of bulk materials. SKB bulk bag stands safely hook open bulk bags for filling, saving time and costs. There are three basic models. The SKB50 is a lightweight unit for easy relocation. The SKB100 is perfect for general site and excavation waste on building sites. And the

FEBRUARY / MARCH 2020

Extended Position

SKB150 is ideal for manufacturing sites that require complete manoeuvrability, with its sheet-metal base, fork pockets, crane lugs and optional wheels.

Retracted Position

Demonstration Unit Available Contact Tente Castors & Wheels for further information 1300 836 831 - E-Drive Flex system can be retrofitted to most trolleys - Increase manpower efficiency by saving effort

The multipurpose SKX100 bulk bag frame has been designed to not only hold a bulk bag open, but when combined with the SKH100 bulk bag hopper with slide gate, it can be used as a bulk bag filling or dispensing station. Additionally, this model can be stacked two high when full or three high empty, saving valuable warehouse space.

- Used a a 5th wheel to improve direction stability

East West Engineering 1800 061 998 www.eastwesteng.com.au

Contact Tente Castors & Wheels To Find Your Product Solution

- Retractable wheel system ensures easy manouverability - Reduces potential injuries for staff â&#x20AC;&#x201C; neck, back, shoulder and wrist pain - Infinite speed control (forward and reverse) - Egonomic handle design with system and battery charge LED indicators

Phone: 1300 836 831

sales.au@tente.com

tente.com.au

INDUSTRYUPDATE.COM.AU

MATERIALS HANDLING

SILENCE IS GOLDEN IN PALLET HANDLING The humble pallet truck is one of the great workhorses of the materials handling sector, and its design has remained unchanged for decades. It is, however, a little “clunky”. With its solid plastic or metal wheels and rigid construction, the basic pallet truck is both noisy and prone to shock and vibration. And while the noise is undesirable in many applications, such as retail spaces, the shock and vibration can be hazardous to users in any application. Enter the Panther Silent, a new breed of pallet trucks designed and manufactured in Denmark by Logitrans, and available in Australia exclusively

to extremely tight tolerances and assembled with nylon caps on all the joints to avoid metal-on-metal contact. This removes that “clunky” noise associated with the old-style pallet truck.

from Maverick Equipment. The Panther Silent is almost exactly what it claims to be – producing no more than 60dBa in use on any surface. And it produces this low noise level due to two key design innovations.

The overall design is particularly easy to manoeuvre, with a 210-degree turning angle made easy by the larger than normal 200mm low-friction steering wheels that also reduce the

First, it has special soft rubber wheels (both for steering and on the forks). These not only deal with any uneven surface without raising the noise level, they are particularly low in friction, which makes the Panther Silent particularly easy to manoeuvre. Secondly, all the metal components of the pallet truck are manufactured

operator effort required to move the load. And the lifting operation is particularly easy on the operator, with fewer pumps of the handle required to raise the load. “The Panther Silent really is a remarkable machine,” says Rohan Plaw of Maverick Equipment, “and we’ve already had enquiries from a number of blue chip Aussie retailers who are keen to keep noise to an acceptable level for

their customers.” “But so quiet and smooth is the Panther Silent that it would be an improvement for many logistics operations – particularly those that operate near residential areas,” he adds. MAVERick Equipment 1800 500 411 www.maverickequipment. com.au

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FEBRUARY / MARCH 2020

MATERIALS HANDLING

TRUCK AND TROLLEY COME TOGETHER Available exclusively in Australia and New Zealand from Tente Castors & Wheels, the Convert-A-Trolley is a novel rethink on some of the most basic materials handling operations, combining the functions of a hand truck and a platform trolley. Whatâ&#x20AC;&#x2122;s more, the lightweight unit can be converted between the two roles even while loaded. The European-made ConvertA-Trolley was originally conceived to overcome unsafe manual handling practices at a well-known global beverages brand. The result is a patented ergonomic design that is easy to manoeuvre in a busy warehouse or in tight spaces and on variable floor surfaces both indoors and out. It converts from a hand truck to a platform trolley with a single latch and lever mechanism. And the whole structure folds flat for space-saving

storage and transport. As a result, the Convert-A-Trolley is equally at home in the warehouse and operating from the back of a delivery vehicle. Ruggedly made from powdercoated steel or stainless steel, the Australian version of the trolley is made using high-quality Tente castors and pneumatic wheels. Weighing in at just 22kg itself, the Convert-A-Trolley is rated for loads up to 150kg as a hand truck and 350kg as a trolley. The V2 model is made fully from 304-grade stainless steel (including the wheels and castors), and so is fully specified for use in heavy washdown areas in food and beverage and pharmaceutical facilities. The Convert-A-Trolley is available now from Tente Castors & Wheels in both powder-coated and stainless steel.

Customised versions can be created to special order. Tente Castors & Wheels 1300 836 831 www.tente.com.au

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FEBRUARY / MARCH 2020

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MATERIALS HANDLING

CONTAINER LOADING SYSTEM FILLS TO WITHIN 0.1% OF TARGET WEIGHT way. That clarity and understanding the special arrangement made the project much simpler to put forward, justify and ultimately deliver.” The entire pre-feeder and pivoted weigh screw conveyor installation is contained on an existing mezzanine situated above the truck loading position. This location has the additional benefit of providing workers with easy access to carry out routine maintenance. The CAD modelling and attention paid by Active Weighing Solutions engineers to careful measurement also aided easy installation of the upgrade to the container loading system.

Engineered for accuracy

In the haulage business, having your trucks sent back from the weighbridge because of over-weight or under-weight containers is a costly exercise. A new loading system installed at Malteurop Australia now fills 25-tonne containers to within 20kg of the target weight. This equates to less than ±0.1% variation from the target payload, and is significantly better than the requested performance. Malteurop Australia needed to resolve a weighing issue when filling 40ft containers with malt. When fully loaded and check weighed at the weighbridge, a 40ft container could be found to be overweight. At this point in the supply chain, rectifying an overweight container means there will be obvious double handling and additional production costs. Overweight trucks were being returned from the weighbridge so that excess product could be removed. This process could mean vacuuming the product out or piercing the plastic liner. The outcome of this also adds the risk of poor container presentation to the customer. Double handling and increased production costs are also an issue where underfilled containers occur. Underfilling means trucks return to the filling station to receive additional product to meet the specification for the load.

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Malteurop Australia approached Active Weighing Solutions for a weighing solution that would enable containers to be loaded within ±0.5% of the total batch. The specification also required the loading system to run at 90t/h (taking about 15-16min to load a nominal 25t batch).

Custom design and 3D modelling Active Weighing Solutions proposed a pivoted weigh screw conveyor (PWS-C) as a solution to improve outloading weighing accuracy. Pivoted weigh screw feeders and conveyors fully enclose the product stream and are particularly useful where weighing accuracy is important, the product flow is consistent, and the material is dusty or hazardous.

Applying a constant weight model design approach to a pivoted weigh screw application ensures the highest possible accuracy. This is achieved through matching screw diameter, pitch, fill capacity and speed, and considering these parameters along with flow rate and material bulk density. This weighing solution is also suited to restricted space situations. (And in this case there was very limited room available in the plant to retrofit more equipment into the loading system.) Active Weighing Solution’s engineers visited the site and measured up the existing plant. They created a CAD 3D model of the proposed solution. The model showed the existing plant constraints and the location of a custom designed screw pre-feeder and a pivoted weigh screw conveyor. This visual representation helped plant management to truly understand how the finished weighing equipment would fit into the available space. The operations manager said that “being able to view a 3D model of the finished product assisted in presenting the concept in a graphic and transparent

The accuracy that can be achieved in each situation depends a great deal on accommodating these design criteria and parameters, and the real-world applications. Pivoted weigh screws perform at their optimum when operating at a constant weight, delivering the same accuracy across the whole operating range. The configuration required for Malteurop Australia called for a pivoted weigh screw with pre-feeder. The prefeeder controls the rate of feed into the pivoted weigh screw and allows the screw to run at a constant weight, and therefore with the highest possible accuracy.

Better than expectation According to Active Weighing Solutions Director Nigel Saul: “The pivoted weigh screw is a great alternative for dusty and toxic products or applications where there is very little height available. We can reliably get within less than ±0.5% if material testing can be performed or ±2% using static weights.” Active Weighing Solutions 03 9873 7677 www.activeweighing.com.au

FEBRUARY / MARCH 2020

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ROBOTICS AND AUTOMATION SMARTER CLEANING WITH ROBOTICS Robotic cleaning machines offer many practical advantages from increasing productivity, to improving the consistency of cleaning, with lower maintenance costs from minimal human operator error. Tennant ANZ is ready to lead the way locally with its T7AMR solution that has already sold more than 1000 units in North America and Japan. Robots have a major role to play a role in making work environments safer by reducing accidents and mistakes due to human error. Overnight cleaning crews, for example, can get tired and make errors of judgment or lose focus. This can lead to accidents and damaged equipment, structures, or products. Some of these mistakes can be costly. Robotic cleaning machines, on the other hand, are programmed to be reliable and consistent. Many have built-in safety features that protect against accidents, whether they’re used independently of, or collaboratively with, human workers. Today’s robotic cleaning machines also offer the latest in sustainable cleaning solutions, technologies, and equipment. Tennant’s machines, for example, minimise environmental impact in seven key categories including energy, CO2 emissions, ozone, smog, acid, eutrophication, and particulates. These machines require less water and fewer chemicals - saving money on supplies while reducing downtime, thereby making cleaning crews more productive.

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What about the workers?

routes as the environment changes. In Australia, the T7AMR will be available from the first quarter of 2020, with local support to be provided by Tennant Australia and New Zealand. “We’re winning with [the T7AMR] globally in retail and building service cleaners,” explains Tennant Australia and New Zealand General Manager, Chad Angeli.

Robotic cleaners also offer benefits that can help retain and attract employees. First, robotics can aid employee retention by improving job satisfaction, performance, and overall work quality. The high-tech equipment training involved enhances workers’ skills, which can make them feel more valued and help them become more desirable employees (while expanding their career opportunities). Robotic cleaning machines can also help companies repurpose existing workers. With less time spent doing repetitive tasks, employees have more time to focus on other cleaning tasks that require a human to perform. For companies having trouble filling positions, robotic cleaning machines can help by enabling current employees to accomplish more in less time, allowing fewer workers to accomplish the work of a larger crew. And when it comes to attracting prospective employees, robotics brings a leadingedge perception that’s attractive to those interested in working for a forward-thinking company.

All about the data Data tracking is increasingly important and widespread across business, technology, and life in general – from sales data, to financial data, to GPS data, to health data, and much more. Choosing robotic cleaning machines with data reporting technology gives fleet

managers greater insight into cleaning performance, enabling them to optimise their cleaning performance and track key performance indicators with dashboard reporting and alerts. This can help companies increase efficiency, reduce expenses, maximise operation time, ensure health and safety, make fewer errors, and identify areas for improvement. Last year US-based retail giant Walmart became the first major retailer to introduce Tennant’s robotic solution, the T7AMR, equipped with Brain Corp’s self-driving operating system, BrainOS, to deliver operational efficiency, cleaning performance and customer value. Following the success of the initial partnership, which saw 360 robotic floor cleaners, powered by BrainOS, deployed in Walmart stores, the fleet has increased by an additional 1500 machines. The robots operate collaboratively alongside Walmart associates by using a “teach and repeat” approach that allows associates to easily deploy the machine and adjust cleaning

“The advantage for ANZ is that we have our direct service organisation and customer care centre team for support. We can set it up as Tennant, service as Tennant, connect with BrainCorp and channel back to customers with anything they may need. “We believe having a strong, local direct service and customer care team will give customers a better experience with robotics. They can always deal with us from the initial set up and teaching their machine routes, to after-market support conducted by Tennant, and also representatives to help with getting them the data usage reports. “Robotics is not for all customers, so we need to make sure we continue to invest in a variety of value propositions. However, we know we will have robotics across more machine platforms in the future with an even more advanced technology. “Robotics will continue to be a very important part of our strategy in ANZ and the value proposition we want to deliver for our customers.” Tennant Australia 1800 226 843 au.tennantco.com

FEBRUARY / MARCH 2020

BE THE CONTROLLER OF YOUR AGV SYSTEMS Now you can, with the newly arrived state-of-the-art MAX AGV & warehouse management system. All system configuration tasks are done visually with the windows-based MAX Editor, enabling you to configure all aspects, from the location & operation of a pick up or storage position. MAX Editor is really easy to use & learn for operators. Ask us for a demonstration. Key benefits are: > Runs on a modern client server WindowsÂŽ environment, utilising MicrosoftÂŽ products > Ability to edit your own AGV track & functions > Easy to create future expansions & edit modifications.

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ROBOTICS AND AUTOMATION

LEASING PROGRAMME CUTS THE COST OF STARTING WITH COBOTS Universal Robots has teamed up with global vendor finance company DLL to launch a cobot leasing programme that will enable any manufacturer to reap the benefits of automation without worrying about cashflow or seasonal fluctuations. The global programme is expected to appeal to the market in Australia and New Zealand, allowing manufacturers to start automating with cobots immediately. According to Darrell Adams, Head of SEAO at Universal Robots: “Locally, systems are in place and this service is available to Australian and New Zealand manufacturers. “The equipment starts generating income before you have made your first payment. It helps the business acquire the cobot it needs now without significant down payment. Leasing also ensures you are never stuck with outdated equipment and there are further tax advantages too. “With automation and Industry 4.0 becoming more and more of a hot conversation topic in the local market, the move could not have come at a better time. Accelerated automation is required, and the UR Leasing Programme will go a long way towards making this a reality for

many small to medium enterprises,” says Adams. DLL is offering UR’s customers tailor-made financing and leasing programmes designed to meet the needs of the modern manufacturing business, while enabling growth. As business needs change, customers will have the option to schedule payments to fit fluctuations in cash flow, upgrade to new equipment, or add cobots anytime during the contract term. At the end of the finance term, customers will have the option to buy the equipment for a fraction of the original cost, upgrade to newer technology, extend the finance term or simply return the equipment. “We are delighted to establish a global partnership with Universal Robots,” said Neal Garnett, President of Construction, Transportation & Industrial (CT&I) Global Business Unit at DLL. “The market we operate in is evolving rapidly. Through this partnership we can now offer financial solutions for a wide variety of automation equipment. “Cobots are transforming the industry and UR is clearly the market leader. Our tailored financial solutions give

Darrell Adams, Head of SEAO at Universal Robots

UR’s end users an easy way to reduce the risk of deploying cobots by shifting from ownership to flexible, usage-based financing. Manufacturers can build the operations they need to compete and thrive, while people work on strategic tasks.” The UR distributor network is working directly with DLL’s dedicated finance experts in each country to provide new payment and leasing options for interested customers.

In the ANZ region, customers can contact UR directly or go via their local UR distributor for more information. “Universal Robots is looking forward to removing the last barrier to automation!” concludes Adams. Universal Robots +65 6635 7270 www.universal-robots.com

MOBILE ROBOT FAMILY GAINS BIG DADDY tested-and-proven technology used in the industry-leading LD-90, with a higher payload capacity and tougher metal skins. Working seamlessly into an integrated Omron mobile fleet, the LD-250 can allow customers to optimise their traffic management, battery management, and routing of vehicles with a more diverse fleet. Unlike AGVs, Omron AMRs can safely navigate without the use of floor magnets or wall-mounted beacons.

The latest addition to Omron’s LD autonomous mobile robot (AMR) range is the strongest yet. The LD-250 has a payload capacity of 250kg, a maximum

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speed of 1.2m/s and can run for 13 hours before it needs recharging. The LD-250 is based on the same

An AMR will first create a baseline map of a facility using built-in sensors, then will constantly detect its surroundings. When processes change, AMRs can easily change as well, creating networks of new routes or being reassigned to new tasks. AGVs require a predefined path to follow, either a network of magnetic lines on the floor or beacons on the walls.

So although AGVs allow modifications to production lines, facilities will need to install new equipment every time the AGV path is changed, leading to downtime and extra costs. And AGVs will stop at obstacles indefinitely, AMRs avoid stationary or moving obstacles and automatically reroute themselves when necessary. AMR paths automatically change without human intervention, making operations more flexible and decreasing total cost of ownership. Safety is a key focus with the LD-250. The robot complies with ISO EN1525, JIS D6802 and ANSI B56.5 safety standards and works safely around people. Omron Industrial Automation 1300 766 766 www.omron.com.au

FEBRUARY / MARCH 2020

ROBOTICS AND AUTOMATION

SELF-ADHESIVE GRIPPER IS AT HOME ON COMPACT ROBOTS OnRobot has launched a compact, single-pad version of its Gecko nomark adhesive gripper designed for applications with small footprints and lower payloads. The Gecko SP is available for payloads of 1, 3 and 5kg. The award-winning Gecko gripper design uses millions of micro-scaled fibrillar stalks that adhere to a surface using van der Waals forces – as used by the lizard of the same name. The grippers need no compressed air or external power, and can be implemented quickly and easily on any major collaborative or light industrial robot arm. Because the technology doesn’t mark even high-shine surfaces, it eliminates the need for a cleaning step in manufacturing processes, saving time and improving output. And it can grip even perforated workpieces such as printed circuit boards or aluminium mesh.

According to Enrico Krog Iversen, CEO of OnRobot: “Our unique Gecko technology automates processes that no other gripper can accomplish, and now it’s available in a compact, flexible format that offers our customers even more options. “This is a true plug-and-play gripper that fulfils our promise of a full range of easy, cost-effective, flexible robotic tooling that lets customers focus on their application rather than the robot.” OnRobot is supported in Australia through six distributor partners: Mobile Electrics, Scott Automation and Robotics, Collaborative Robots Australia, Auto Controls Systems, Australis Engineering, and Diverseco. OnRobot onrobot.com

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FEBRUARY / MARCH 2020

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ROBOTICS AND AUTOMATION because the decision-making process is now overseas and no longer in Australian hands. This is another reason why automation projects simply don’t happen or die through lack of continuity.

COLIN WELLS

THE CONTINUITY FACTOR Australia really needs to lift a gear in the field of industrial automation to avoid falling further behind. But it’s just not happening. Why?

On average it takes about 6 to 9 months for an ASI to get to the point of having a solid proposal to fit a solution. Then it can be anything up to a year to fully implement the system. Senior management will complain that this is way too long. And they are right.

If you look at the differences between the Australian industrial automation market and that of say Europe, it is what I call the “continuity factor” that really stands out.

But these long timescales are generally caused by a lack of engagement from the client, leaving the ASI with a shortage of key information. This will be made worse by continuing staff changes, and worse still by the need for overseas approval.

This is glaringly obvious if you attend the same international exhibitions over the years and you find you are still talking to the same people from most of the automation suppliers - particularly if they are from Northern Europe.

As an example, if a manufacturer anywhere in the world has a high turnover of its key engineering staff then the probability of that manufacturer being able to conceive, procure and implement an appropriate automation project is severely hampered, and probably will not happen - thus falling further behind. Over the years it’s not uncommon for an automation systems integrator (ASI) in Australia to be asked to look at solving the same automation problem for the third time, with the manufacturing staff completely unaware that the problem has been “doing the rounds” for some years but with no result. The effect on this manufacturer is disastrous as it will continue to fall behind in productivity - possibly to the point of no return as the cost to upgrade may have now gone past the tipping point and has become an unviable option. This “continuity factor” not only plagues the manufacturers it’s also a problem for the ASI as it appears that millennials (in particular) simply don’t want to stay anywhere long enough

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So what’s the answer? There’s no single answer. However, procrastination from CFOs and senior management in manufacturing companies can lead to key staff moving on as there’s not enough actually happening, as already mentioned some don’t need much to move on .

Personally, I think there are a number of factors, such as the lack of continuity of staff across the board from end users to suppliers. There is a lack of direction of manufacturers to adopt continuing improvement. And often the decision to go ahead is not made in Australia.

The “continuity factor” really helps in the continuance of development and knowledge in a vein of a particular technology.

I would also point out that the continuity factor is considerably less of a problem in rural or far-flung locations, where it is refreshing to engage with people that really know how their plant works and have done so for many years.

You can see how so many projects are never completed.

If you look at the differences between the Australian industrial automation market and that of say Europe, it is what I call the “continuity factor” that really stands out. to actually really get to grips with the role and the technology as depth of knowledge is not high on the agenda . This particularly exasperating as the technology depth in automation is continuously increasing to the extent that companies need more exposure to it in order to cope and fully absorb the issues. My extensive experience in interviewing many candidates and listening to the tales of woe they have brought on themselves in a series of jobs

that actually all started by them leaving a perfectly good job for a seemingly better one that did not turn out so well is significant. The only winners it appears are the recruitment consultants. As a result, in some manufacturers, the ASI is one of the few “continuity factors” they have and while this is not ideal, at least there is some continuance of knowledge. It’s also worth noting that many solid automation projects just don’t go ahead

I guess if a manufacturer believes it has a valid project then the company should do the due diligence in picking the ASI that’s right for the job. This doesn’t mean inviting eight different ASI’s to “have a go”. That leads to all sorts of differing specs that will create confusion for the manufacturer and ensure that project will go nowhere. Experienced ASIs will know this is a shambles from the start and will allocate resources accordingly or not bother at all. Australian manufacturing industry needs to wake up to what’s happening in the world and get cracking on doing what it can now. Start with the low-hanging fruit – the easy projects. There are generally plenty of these in many plants we visit. But do get on with it. If I sound concerned, it’s because I’m not sure how many years Australian manufacturing has left if it does not wake up and start actually doing it instead of talking about it.

Colin Wells is Managing Director of Robotic Automation.

FEBRUARY / MARCH 2020

AMX PREVIEW

EXPO FOCUSES ON SUPPORTING AUSTRALIAN MANUFACTURING’S EVOLUTION In May, Advanced Manufacturing Expo will be held for the first time to inspire future growth for the manufacturing industry and industrial sector. The expo’s conference and exhibition will showcase the latest advanced manufacturing production solutions and insights with dedicated solutions providers and over 40 expert speakers. According to the Advanced Manufacturing Growth Centre, Australian manufacturing contributes $100 billion to Australia’s GDP and supports 1.27 million jobs, with the potential to increase its value nationally by as much as $34.6 billion between now and 2026. Yet this growth is dependent on manufacturers adopting more sophisticated processes, taking advantage of cutting-edge technologies, implementing more robust business models and investing in highly skilled staff or high value services wherever possible. It is this challenge that lays the foundation for the inaugural Advanced Manufacturing Expo, which has been developed to inspire growth in the Australian manufacturing industry and more progressive manufacturing processes. Visitors to the expo will hear how they can increase their global competitiveness by adopting the state-of-the-art technology, revising their R&D or design processes and emphasising value creation. Within the expo’s conference programme, visitors will have the opportunity to hear from industry thought leaders on topics including: the future of manufacturing, implementation of IoT devices, the evolution of Industry 4.0, food manufacturing, AI integration into manufacturing processes, empowering automation, autonomous and collaborative robots, additive manufacturing, government grant insights, defence and space supply chains, and advanced manufacturing skills. The expo’s location at the Sydney Showground (Sydney Olympic Park) is a strategic decision to ensure the NSW industrial sector has direct access to these advanced manufacturing insights, which inspire future growth and evolution, whether in the conference program or through the innovative pre- and post- production solutions displayed in the exhibition. This location also ensures easy accessibility for manufacturers and industrial SMEs based in Western Sydney, factoring in the region’s focal point for investment and growth in NSW, and the Western Sydney

FEBRUARY / MARCH 2020

Aerotropolis that is under development and will be a hub for advanced manufacturing. Advanced Manufacturing Expo is being introduced following the NSW Government’s launch of the Advanced Manufacturing Industry Development Strategy in 2018 and replaces the Sydney edition of National Manufacturing Week, ensuring NSW manufacturers are provided with an educational business focused industry platform. “We are incredibly excited and proud to be able to provide Australian manufacturers with this growth focused forum. The opportunities available to manufacturers and suppliers, who adopt state-of-the-art technology like industrial IoT and integrate high-level engineering into their production processes, are incredible. We’re also thankful for the contributions of our industry partners, who will have a strong presence at the expo, including the Advanced Manufacturing Growth Centre, Innovative Manufacturing CRC (IMCRC), Engineers Australia, AMTIL and Weld Australia.” Jono Whyman, Exhibition Director of Advanced Manufacturing Expo, explained. On the exhibition floor, visitors will be able to navigate through the various range of industrial and manufacturing suppliers via six designated product zones.

Automation & Robotics The Automation & Robotic Zone will help visitors discover the latest cutting-edge technologies and find solutions to their automation challenges. This will complement the insights shared within the conference program about automation integration within manufacturing, the expansion of robots and how to address current challenges or maximise opportunities through robotics and automation.

Additive Manufacturing Additive manufacturing or 3D printing will be a key zone for visitors due to the transformative approach to industrial production, enabled by the creation of lighter, stronger parts and systems. Visitors can expect to see solutions relating to computer-aided-design software, 3D object scanners and direct hardware, with additive manufacturing simplifying the traditional manufacturing process and material removal requirements.

Engineering & Manufacturing Solutions The rapid emergence of Industry 4.0 (Internet of Things) within manufacturing, requires the input of high-level engineering and engineers to redesign processes and operations to accommodate the new technology that is typical of smart manufacturing facilities. This zone will be reflective of the importance of engineering in modern manufacturing, with exhibitors showcasing the latest manufacturing equipment and tools relevant to a broad cross-section of engineering disciplines, while complementing the conference program’s focus on highlighting design and process improvement approaches in manufacturing.

Industrial Internet of Things This zone will be focused on the next industrial revolution that has already begun –

the Industrial Internet of Things (IIoT). With IIoT driving unprecedented disruption in manufacturing as more and more machines are fitted with sensors, switches or intelligent controls to make factories smarter, improve operations, reduce costs and provide a safer working environment. Exhibitors in the Industrial Internet of Things Zone will display the latest IoT software and solutions, providing a unique business interaction opportunity for manufacturers focused on becoming market leaders.

Machine Tools The machine tool zone will be primarily focused on handling or machining metal and other rigid materials, whether by cutting, boring, grinding, shearing, or other forms of deformation.

Welding Technology With Weld Australia finding that the nation continues to face a significant shortage of qualified welders, despite a growing demand for welders for major projects in industries such as defence shipbuilding and aerospace, local welders must be as well trained and qualified against global best practice to deliver these multi-billion-dollar projects. The Welding Technology Zone will highlight advanced welding processes and provide high-quality interactive experiences that capture the imagination. These exhibitors will be complemented by live demonstrations through virtual and augmented reality welding simulators. And expert speakers will discuss the latest technological developments and applications in the welding sector in the conference programme. Registration for Advanced Manufacturing Expo 2020 is now open and is free to attend for all registered industry professionals at www. advancedmanufacturingexpo. com.au.

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Visy Packaging operates a state-of the-art drink-can manufacturing plant in Stapylton, Queensland. The plant employs more than 50 people and produces export-quality cans for local and overseas markets. The company was however having chronic reliability issues with its submersible wastewater pumps. Engineers had been trying to solve this issue for seven years when Paul Carter, Engineering Manager – Beverage and Food Can, spoke to one of his contractors. This contractor suggested he look at Gorman-Rupp self-priming wastewater pumps, which had been successfully installed at the Pacific Fair shopping centre on the Gold Coast. Carter instantly saw the benefit of this style of pumping equipment and the maintenance and reliability benefits that they offered. Being surface mounted meant they would be easier to access for monitoring and service. He says: “The submersibles couldn’t pump against back pressure and wouldn’t allow us to change the design, but the

Gorman Rupp units have allowed us to achieve that, and we now have no issues with our system.” The most suitable pump for the Visy application was the Gorman-Rupp T2A65-B. This is a 50mm self-priming trash pump, which is capable of selfpriming to depths of 7.5 metres, and can handle solid particles up to 38mm diameter and also stringy materials such as rags. If anything too big does get into the pump, there is a large inspection coverplate for operators to access the pump interior. The Gorman-Rupp T2 is able to deliver flows up to 10L/s, but larger pumps in the range are capable of flows up to 200L/s. Pumps also come in various materials of construction to cope with abrasive and/or corrosive wastewater. Hydro Innovations 02 9898 1800 www.hydroinnovations.com.au

FEBRUARY / MARCH 2020

ENVIRONMENT, ENERGY & WASTE MANAGEMENT

HOLISTIC APPROACH TO ENERGY MANAGEMENT AND EFFICIENCY PAYS OFF FOR MANUFACTURERS network provider, saving some $19,000 a year. Choice Energy also installed a power factor correction unit for the business, in an effort to reduce the demand from its network provider, and this has proved to save a further $16,300 a year. What these case studies illustrate is that the Choice Energy energy management team continues to identify new ways to help manufacturers take charge of their energy bills and secure their vital energy supplies.

Replas will save $2.8 million over the next 25 years across its two sites

It’s no secret that as Australia’s largest energy users, in recent years the nation’s manufacturers have suffered “bill shock” of a massive magnitude when their time came to negotiate their latest round of energy contracts. However, there are always alternatives, whether it be changing energy supplier, introducing a degree of on-site generation with rooftop solar (bearing in mind that manufacturing plants are not exactly short of roof space), or looking in greater depth of the energy efficiency of the manufacturing process. Increasingly, manufacturers are turning to energy consultants such as Choice Energy that can provide a balanced view of the problem, addressing all sides of the energy equation. One such manufacturer is Ballaratbased Replas, Australia’s leading manufacturer turning plastic waste into sustainable products. Recognising the irony of producing sustainable products in a factory running 24/7 with very energy-intensive processes, the company approached Choice Energy to carry out a solar feasibility study. Not only did Choice Energy enable significant savings for Replas by adding solar energy to its mix, the company also identified significant energy wastage throughout the plant due to the poor power factor caused by the nature of the loads within the factory. The addition of a power factor correction unit restored the power factor and removed this energy wastage. Replas went on to commission a further

FEBRUARY / MARCH 2020

solar installation at its Recycling Education Centre in Carrum Downs. And between the two sites, the company calculates that it will save $2.8 million over the next 25 years. One case that illustrates that solar is not the only solution is Ryan & McNulty Sawmillers, a company that makes high-quality timber products for flooring, cladding and decking based in Benalla in NE Victoria.

Then, having built a consumption and load profile of the energy Lago was using and submitting this as an evidence-based application, Choice Energy was able to renegotiate a better tariff from Lago’s

At the same time, the company is committed to providing high-quality, safe and effective PV solar solutions that it will support long into the future. Choice Energy 1300 304 448 www.choiceenergy.com.au

After reviewing the company’s energy bills, Choice Energy helped procure new retail electricity contracts, securing forward pricing well before huge market increases. This alone, saved Ryan & McNulty $186,000 over a three-year period. Ryan & McNulty also signed up for Choice Energy’s metering and monitoring service, which not only validates the company’s monthly energy bills, it also records all consumption and the allimportant load profile. This soon proved its worth when Choice Energy switched Ryan & McNulty to a different network tariff, saving a further $6500 per year. Eventually, though, Ryan & McNulty did invest in a 320kW solar system, which is by far the largest solar installation in Benalla, generating 1MWh of solar energy per day. Sometimes, it is a combination of measures that produces the desired effect. So, when Lago Quality Smallgoods called on Choice Energy for solutions to its rising power bills. The company’s timing was good, because Choice Energy was able to lock in new electricity retail contracts before a significant rate increase.

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MANUFACTURING IN SOUTH AUSTRALIA & THE NT SOUTH AUSTRALIA IS READY FOR DEFENCE INDUSTRY BOOM

By David Pisoni

South Australia boasts a highly skilled and educated workforce, a renewed focus on entrepreneurship and innovation, and multi-billion-dollar defence industry contracts. The state’s world-class research institutions and universities, an investment in skills and the development of entrepreneurial education in high schools are giving young people the tools they need for the jobs of the future. Under the Growth State plan, the Marshall Government is working with industry to identify areas of growth and unlock and accelerate business expansion and job creation. Nine priority sectors have been identified as focus areas because of their strong potential to meet increasing interstate and global demand, attract investors and leverage comparative advantages: tourism, international education, defence industry, food, wine and agribusiness, high-tech, health and medical industries, energy and mining, space industry and creative industries. South Australia’s size and agility means we can respond quickly to economic and social changes and grasp new opportunities. We have leading capabilities in cyber security, underpinning defence intelligence, space and electronic warfare. South Australia’s naval shipbuilding programmes and other major projects

are creating enormous technological advances and business and employment opportunities that will have an impact for decades to come. Recently, the $2.9 million Innovative Manufacturing Cooperative Research Centre (IMCRC) located at the Tonsley Innovation District in Adelaide’s south was officially opened. This CRC will develop and pilot cutting-edge manufacturing technologies for the Hunter class frigates for the Royal Australian Navy, to be built at the Osborne shipyard. In partnership with Flinders University, BAE Systems Australia’s shipbuilding business ASC Shipbuilding and local businesses, the IMCRC will drive digital transformation through advanced robotics, assistive manufacturing and readiness for Industry 4.0 – both inside the shipyard and more widely across the Australian supply chain. To continue to capitalise on these opportunities, unlock our full potential and stay ahead of the skills race, it is vital that South Australia has the right people skilled up and ready to step into these career opportunities.

In schools, we’re providing young South Australians with high-level trade, STEM and entrepreneurial skills to prepare them for careers in advanced manufacturing and the defence industry. Through Skilling South Australia, a $200 million partnership with the Australian Government, we’re focusing on increasing apprenticeships to make sure we’re supplying the skills required by industries.

We are committed to equipping South Australians with the right skills and qualifications to meet industry demands.

We’re doing this by prioritising funding for apprentices and trainees, by introducing flexible apprenticeship pathways for school students, and by supporting group training organisations to enter new industries, including defence industries and the supply chain.

We’re designing and implementing secondary and vocational training that is modular, agile and responsive to technology.

And we’re partnering with industry on innovative projects that increase apprenticeship and traineeship opportunities, such as the Australian

Industry Group’s Higher Apprenticeships Programme, which combines vocational and higher education, with a focus on emerging technologies such as robotic systems, cloud-based data and computer aided design tools alongside traditional mechanical engineering trade units. And there are other projects that will advance the skills we’ll need in our advanced manufacturing and defence industries in the future, including a new, tailor-made cybersecurity traineeship. Along with the pipeline of defence industries projects and jobs, developments like Lot Fourteen, the home of the Australian Space Agency and SmartSat CRC, South Australia is fast becoming a renowned leader in future industries and advanced manufacturing. The Hon David Pisoni MP is Minister for Innovation and Skills in the Government of South Australia.

HONG KONG MASS TRANSIT RAILWAY LOOKS TO SOUTH AUSTRALIA FOR SAFETY Over the past 30 years, Adelaide manufactured Floorsafe brand safety products have gained global renown amongst architects, builders and contractors for providing long lasting safety. Now the company’s safety tread nosings have been selected for use by the Operations Division of the Hong Kong Mass Transit Railway. According to Floorsafe MD Philip Zagni: “Having previously supplied safety treads to offshore oil rigs in Malaysia, we were delighted when the same contractor contacted us to provide enough

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stair nosings in order to complete the concourse and platform levels at the Tin Shui Wai station.” The contract called for a tough, long wearing product manufactured to a required size and colour. Floorsafe’s RMN safety treads are completely anti-slip safe and chemical resistant. Test reports show that the product exceeds the AS/NZS 4586-2004 slip resistance classification of new pedestrian surface materials and exceeds the recommendations of the HB-197 slip resistance standard for external stairs.

Says Zagni: “That’s why companies such as Shell, Esso, Qantas, Origin Energy, Thiess Black, Liebherr Australia and many other manufacturing companies are among those who are overcoming OH&S safety issues by using our quality made products.” The RMN safety treads are made at Floorsafe’s Adelaide factory using 1.6mm galvanised metal. The plate is first prepared with a special primer coat, and after drying three coloured coats of chemical-resistant two-part polyurethane are applied. During the three-stage process an

aluminium oxide granule is incorporated, which provides both the anti-slip performance and the extreme hardness of the finished product. Although safety yellow is the most popular colour, any Australian standard colour can be provided. Floorsafe 1300 717 769 www.floorsafe.com.au FEBRUARY / MARCH 2020

acetic acid, alkalis, animal vaccines, bacterial remediation treatments, bases and hydrocarbons, beer, biocides, biological broths, caustic soda, chocolate, chromic acid, cleaning chemicals, coagulants, copper

What are you pumping today? sulphate, corrosive acids, dairy, diatomaceous earth, dosing lime, dyes and glue, equipment sterilisation, feed additives, ferric chloride, filter press feeds, flocculants, gelato, hexafluorosilicic acid, hydrogen peroxide, hypochlorite, inks, lime mixing, paints, polluted streams, polymers, process chemicals, seed coating, silicate, sludge transfer, slurry transfer, sodium hypochlorite, sugar, thickener underflow, tomato paste, waste transfer, whiskey, wine ... Whether youâ&#x20AC;&#x2122;re pumping chocolate or corrosive slurry, Verderflex peristaltic hose and tube pumps solve tough challenges. Contact our pump experts about your next application. 1300 1 GLOBAL sales@globalpumps.com.au globalpumps.com.au/verderflex

MANUFACTURING IN SOUTH AUSTRALIA & NT

100 YEARS OF SOUTH AUSTRALIAN ENGINEERING proved to be as popular as the previous model. The 1980s saw the widespread introduction of CNC machine tools, and to meet this demand Hercus developed its own, the Hercus HNL lathe, the Computurn lathe and Compumill machining centre. These CNC machines were sold throughout Australia and exported to Asia and North America.

1920

All things have a beginning, and for FW Hercus it came one morning in May 1920, when Frederick William Hercus moved into a small building on Payneham Road in St Peters. The engineering industry in Adelaide was in its infancy. Specialisation as it is understood today was unknown, and the small engineering business was eager to grasp any work that was offered. While accepting whatever work came along, Fred Hercus never lost sight of his longterm ambition and that was to become a machine tool maker. By 1925 Hercus was producing a small range of simple machines. In 1926 the business moved into a larger premise at Chapel Street, Norwood. The remainder of the 1920s saw the business grow, the product range extended and new industries open up as the motor vehicle industry began to develop. Unfortunately, all good things must come to an end, and by 1930 the economic catastrophe that was the great depression had hit. This was a time that no job was turned away and Hercus produced anything from butchersâ&#x20AC;&#x2122; equipment to flywheels, ring gears and automotive repair equipment.

was in full swing and under the direction of the Department of Machine Tools and Gauges, Hercus was producing only certain machines from its range for the war effort. During the war years Hercus produced in excess of 2300 machines. With the advent of peace, Hercus once again was able to refocus on developing and producing its range of machine tools. The 1950s and 60s saw continuing redesign and improvement of its machine tool range. Hercus needed to meet the changing needs of industry and the realities of a competitive and discriminating market. To this day some see the 1960s as the pinnacle for manufacturing at Hercus as well as for Australia. The 1970s presented Hercus with a raft of new challenges mainly from cheaper imported competition. This led to a reduction in the range of machine tools that were being manufactured. Hercus decided to retire its mainstay, the 9-inch swing lathe after around 15,000 units and by the end of the 1970s had introduced the more modern 260 lathe. The 260 lathe

Unfortunately, the challenges of the 1970s only intensified during the 1980s, and by 1987 Hercus found itself in deep financial trouble and was eventually purchased by the Durden Group who had been producing woodworking machinery since the late 1940s. With the enthusiasm of the new owners Hercus embarked on a programme to further develop their CNC machine tools. This saw the machines go from using dedicated controllers to personal computers and windows-based software to operate the machines, which at the time was state of the art. Early in the 1990s Hercus moved to its present location at Regency Park where it continued to produce the CNC machine tools, at the time being sold throughout Australia and exported to North America as Rockford CNC. Other products being manufactured were the 260 lathe, OLM mill and the Durden Range of woodworking machine tools. One of these, the Durden Top Turn Lathe, was being exported to north America as the Delta Top Turn Lathe. However, by the late 1990s those challenges that appeared during the 1970s were still there and this meant that tough decisions had to be made. Hercus ceased production of a majority of its machine tool range: this included the 260 lathe

of which around 7000 units were made. The manufacture of all machine tools had ceased by 2005. One essential aspect of machine tool manufacturing is to produce accurate components, whether they be one off or mass produced. Hercus had always offered a general engineering service to other companies, and as Australian industry grew so did this side of the company. It was in 2000 that Hercus decided to reinvent the company and make the general engineering services its main focus. This meant Hercus was able to compete on a level playing field with other Australian companies. The 2000s was a time of moderate growth. However, this period was essential for the consolidation of the company and for the development of some key customers. Since 2010 Hercus has seen continual growth within the general engineering sector. This, however, has not always been easy. Hercus has invested heavily in new, up to date, computerised machinery, operating software and quality assurance accreditation, while also improving its manufacturing and factory processes, which include training and all OH&S requirements. Looking to the future, Hercus sees a positive outlook with further expansion in the key areas of mining and mineral processing. Also having the Australian federal government commit to large defence projects gives Hercus the opportunity for further expansion. FW Hercus 08 8346 5522 www.hercus.com.au

By 1936 business had improved and Hercus returned to machine tool manufacturing in earnest, developing a range of drilling, grinding, milling and slotting machines along with a range of metal turning lathes. This range of machine tools proved to be so successful, that in 1939 Hercus had to move into much larger premises on Anderson Street in Southwark (known today as Thebarton). The first years at Southwark saw the development of machines that were destined to become the workhorses of Australian industry. The most prominent being the Hercus 9-inch swing lathe. During the early 1940s World War 2

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2020

FEBRUARY / MARCH 2020

MANUFACTURING IN SOUTH AUSTRALIA & NT

DURABLE HOSE PUMP SOLVES DELICIOUS DILEMMA

Tough and durable pumps are hard to come by. With the complexities that come with pumping abrasive or corrosive fluids, an understanding of applications, including operational and production requirements, is crucial. With its head office in South Australia and representatives around the country, Global Pumps has more than 40-years’ experience solving difficult pumping applications. Having worked across all industries, the team understands the desire for reliable, durable and safe pumps. One of the company’s core products, the Verderflex range of peristaltic hose pumps, is an example of Global Pumps’ commitment to offering consistent and tough solutions to industry concerns. The peristaltic action of the Verderflex hose pump is the gentlest and most abrasion resistant pumping action available. Able to self-prime, run dry and pump in reverse, they are extremely versatile. There are no valves or seals in contact with the process fluid, eliminating sealing and “vapour lock” problems. These features make them suitable for harsh abrasives and thick slurries through to food and beverage, chemicals and highly corrosive substances. The Verderflex hose pumps are capable of pressures of 15bar and flow rates of 180m3/h. When looking for the most rugged slurry pump or accurate dosing pump, it’s the hose that is the life of the Verderflex pump. They are designed to minimise the effects of fatigue, giving an extremely long hose service life. Having been tried and tested over numerous arduous applications, Verderflex hose pumps give substantially longer service life than competitors.

Verderflex in action Recently, Global Pumps was approached by South Australian ice cream and gelato manufacturer Gelista, which was looking for an efficient and effective pump to evenly distribute fruit ripples through its ice cream. Having briefed the expert Global Pumps on the operational requirements,

FEBRUARY / MARCH 2020

the Verderflex peristaltic hose pump range was selected. This pump allowed the team to create premium dairy products to exacting requirements, minimising waste and facilitating increased production efficiencies. The Rapide Series by Verderflex offered Gelista a compact design, simple operation and easy maintenance for accurately metering the fruit syrup. The hose is simple and quick to remove, giving the gelato manufacturer the certainty that the staff could efficiently clean the pump between production cycles. As the Verderflex Rapide is capable of handling viscous fluids with total containment and leak-free pumping, it offered the perfect solution for fruit pulps and other gelato inclusions. Peter Cox, founder at Gelista, chose the peristaltic hose pump due to its flexibility in speed, accuracy and serviceability, making it one of the more versatile pumps on the market.

Global Pumps, delicious results continue to be achieved for the South Australian manufacturer months after the purchase.

selecting the right peristaltic hose pump for any application, and guaranteeing it meets production and operational requirements.

Global Pumps offers free site visits to customers around Australia, with options to hire hose pumps before committing to purchase. This reassurance is crucial in

Global Pumps 1300 1 GLOBAL www.globalpumps.com.au

100 YEARS

1920 - 2020 www.hercus.com.au

CNC Machining - Gear Cutting - Fitting & Assembly

Gearbox Refurbishment - Industrial Transmission Equipment

“One of the other major advantages of the peristaltic pump was [Gelista’s] ability to very quickly and easily clean and sanitise the pump, prior to next production.” Global Pumps was also able to add a stainless-steel cover to the pump to ensure it meets with stringent food handling requirements.

Delicious results Following the pump’s installation, Gelista successfully increased production uptime, reduced cleaning downtime and expanded its capabilities across all operations.

Dynamic Solutions from Concept to Manufacture

Installing the correct pump through consultation with experts ensures the best solution is achieved. By gaining assistance from Australia’s leading team at

1 2 C a m i r a S t r e e t , Re g e n c y P a r k , S ou t h A u s t r a l i a , 5 0 1 0 . P 08 8346 5522 F 08 8346 5811 E - sales@hercus.com.au

Hercus Pty. Ltd.

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MANUFACTURING IN SOUTH AUSTRALIA & NT

GASSING ABOUT COMPRESSED AIR SAFETY AND EFFICIENCY IN THE TOP END After 15 years in the Top End, Compressed Air Australia is transforming safety and energy efficiency right across the country. Which means life is quite literally a gas for June Lindsay-Lorman, Director of the Darwin-based compressed air specialists. June likes to say that the company she helps run is ‘a breath of fresh air’, as it’s on a mission to do more than simply shift product. Compressed Air Australia has set itself broad industry wide goals aimed at maximising efficiency and dramatically cutting energy costs while improving all round safety for compressed air users. And it’s doing this with latest EXAIR products that amplify existing room air to maximise efficiency – making them a safer and more efficient replacement that literally pays for itself compared to some of the homemade compressed air solutions still in use, some of which are ‘unsafe’ according to June. Industry Update Editor-In-Chief, Laurence Marchini caught up with June recently to find out how the mission was progressing. Before getting into specifics he discovered that Compressed Air Australia now offers a range of products in keeping with an industry leader. The comprehensive list includes: air amplifiers, air knives, air nozzles, optimisation products, air wipes, safety air guns, air fuses, in-line regulators, vacuum generators and air operated conveyors. The range also extends into liquid atomising nozzles, industrial vacuums, vortex tubes and applied products utilising vortex tube technology,

such as coolers for electrical cabinets and ionising products to eliminate static electricity. Naturally, in line Compressed Air Australia’s commitment to boosting user safety, all of these products meet CE requirements, OSHA and WorkSafe Australia standards for dead-end pressure and noise exposure, as well as RoHS compliance. Laurence then asked June how business was progressing generally, particularly as more and more businesses are seeking to boost energy efficiency and compressed air applications are famous using large chunks of electricity or gas. June replied: ‘Things are going well. With energy prices constantly on the rise, companies are looking for ways to drastically cut their use of compressed air. Our EXAIR products are designed to replace the homemade compressed air products that so many facilities have been using up to now” she then explained: ‘In many cases, the EXAIR product retrofits into the existing application. And, they’re ideal because they amplify surrounding room air. As an example, the Super Air Knife pulls in 40-parts room air to the one-part compressed air consumed.’ LM: June, we all know that Australian industry is struggling with energy price rises. Has this helped you push your energy efficiency message? June’s enthusiastic reply was: ‘That’s a resounding yes! We can help companies identify the homemade low efficiency products in their facility and make a recommendation for their

replacement. In many cases, replacing homemade blowoffs with an EXAIR Super Air Nozzle drastically reduces air consumption and noise. The Super Air Nozzle pays for itself within 2 weeks.’ LM: So, what sort of companies are coming to you now for help? Are they larger or smaller? ‘Large and small. When a company upgrades to a high efficiency EXAIR product, the compressor runs less. We’ve found that, in some cases, they’re saving enough compressed air that they can even turn a backup air compressor off.’ LM: The other major aspect of your company’s mission is to improve the safety of compressed air applications. Do you think that the safety culture has changed for the better in Australian industry over the last 15 years? In answer to this June stressed: ‘There are still companies out there who manufacture products that are not safe. EXAIR on the other hand makes products that can operate at full line pressure but not breach the 30 PSIG dead-ended pressure limitation. She then went on to outline some major safety benefits within Compressed Air Australia’s product rage, ‘We also have the Protect-Air HoseGuard that acts as an air fuse, so in the event that a hose is cut or damaged, the air is turned off immediately, eliminating whiplash hazard. And, Protect-Air ToolReg inline regulators, have automatic secondary pressure relief that eliminate accidental activation of the pneumatic tool once disconnected from the compressed air line.’

She explained this is crucial safety feature when working with nail guns and staplers. LM: Do these improved safety features only relate to the safety of compressed air systems? Or do they make using compressed air a safer power source option for other applications? June was typically forthright, simply saying: ‘We think it applies to the overall safety of personnel and equipment.’ LM: Finally, I do have to ask the question, what’s it like running a nationwide business from Darwin? Has it been a problem? Or is Australia getting smaller? June responded with a shrug, saying: ‘It's no problem at all. We have great coverage throughout the country. The key is our distributor network. They know our products well and cover most of the primary business centres in Australia.’ Compressed Air Australia 1300 787 688 www.caasafety.com.au

DEFENCE COMPANIES VIE FOR SLICE OF $35 BILLION FRIGATE PIE Detailed planning for Australia’s Hunter Class Frigate Programme is well underway as South Australian companies vie for a slice of the $35 billion project. Nine antisubmarine warfare frigates will be built by ASC Shipbuilding at the Osborne Naval Shipyard in South Australia in what is being described as the largest surface ship project in Australia’s defence history. Construction of the first test blocks for the project will begin towards the end of this year with defence companies now being short-listed to carry out part of the work. Among them is Adelaide defence company AFL services, which has been downselected for lucrative blast and paint work. AFL services was one of four Australian companies recently invited to tour global defence company BAE Systems’ world-class shipyards in Scotland to inspect painting processes used on the Type 26 Global Combat Ship.

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“AFL Services has a proud history of working on defence projects, from land vehicles with BAE/Tenix toll defence, and components for Navantia to the Collins Class submarines,” General manager Adam Levi said.

“We appreciate that BAE System is embracing Australian industry content and helping small businesses reach their potential to bid for the Hunter Class Frigate Programme work,” Levi said.

AFL Services now has more than 60 staff and winning a slice of the Frigate work would boost projections.

“Personally being from South Australia, I have set goals to assist industry at Osborne and create flow-on to the schools and the community for years to come.

ASC Shipbuilding won the head contract to provide the design and build framework of the nine anti-submarine warfare frigates that will be replacing the nation’s eight Anzac Class frigates. ASC Shipbuilding has become a subsidiary of BAE Systems throughout the build process before ownership is returned to the Commonwealth at the completion of the project. The two-year first building of five test blocks at the world-class digital shipyard in Osborne, Adelaide, is beginning in December this year with building of the first frigate expected to commence in 2022.

“The Hunter class project is a national endeavour that will provide many Australian small businesses with unprecedented opportunities.” Three other Australian companies, Broadspectrum, Eptec Group and Altrad Services – Asia Pacific, are all vying for the work that involves blasting back material of the ship to create the right conditions for painting. The Hunter programme is designed to create a continuous naval shipbuilding endeavour in Australia, creating more than 5000 jobs across BAE Systems and the wider

Australian defence supply chain over the life of the decades-long project. More than 1000 Australian suppliers have registered through the Industry Capability Network Gateway to compete for work on the frigate programme, with placing of contracts for the prototyping phase of the project happening throughout 2020 and 2021. “The prototyping phase is one of the first real chances for Australian industry to be actively involved in the manufacturing phases of the programme,” ASC Shipbuilding MD Craig Lockhart said. The nine antisubmarine warfare frigates will be built at the ASC shipyard in Osborne using local workers and Australian steel. Work on the frigates is expected to create 1000 apprentice and graduate jobs throughout the programme’s life, with opportunities for engineers and project managers, specialists in steel work, mechanical, electrical and technical trades.

FEBRUARY / MARCH 2020

WORKSPACE SAFETY WORKPLACE MANSLAUGHTER: LEARNING FROM THE UK EXPERIENCE

Show is the official trade show of the #Safetyscape convention. The show features a free programme of seminars, interactive forums, and roundtable discussions allowing you to meet health and safety delegates and suppliers from across the country. 2020 is the year to make sure your organisation has the technology, equipment, and policies in place to make sure everyone gets to leave work safe and healthy.

result in jail terms of up to 20 years for individuals found responsible of negligent conduct that results in a workplace death. This can include situations where a person doesn’t take reasonable action to fix a dangerous situation, and the failure of that action creates a high risk of serious injury, illness, or death.

“Lessons we can learn from the British Corporate Manslaughter experience” will be presented by Ian Wallis, Senior Work Health and Safety Consultant with the Victorian Chamber of Commerce and Industry (VCCI) at the Workplace Health & Safety Show on 27th and 28th May 2020. Entry is free.

MARIE KINSELLA

New workplace manslaughter laws coming into effect in Victoria on the 1st July 2020 will impact decisions made by organisational leaders now and into the future. What kinds of risks is your organisation now open to with this change in legislation, and how will you mitigate those risks? Company directors, partnerships, and trustees may all be impacted by these incoming laws, which may

We can learn from the United Kingdom, where similar legislation was

introduced 12 years ago in the form of the Corporate Manslaughter Act (2007). Join us on 27th and 28th May at the Workplace Health & Safety Show for a seminar presented by the Victorian Chamber of Commerce and Industry (VCCI) focusing on the outcomes of the UK implementation and the key legal precedents that may guide the Australian experience. The Workplace Health & Safety

Marie Kinsella is CEO of International Exhibition and Conference Group.

PROTECT YOUR STAFF AND MACHINERY WITH WEARGUARD™ Machine guards are crucial to ensure employee safety and equipment longevity for machinery with moving parts or sharp edges.

Cut To Size Plastics supplies tough,

custom-fabricated polycarbonate Wearguard™ machine guards throughout Australian industry.

WearguardTM machine guard benefits include: • High strength • Impact resistance • Ease-of-fabrication • Customisable to customer designs • Delivered ready to install • UV protected grade Make sure you’re protected. Contact us today to see if WearguardTM is right for your application.

1800 CUT2SIZE | sales@cuttosize.com.au | www.cuttosize.com.au FEBRUARY / MARCH 2020

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WORKPLACE SAFETY

LED BEACON IS BRIGHT CHOICE FOR HAZARDOUS AREAS duplicated pluggable terminals that not only simplify installation, but also enable a four-wire connection. Multiple units will automatically synchronise when powered from the same source, removing the need for additional synchronisation modules and reducing power supply requirements. The unit is globally approved to UL, cUL and ULC for Class I Div 2, Class II Div 2, Class I Zone 2/22 as well as IECEx and ATEX certified for Zone 2 and 22 hazardous area applications. Available throughout Australia from Mechtric, the Haz Loc D2xB1LD3 LED beacon from E2S Warning Signals is billed as the brightest UL1971-compliant visual emergency signalling device from any manufacturer. With an effective candela rating of 82.1cd under UL1971 test conditions it is ideal for use as part of a public mode fire alarm installation in hazardous areas. The NFPA 72 compliant 20ms high-intensity pulse generates light output equivalent in perception to a traditional strobe, but with ultra-low current consumption (150mA) and low inrush. The array of high-output LEDs optimises visibility in all directions. The D2xB1LD3 contains a supervisory diode and

To create a complete audio-visual warning system the D2xB1LD3 can be paired with a D2xS1 alarm horn sounder with an audible output up to 116dB(A), 64 embedded alarm tones and four remotely selectable stages/channels to create the D2xC2LD3 combination signal. The alarm tone will also synchronise automatically on multi-unit systems where powered from the same source. All members of the D2x family are housed in marine grade aluminium enclosures with ingress protection ratings of IP66, NEMA Type 4 and 4X. Mechtric 1800 252 995 www.mechtric.com.au

PALLET RACK PROTECTION SAFEGUARDS COLD STORAGE Rack Armour reckons its high-bay racking upright protectors are ideal for use in cold stores. Manufactured locally using the highest-quality materials, the patented Rack Armour design and unique style ensure that the protection is of the highest quality. The company guarantees that its products will not rust or corrode, and are effective in temperatures down to -40Â°C. They are ideal for protecting high-risk areas, avoiding racking repairs and costly downtime. Rack Armour Australia 02 9722 0502 www.rackarmour.com.au

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*When audited by the AMAA *When audited by the AMAA

Industry Update is committed Industry Updateadvertisers is committedby to protecting to protecting by having theiradvertisers distribution having their distribution independently verified by AMAA. independently verified by AMAA.

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WORKPLACE SAFETY

SEE-THROUGH POLYCARBONATE GUARDS IMPROVE MACHINERY SAFETY

Advances in engineering plastics are delivering new machinery and structural safeguarding benefits with lightweight and strong see-through materials such as Wearguard polycarbonates that can be used in place of metals for outstanding protection against hazards. These transparent and tough materials - which simultaneously enable high visibility of processes while providing protection against hazards - are well suited to industrial machinery retrofits, updates and new technology installations as employers introduce advanced and often high-speed machinery to gain the benefits of digital automation initiatives under Industry 4.0. “As the pace of industrial change accelerates, employers have a commensurate obligation to update their risk management plans in accordance with recognised safe work codes and employer duties of care,” says Laurie Green, Managing Director of Cut To Size Plastics. These changing needs – and the seethrough protective materials applicable to them – particularly apply to industries that may be employing new technology or introducing new workplace environments centring on high-speed production, distribution and maintenance. The environments against which employees must be protected include impact and injury hazard, moving parts and electrical, heat and chemical processes across a wide range of industries. One of the future-focused materials from Laurie Green’s company’s global ranges of engineering plastics is Wearguard polycarbonate, which is outstanding for its impact resistance (Izod impact tested to 90kgfcm/cm) and for its shock load resistance, which is many times that of acrylic clear sheet, for example.

FEBRUARY / MARCH 2020

These properties make it ideal for seethrough safety and indoor and outdoor glazing and protective applications, which until recent years required the use of metal or similar material. Wearguard is virtually unbreakable, even where exposed to robust interior industrial environments, or to exterior security or protective challenges where it may be required to resist rough weather and vandalism. Applications include: viewing and protective panels and machine guards for safety in industry; cabin panels on heavy machinery and materials handling machinery; and sight glass tubes for observation of industrial and process liquid levels. Wearguard displays consistent high transparency – commensurate with thicknesses used – and also offers high heat resistance, with a melting point of 150°C. The material is not influenced by sudden changes in temperature and humidity, which makes it ideal for applications such as skylights, sign faces and institutional vandal-resistant glazing. It offers excellent dimensional stability and is readily machined by cutting, drilling or bending. Cut To Size has expanded its capacity to custom-fabricate Wearguard safety and glazing products with its new Morbidelli Author M100F heavy duty CNC router and machining centre. The machinery’s rapid working cycle times and reduction of idle times also enhance Cut To Size’s ability to cost-effectively supply high precision components from its broader ranges of versatile engineering plastics. Cut To Size Plastics 1800 288 274 www.cuttosize.com.au

CHILL. WE’VE GOT YOU PROTECTED. The A-SAFE Cold Storage range has been meticulously engineered to provide the highest levels of protection to pedestrians, assets and infrastructure. The range includes a full suite of high-performance safety products for applications within very low-temperature environments. Food-safe, robust and effective to -30°C, Cold Storage products from A-SAFE have been purpose-designed for use in frozen food storage facilities and other challenging sub-zero environments.

For more information contact sales@asafeau.com A-Safe Australasia Pty Ltd (02) 9625 8927 www.asafe.com

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DOORS

EXPANDING ROLE OF DISTRIBUTION CENTRES RAISES SECURITY STAKES Security specialist Alastair Russell looks at access control liabilities in today’s logistics centres. Major logistics, intermodal distribution and warehouse facilities are large and valuable facilities, operating 24/7 and filled with millions of dollars’ worth of merchandise. And their importance to the industrial, commercial and retail sectors – and the value of the goods they handle – has increased by leaps and bounds as buyers move to online buying of the merchandise they want. Properly planned and layered use of new generation security entrances can help reduce vulnerability of rapidly expanding warehouse, distribution and intermodal logistics precincts to emerging risk management issues. Risk management is an important issue, with security issues growing in scale and type as the facilities involved expand to accommodate trends in online trading, and as entirely new facilities emerge, such as the purpose-built “aerotropolis” of which Sydney’s new Western Sydney International (Nancy-Bird Walton) Airport, is a major example.

individuals from entering the premises; reduce theft of merchandise or access to sensitive commercial data; keep weapons off the premises; and create a safe environment and a culture of safety and security among the employee population.

A layered approach to physical security Meeting these objectives calls for a layered programme of security entrances with manpower and technology.

The national freight agenda is now clearly focused on integration and concentration to provide seamless, efficient transfer movements across all modes of transport, both at capital city and regional centre level.

The fenceline perimeter should discourage casual infiltration from nonemployees. Since higher security practices exist inside the building, the goal at the fenceline is to primarily deter and potentially respond if an incident occurs.

Expanding risks implicit in this rapid growth of high volume distribution facilities include theft, product contamination, unauthorised personnel gaining access to sensitive data or logistical information, outright sabotage by disgruntled individuals – and even violence against employees and visitors, which is an employer’s and facility manager’s Duty of Care issue to protect against.

Full height turnstiles achieve their primary security objectives through their robust barrier construction and ability to efficiently control the flow of visitors and staff to the facility, who are recorded also via security cameras during entry.

Workplace violence can often stem from the employee population. It could be domestic violence issues, such as an ex-partner coming into the facility, or former employees who are angry after being terminated. Beyond the violence itself, such an incident disrupts business continuity. When a distribution centre is perceived as an unsafe place for any reason, it takes a toll on brand perception. Crime places an unwanted spotlight on the organisation, whether it is actual violence, a protest, or any other incident that turns an unwanted spotlight on an unprepared employer. To effectively mitigate these risks, distribution centres can formulate a physical security plan to: prevent unauthorised

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Because building and perimeter entrances are key points for physical security, much of the technology for physical security devices has been developed to protect entrances. A survey of security integrators and

consultants in the USA found that 71 per cent thought that it was “somewhat likely” or “very likely” that a security breach could happen at their facility as a result of a tailgating incident (additional people following someone through the door or gate). One in three said a tailgating incident would cost their organisations sums from US $2 million to sums “too high to measure”. Most surveyed believe barriers and education are the most effective tailgating mitigation strategies.

Inside the building Advanced security entrances can offer a unique level of protection within the building, as they not only fully prevent tailgating, but also verify the identity of every individual entering a facility. They cannot be compromised in the way that a security guard can through social engineering, and they cannot be fooled or tricked. When integrated with access control systems, they reliably deter and detect unauthorised entry attempts. Certain types can even prevent unauthorised entry without supervision. And, they also enable accurate monitoring of who is in the building at all times. Based on its experience in 27 countries, Boon Edam advocates a layered cost-

effective system of security entrances to sensitive business facilities, increasing in sophistication and features as employees and visitors advance from the perimeter of the facility involved, to the core areas where sensitive data, distribution and commercial information is managed. Importantly, in terms of presentation to staff and visitors, this security cannot be ugly or threatening; it has to be architecturally crisp and harmonious, reflecting the style and presentation standards of the leading organisations involved as well as providing an attractive workplace.

Conclusion One of the most important reasons that security entrances are being deployed today is to accurately control and monitor who is on the premises, along with when they entered and exited. And security entrances can also cost-efficiently govern the unwanted passage of people through tailgating or piggybacking. While distribution centres present several significant vulnerabilities, security entrances, along with guards and technology, can work in an effective layered approach. You can leave far less to chance for error compared to using guards alone or swinging doors with access control systems. You can effectively deter and control access to the secure facility, track who is in the building 24/7, and minimise theft. In the end, security entrances enable an overall physical security plan that ensures maximised safety and optimal risk mitigation. Alastair Russell is National Sales Manager for Boon Edam Australia and a security specialist with 30 years local and international experience in protecting corporate assets Boon Edam Australia 1300 689 905 www.boonedam.com.au

FEBRUARY / MARCH 2020

DOORS

LOCALLY MADE DOORS ANSWER FOOD MANUFACTURERS’ DEMANDS Australia’s booming food and beverage manufacturing sector is proving to be a very lucrative market for one Melbourne-based door manufacturer. MTI Qualos has been designing and making PVC industrial doors in Melbourne since 1970. And today the company is reaping benefits from its decision to bring all its manufacturing operations in-house. Mil Lozanovski heads up the MTI Qualos door manufacturing operation. He says: “We’re now at a stage where all our doors are manufactured here, and we use upwards of 85% of locally made components, including all the steelwork and the vinyl.” He does concede that “there are a few parts we have to bring in, like some door seals, but we buy them in huge bulk so that we’ve always got stocks.” So, with no reliance on complex international supply chains that may have been interrupted by the Coronavirus crisis, MTI Qualos is well placed to service

increasing demand from the food and beverage sector. Two types of doors are proving to be particularly popular: PVC strip curtains and the company’s flagship SI163 VSD internal Roll-Fast door. “The PVC curtains are a great lowcost way of keeping bugs out of food-safe

areas,” says Lozanovski. “And that’s really down to the quality of the PVC rolls that we use. It’s so good that we’re even supplying it to our competitors.”

improved motor/gearbox combination that enables opening and closing speeds of 1200-1500mm/s and virtually non-stop operation.

And for food manufacturers with a little more to spend, the SI163 internal high-speed door comes with a variablespeed drive as standard and a newly

MTI Qualos 1300 135 539 www.mtiqualos.com.au

MTI PE200 SWING DOORS The most robust solution for food industry, retail and logistics The new PE200 HDPE double acting impact traffic door, exclusively available from MTI See-Thru, offers the perfect solution for insulation, functionality and durability. Benefits of the MTI PE200 Swing Door; • Made of solid polyethylene – non breakable • Hygienic (EU/FDA approved) • Maintenance-free • Made to measure • Short production time • Easy installation • Long service life • PVC finger protection • 10 year guarantee on door leaves • Stainless steel hinges

MTI PE200 IndUpd_HalfPage.indd 1

FEBRUARY / MARCH 2020

Trusted by food and retail companies worldwide;

Contact M.T.I. Qualos today to discuss your industrial door needs.

• Kraft Foods, Bahrain • Nestlé, Germany • Aldi, Ireland • Lidl , Germany, England • Edeka, Germany • Kaufland, Germany • IKEA, Turkey

INDUSTRIAL DOOR SOLUTIONS www.mtiqualos.com.au Free call: 1300 135 539 sales@mtiqualos.com.au 25/10/2018 8:32 AM

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ARBS 2020 PREVIEW

REGISTER ONLINE FOR ARBS Returning to Melbourne in May is Australia’s only international air conditioning, refrigeration and building services trade exhibition, ARBS 2020. The event is set to dominate the HVAC&R and building services landscape as it hosts more than 300 exhibitors, a renowned industry awards programme and a comprehensive seminar presentation series. ARBS 2020 is recognised as the must attend event for the entire industry. The vibrant show floor will offer visitors numerous immersive experiences as well as unparalleled access to the latest new technologies, products and services from around the globe.

The ARBS Industry Awards offers an inclusive and social forum to recognise and celebrate the multitude of talented individuals and organisations that continue to strengthen the industry. Running in conjunction with the exhibition is the ARBS Speaker Series where industry thought leaders will present information on current topics, updates and trending issues. Each session will provide visitors with invaluable learning opportunities and the opportunity to accrue continuing professional development (CPD) points. The complete ARBS 2020 programme will

be launched shortly and will offer much more for manufacturers, particularly those wanting to explore the latest advances in smart buildings. ARBS is Australia's premiere event for HVAC&R and building services professionals, and since 1998 has provided a unique B2B

forum for the entire industry to connect. ARBS 2020 will be held at the Melbourne Convention and Exhibition Centre from Tuesday 19th May to Thursday 21st May 2020. Registration is open now at www.arbs.com.au.

HIGHLIGHTS OF THE ARBS 2020 SPEAKER SERIES The ARBS 2020 Speaker Series will feature some of the industry’s top names presenting on a diverse range of HVAC&R and building services topics, updates and trending issues. Each session will provide visitors with invaluable learning opportunities and the opportunity to accrue continuing professional development (CPD) points. “Infrastructure without tears: how to transition from commercial to industrial contracts without losing your shirt”, by Melissa Kirby and Murray Walls, Sharpe & Abel and RMIT University. This will be a unique presentation for ambitious HVAC&R companies and commercial building services contractors to learn both the theory and the practice of transitioning from commercial to industrial infrastructure projects.

“Decommissioning of existing HFC based, air-cooled refrigeration plants and replacement with NH3 DX based solutions”, by Stefen Jensen, Scantec. This informative seminar will detail the decommissioning of several existing HFC based, air-cooled refrigeration plants servicing a refrigerated warehouse and replacement of these with a central, low charge, dry expansion, NH3 based refrigeration plant. “The efficiency of air movement systems – Improve your ROI by focusing on upgrading your HVAC&R systems”, by Suzanne Lohmann and Thomas Heine, ebmpapst. This seminar will outline the new technologies and improvements that have been made on the European stage and shares tips and lessons learnt to enable Australasian designers to improve their systems. “The future of NABERS energy”, by

Corine Mulet, National Australian Built Environment Rating System (NABERS).

“Seismic restraint of HVAC explained”, by Jordan Bartlett, Eurofast.

Over the last 20 years, NABERS has achieved world leading results – including a 40% drop in energy use for buildings that have participated in the programme over 10 years. Today, the future of NABERS energy project is looking at how NABERS will adapt to achieve the same results over the next 20 years.

This session will address Part B1 Structural Provisions of the National Construction Code of Australia.

“Cold Hard Facts: an annual update”, by Michael McCann and Peter Brodribb, Expert Group. Cold Hard Facts is widely recognised as the most comprehensive inventory available of the Australian HVAC&R sector, and so this will be a session not to miss.

“HVACPRO – AI: MPC for optimisation of HVACR systems with hybrid energy sources including renewables”, by Chirayu Shah, Subbu Sethuvenkatraman and Mark Hooper, Conserve It, CSIRO and Echuca Regional Health. This session will outline an artificial intelligence-supported model predictive controller (AI-MPC) framework using a highlevel model to generate predictions of system load and resources to minimise operation costs.

FINALISTS NAMED FOR ARBS 2020 INDUSTRY AWARDS The ARBS air conditioning, refrigeration and building services trade exhibition has revealed its industry awards finalists for 2020. Officially launched in 2010, this year marks the tenth anniversary of the awards, which honour and reward the talent in Australia that sustains the industry. ARBS Exhibition Manager, Sue Falcke, says that the industry is constantly evolving to meet the needs of a changing landscape, and this is reflected in the superb line-up of individuals and organisations this year. “Not only do the ARBS Industry Awards culminate in a fantastic celebration, the award recipients will join a small but influential

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group of industry high-achievers with their accomplishments in their respective fields publicly acknowledged. We are proud to be applauding their hard work and commitment via the ARBS Industry Awards,” says Falcke. A panel of industry experts chose the finalists based on criteria such as leadership, sustainability, performance and origination. The award winners will be announced and honoured at a gala dinner to be held on Wednesday 20th May 2020 at Melbourne’s Crown Casino, hosted by comedian and actor Shane Jacobsen. There are three finalists for each award, as follows: ARBS Young Achiever Award: Chris

Stamatis, CopperTree Analytics; Grace Foo, DeltaQ; Abraham Corona, TechIN. ARBS Product Excellence Award: Temperzone Australia, OPA2100 Eco Ultra; Shepherd Filters, Shepherd Filters; Actrol, DC-3 Smart Refrigeration System. ARBS Software/Digital Excellence Award: Kaizen, CopperTree Analytics; Smart Access Cylinder Management & Gas2Go App, Kirby; Bueno Platform, Bueno. ARBS Project Excellence Award: NewTon Plant Installation, Tri Tech Refrigeration Australia and Mayekawa; The Woolworths Energy Management Centre, Bueno and Woolworths; 177 Pacific Hwy, Fredon.

ARBS Outstanding Industry Education/ Training Award: CO2 Systems Training Course, Kirby & SCM Frigo; Professional Diploma of Building Services, HVAC&R, AIRAH; HVAC Centre of Excellence, AMCA. ARBS 2020 will be held at the Melbourne Convention & Exhibition Centre from Tuesday 19th May to Thursday 21st May 2020. Tickets for the Gala Dinner on Wednesday 20th May can be purchased online. ARBS 2020 www.arbs.com.au

FEBRUARY / MARCH 2020

PRODUCTS

LIGHTWEIGHT CYLINDERS MAXIMISE MOBILITY Enerpac has expanded its RAC-Series of lightweight aluminium cylinders with new 10 and 15t models for smaller lifts requiring a high degree of portability. The cylinders, with strokes from 50250mm, weigh from just 1.3-2.0kg for the new 10t models and 1.9-2.9kg for the 15t models, through to a maximum of 41.3kg for the top-of-the-range 150t cylinders. “The new 10t and 15t models, which further extend the range, are particularly useful for maintenance tasks, and in situations where they need to be moved from job to job,” says Enerpac Asia-Pacific Marketing Manager, Tony Cooper. The RAC-Series has been proven globally for years on lifts between 20 and 150t, where it provides the same lifting performance and safety in half the weight of equivalent steel hydraulic cylinders. Frequently used in workshops, fabrication and manufacturing applications, Enerpac’s range of RAC single-acting

spring-return aluminium cylinders are one of the most widely used ranges in Australasia. “Cylinders often need to be carried for field maintenance, elevated platform work, up stairs or across processing plants. The light weight and outstanding portability of the RAC-Series cylinders are highly valuable in these situations, especially on remote sites, where they may need to be carried in by air or 4WD,” says Cooper. The aluminium versions are also perfect for mounting on machines or applications where the weight of the hydraulic components is important. Because of their weight, aluminium hydraulic components are easier to move or remove for maintenance and repair. Their nonmagnetic properties can also be useful in uses around high technology equipment and magnetically or electronically sensitive instruments and applications in resources, processing and exploration.

Robyn Kiddle and John Evans

“Additionally, because it is noncorrosive by design, aluminium has always been a good material for use in many caustic environments, including those encountered in the production of food, electricity, manufactured goods and resources,” adds Cooper.

As an ideal complement to the RAC-Series cylinders, Enerpac’s P-392 and P-802 lightweight hand pumps are constructed of composite materials including aluminium to create an optimal lightweight pump and cylinder set. The cylinders can also be powered by Enerpac’s fast-acting electric, air and petrol pumps.

RAC-Series cylinders incorporate composite bearings on all moving surfaces to prevent metal-to-metal contact, resist side loads and extend cylinder life.

Enerpac 02 8717 7200 www.enerpac.com

TINY BARCODE READER AIDS AUTOMATION INTEGRATION New from Datalogic, the Matrix 220 is an ultracompact image-based barcode reader designed for maximum performance and flexibility in high-speed and direct part marking applications. Measuring just 73 x 47 x 38mm and weighing only 173g the unit features rotating connectors for easy installation and integration into tight spaces encountered in industrial automation and high-speed machinery applications. The extreme industrial grade Matrix 220 can read barcodes in the widest variety of applications, including difficult lighting, at high speeds and in a large range of temperatures, making it an ideal industrial scanner for automotive, packaging, food and beverage, electrical, document handling, manufacturing and a wide range of Industry 4.0 and automation-ready industries. “The new Matrix 220 imager has been designed for industries needing a robust and reliable scanner that can support their digitalisation and automation growth,” says Morena Corradini, Identification Product Marketing Manager, Datalogic. The Matrix 220 imager features IP67 and IP65 industrial grade ratings and can

FEBRUARY / MARCH 2020

safely operate in temperatures between -10 and +50°C. The imager’s 1.2Mpixel high-resolution sensor and a new multicore imageprocessing platform offer outstanding performance and the ability to read up to 2mil code resolution. The Matrix 220 is the first stationary industrial scanner on the market supporting OPC UA (Open Platform Communications Unified Architecture) protocol for Industry 4.0 communication and Digimarc Barcode technology for added value decoding applications. Matrix 220 is also the first reader of its market segment to embed high dynamic range (HDR) imaging. This improves image quality and contrast for higher code readability in applications with lower exposure time and faster line speeds. “Integrated HDR imaging provides outstanding efficiency benefits in manufacturing, food and beverage, automotive and industrial applications featuring a production line or conveyor. Parts can be accurately scanned as they move past at speeds, even in low lighting,” says Corradini.

setup mode for quick and easy code reading. “Another major benefit of the new Matrix 220 imager is that it’s simple to set up, easy to use, and can be easily reconfigured as scanning needs evolve in the future,” says Corradini. The Matrix 220 offers in a single model polarised and diffused light options resulting in optimal illumination on any type of surface. The electronic focus control allows easy remote job changing during assembly line reconfiguration with extreme reading flexibility. The imager’s ease of use is enhanced by green and red spotlights, the X-Press button and an intuitive human-machine interface, and the configuration software has been improved with an automatic

To reduce the number of models, the new Matrix 220 imager comes with a range of front cover accessories – including ESD protection – to enhance its flexibility and simplify stock management. The imager also offers cost-effective communication and connectivity with Power over Ethernet, Profinet/IO and Ethernet/IP options. Datalogic 03 9558 9299 www.datalogic.com

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PRODUCTS

DIN RAIL TERMINAL DEAL SECURES INDUSTRIAL CONNECTIONS

SIPHON-FED SPRAY NOZZLES DISTRIBUTE NONPRESSURISED LIQUIDS

Following the conclusion of an exclusive distribution agreement, Arlin Components & Hardware now offers a full range of standards compliant DIN rail terminal blocks from Dinkle International.

Exair has added a new smaller 1/8 NPT model to its range of siphon-fed atomising nozzles suitable for integration into tight spaces within machines and processes.

Mounted on industry-standard TS35/32 DIN rails, these terminal blocks are designed to provide secure connections that survive industrial environments, including high tolerance to variations in temperature and pressure, as well as high levels of shock and vibration. This makes them ideal for industrial power distribution in switchboards, on control panels and in machine building applications. The Dinkle range of DIN rail terminal blocks offers a choice of terminations to suit different applications. These include screw terminals, spring clamps, push-in terminals and stud terminations, with different ranges capable of accommodating wire sizes from 0.5 to 240mm2. A full set of accessories is available to complete each installation, including marking blocks to provide clear identification of each terminal in highdensity applications and partition plates and end brackets to ensure clearance

distances between different terminal blocks and maintain secure mounting on the DIN rail. In addition to supplying the full range of Dinkle DIN rail terminal blocks and accessories, Arlin also offers full technical support, including customised DIN rail terminal block assembly, together with panel building and cable harness design. Dinkle terminal blocks carry an array of safety approvals, and are compliant with IEC60947 and UL1059 standards. All materials are compliant with RoHS and REACH environmental standards. Arlin Components & Hardware 1300 362 191 arlin.com.au

MOISTURE CURING ADHESIVE SEALS UNDER WATER Available now from Pack King, Sub Aqua is a high-tack adhesive and sealant that quite literally works both in and under water. Billed as “the tradie in your toolbox”, this versatile adhesive cures using moisture from the air or from direct contact with water. It bonds quickly, but after 48 hours Sub Aqua cures to a rubber-like consistency (Shore A55). Yet it remains flexible, so it can accommodate movement and so can be used to join almost anything to almost anything. It is non-flammable, and does not contain isocyanate, solvent or silicone. However, as it is an MS polymer (or silylmodified polyether) it is not suitable for direct food contact. Applications include sealing leaking vessels or roofs, fixing broken pavers or expansion joints, and sealing pipe joints. And Sub Aqua can be applied directly to any surface without the need for elaborate

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cleaning – just remove loose debris. It enables up to 20kg of stone, metal, wood, many plastics to be fixed directly to a wall, ceiling or floor. Sub Aqua is available in black or white, in a standard 290mL cartridge for use in a handyman's cartridge gun. See it in use by scanning the QR code below. Pack King 03 9720 0425 www.packking.com.au

Siphon-fed atomising nozzles need no liquid pressure and can be used with gravity fed liquids or lift liquids from a siphon height as high as 914mm (36in). They combine liquid and compressed air to create a mist of atomised liquid that can be easily adjusted to meet the needs of the application. Available from Compressed Air Australia, Exair’s siphon-fed atomising nozzles can coat, lubricate, cool, treat and paint a variety of products using compressed air and liquids with viscosities up to 200cP. When used with water, the nozzles offer an efficient way to evenly cool hot items in automated processes. The stainless-steel nozzles are durable and corrosion resistant, and are available with a variety of flow patterns and rates. Models for pressurised liquids, internal mix, external

mix, quarter and half-inch atomising nozzles are also available. Patented no-drip versions to conserve valuable liquids and improve product finishes round out the complete product line. All models are CE compliant, adjustable and come with a 5-year warranty. Compressed Air Australia 1300 787 688 www.caasafety.com.au

SENSORS AND GAUGES COVER INDUSTRIAL FLUID DEMANDS Mouser Electronics is now stocking a new range of sensors and sensing solutions for the global automotive and industrial markets following the conclusion of a global distribution agreement with Amphenol SSI. Products include pressure sensors and gauges, drum liquid level gauges, and combination temperature and pressure gauges. The Amphenol SSI P51 Pressure MediaSensor and P61 Pressure and Temperature MediaSensor families are micromachined sensors suitable for measuring both harsh and benign media in a variety of automotive, industrial, and commercial applications with superior accuracy.

four-digit display.

P51 family devices are available in absolute, vented gauge, or sealed gauge conventions, and measure pressures from 3 to 7500 PSI, whereas P61 family transducers and transmitters are available in absolute and sealed gauge configurations, and measure pressures from 100 to 3000 PSI.

Digital Fluid-Trac devices are noncontact continuous drum liquid level gauges based on ultrasonic technology. The gauges include a liquid crystal display (with 4-20mA output available) and are designed for use on standard 13-, 30-, and 55-gallon vertical drums storing a wide variety of media such as water, wastewater, motor oil, hydraulic fluid, and diesel fuel.

The MediaGauge family comprises three stand-alone battery-operated digital pressure gauges, each containing a piezoresistive pressure sensing element, signal conditioning for temperature and calibration, a stainless-steel input port, and a

MediaGauge devices offer a range of accuracies, media isolation, user functions, and output capabilities for applications such as refrigeration, process control, fuel cells, pumps, hydraulics, pneumatics, compressors, and agriculture.

Mouser Electronics +852 3756 4700 au.mouser.com

FEBRUARY / MARCH 2020

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PRODUCTS

TRY OUT DRIVE CONFIGURATION SOFTWARE FOR FREE For a limited time, Control Logic is offering ABB’s virtual commissioning software for variable speed drives free of charge. The software will allow automation systems and machine developers to save time, reduce risks and increase engineering productivity. ABB Drive Composer software allows developers to quickly and accurately simulate real-world variables, sensors and feedback loops, removing the need for lengthy commissioning, long execution times, and costs associated with onsite presence.

operators or to test solutions to improve productivity.

Virtual testing and simulation early in an implementation project is proven to reduce costs by 25%, minimising engineering time in preconfiguration, dimensioning and programming drives. Early validation of the complete automation system and energy consumption means there are no surprises.

“Integrators can test design concepts, save engineering and commissioning time and derisk projects, whereas machine operators can improve training and test configuration changes offline.”

It also allows users to create a safe space to deliver training for machine

“ABB’s virtual commissioning can provide benefits at every stage of the automation lifecycle,” says ABB Design Manager Jarkko Lalu.

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

LASER SCANNER IS DESIGNED FOR DYNAMIC MEASUREMENT Available now from Bestech Australia, the Micro-Epsilon scanControl 30xx/ BL laser scanner is designed for dynamic measurement applications that demand high resolution and accuracy. This laser scanner is ideal for process automation tasks, but can also be used in production, process monitoring and quality control. It incorporates a high dynamic range feature that provides additional exposure and control features for generating accurate measurements on challenging surfaces. The scanner is available with a measuring range of 25 and 50mm along the laser line with a capability to measure up to 5.5 million points per second and generate up to 2048 measuring points per profile. This translates to extremely fine x-axis resolution of 12µm, which is ideal for measuring heterogenous surfaces. The sensor also offers a high measuring speed of 10kHz for dynamic and high-speed measurement applications. The data output from the scanControl 30xx/BL is available via Ethernet or RS422 interfaces. And there is an optional gateway to enable integration with other popular industrial communication interfaces such as Profinet, EtherCAT or

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Ethernet/IP industrial control systems. The scanControl 30xx/BL is also available with blue laser technology. The blue laser diode generates short-wavelength laser light, which hardly penetrates the objects. This provides advantages in some measurement applications particularly when measuring organic materials or objects with reflective surfaces. Micro-Epsilon scanControl laser profile scanners from are regarded as one of the highest performing laser profile scanners due to their superior accuracy and measuring rate. They are also compact and can be easily integrated in industrial environments and applications where space is limited. Bestech Australia 03 9540 5100 www.bestech.com.au

SQUARE WASHERS PROVIDE IMPROVED LOAD DISPERSAL Boker’s produces nonstandard and customised square and rectangular washers and spacers that provide secure fastening, high turn resistance and even load distribution - even in the tightest clearances. The square and rectangular washers are manufactured from a wide range of materials, with a wide choice of bolt and ID sizes, and in OD sizes up to 305mm (12in) square. Thicknesses range from 0.127 to 4.8mm (0.005 to 0.190in). “Like round washers, square washers are often used to distribute torque loads in secure fastening applications,” said Chuck Kersey, Assistant Sales Manager. “But precision stamped square and rectangular washers offer the added advantage of being able to work in more restricted spaces and can be used to provide edgeto-edge contact to resist turning.” Square washers are also widely used as shims, separating the bolt crown from the load being anchored, reducing the likelihood of deformation when tightening, and helping to keep joining surfaces undamaged. This bushing or packing approach is often used in the construction industry or to act as a force-countering support in fastener rods and complex part profiles. Square and rectangular washers are increasingly used as higher-performance alternatives to round washers in applications subject to vibration. These range from industrial machinery to aerospace and from washing machines to

automotive applications. The square washer effectively expands the diameter of the bolt’s head, thereby improving load dispersal and turning resistance. This helps to maintain fastening integrity, protecting and prolonging the life of connected parts. Boker’s square and rectangular washers are custom produced to order in short, medium and long runs with fast delivery and minimal tooling costs. 3D prototypes are available. Options include more than 2000 metallic and nonmetallic materials, including low-carbon sheet steel, various spring steels, stainless steel, aluminium, brass, and copper. Metal finishes include black oxide, nickel and zinc. Boker’s +1 612 729 9365 bokers.com

ELECTRIC CHAIN CUTTERS ARE SAFER AND MORE DURABLE Enerpac reckons its new ECC series electric chain cutters are a safer and more durable option for swiftly cutting through high strength industrial chain. The cutters not only outlast angle grinders or saw blades due to their highly durable blades, but they also incorporate an enclosed, transparent safety guard, protecting the operator’s hands from potential injury while allowing them to monitor the cutting process, for optimum levels of safety and precision. The ECC-series cutters are available for either 120 or 230V operation, and can handle material hardness up to 43 HRc (Rockwell measure), including chains up to grade 80 with up to 32mm diameter, for industries including manufacturing, mining, rigging, materials handling, transport, oil and gas and marine.

Weighing in at 48kg, the ECC chain cutters are capable of producing up to 52.9 tons of force driven by a radial pump and powered by an electric motor. They feature a lifting handle and eyebolt to enable easy positioning and transportation. A doubleacting cylinder improves user control and reduces jamming of the tool. Enerpac 02 8717 7200 www.enerpac.com

FEBRUARY / MARCH 2020

PRODUCTS

INDUSTRIAL SCANNER SPEEDS UNATTENDED DATA CAPTURE Datalogic has developed a novel industrial scanner for use in unattended data-capture systems. The AV500 is a 2D image-based reader that can be used in a wide range of logistics, transport, distribution, retail and airport applications without compromising on accuracy.

reading attempts are no longer needed, because this powerful scanner covers a large area within a single image,” says Svetal. “Additionally, the variable dynamic focus of the optical system increases the working depth of field of the camera, and its toggle mode provides variable focus for applications without the need for distance input, reducing overall system costs without sacrificing performance.”

“Advantages of unattended data capture solutions include improved accuracy and speed, improved costefficiency, reduced errors, faster turnaround times and reduced frustrations with paperwork or tedious tasks,” says Mike Svetal, Senior Product Manager, Datalogic.

The rugged scanners come with IP65 rated metal enclosures, suitable for harsh environments with operating temperatures from 0 to +50°C. In-built active cooling maintains optimal processor performance and ensures a long lifecycle, even in the most extreme operating environments.

“Datalogic’s new AV500 scanner enables unattended data capture to function to the highest levels of precision and efficiency, due to its industry-leading high-resolution 5Mpixel sensor, image acquisition at 32 frames per second, dynamic or adjustable focus, and multiple lens options,” he adds.

The AV500 scanners incorporate Datalogic’s patented PackTrack technology, which allows parcels to be accurately scanned, even at high speeds, with distances as little as 100mm between objects.

“The AV500 means that multiple

“PackTrack technology ensures the

precise assignment of labels to the right parcels, no matter the shape of the object. By incorporating this into the reading station, Datalogic can provide accurate, error-proof object sorting in real time, with a conveyor loaded to maximum capacity,” says Svetal. To aid systems integration, the scanners have been designed with an intuitive, multi-language interface for simple installation and configuration. They are fully compatible with WebSentinel Plus for real-time performance monitoring.

The scanners can be interfaced directly with Profinet and Ethernet IP enabled PLCs with two Ethernet TCP/IP and two serial communications interfaces. SyncNet Technology with Master/Slave allows enables a simplified way to network multiple devices in a solution with a single interface. Datalogic 03 9558 9299 www.datalogic.com

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COMMUNITY

CHARITY GALA ROUNDS OFF BIG YEAR FOR AMAZE On Friday 25th October 2019, SEW-Eurodrive held one of its largest fundraising events of the year, its annual Charity Gala in aid of Amaze. With a raft of generous donors and more than 200 guests who dug deep on the night, the event along with smaller events throughout the year raised in excess of $58,000. The funds will support Amaze in helping autistic people and their families.

(L to R) Andrew Mansour, Chairman of the Board, SEW-Eurodrive; Robert Merola, Mananging Director, SEW-Eurodrive; Fiona Sharkie, CEO Amaze; and Warren Bebbington, Chairman of the Board Amaze

Held at Melrose Receptions and hosted by Michael Christian, the theme was “Carnival”. The night featured the rhythmic sound of Brazilian drums and an exciting display of authentic Brazilian

Capoeira dancers who flew through the air with somersaults and spins, followed by an entertaining Samba dancing show. Amaze is incredibly grateful to all those who showed their support on the night and throughout the yearly events. SEW-Eurodrive has locked in a number of fundraising events for 2020. Stay tuned for more information on this year’s Golf Day in May and Charity Gala “Disco” themed event to be held in October. To subscribe, attend an event or to become a donor, contact events@sew-eurodrive.com.au.

GAS GIANT SUPPORTS KIDS' CANCER ORGANISATION BOC New Zealand has set up a new national corporate giving partnership with Child Cancer Foundation. BOC’s staff across New Zealand will rally behind the Child Cancer Foundation through an exclusive programme of fundraising and volunteering initiatives in 2020. John Evans, BOC South Pacific Managing Director, says that BOC is proud to support the inspiring staff and volunteers at Child Cancer Foundation who provide vital, personalised support to hundreds of families throughout their cancer experience. “For more than 40 years, Child Cancer Foundation has supported families across

New Zealand. With three children being diagnosed with cancer each week in New Zealand, BOC is committed to helping this important organisation continue and expand its work.

families and friends. Their pay for the hours taken will be donated to the Child Cancer Foundation. This will run alongside other event sponsorship, fundraising and volunteering opportunities.”

“BOC and our staff are incredibly passionate about supporting the communities where we work and live, including families and children and look forward to working with the Child Cancer Foundation as we launch an exciting programme of activities in 2020.

Robyn Kiddle, Chief Executive Officer at Child Cancer Foundation added: “We are delighted to welcome BOC New Zealand on board as a business partner. Child Cancer Foundation doesn’t receive any government funding and we rely entirely on our supporters such as business partners and donors to support children with cancer and their loved ones.”

“This will include our Hero Time initiative that encourages staff to take 2-8 hours of annual leave to spend with their

“BOC has a wonderful reputation of

Robyn Kiddle and John Evans

supporting charitable causes and we see this as the beginning of a long and meaningful relationship. We’d like to sincerely thank BOC New Zealand for their support and look forward to working with them in 2020.”

CENTENARY CELEBRATIONS CHEER CHILDREN’S CHRISTMAS CHARITY Staff in the offices of NCH Australia spent time in the run-up to Christmas packing toys into 100 shoeboxes as part of the company’s NCH Cares 100 years celebrations.

“We just loved the idea of being able to provide a smile for kids at Christmas time,” said Caryanne Cleevely, Marketing Manager of NCH Australia.

NCH celebrated its centenary during 2019, and decided to commemorate the milestone through its NCH Cares programme, which is run across 55 global locations with the goal of contributing to 100 not-for-profit organisations by the end of the year.

Operation Christmas Child sends a shoebox filled with Christmas gifts to children in developing countries. Each box contains something to wear, something to play with, something for school, something special and of course, something to love.

After donating to the Buy-a-Bale programme to help Australian farmers suffering through drought, the Australian staff wanted their second project to have a holiday theme.

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NCH staff in Australia spent a day carefully preparing 100 boxes for 100 kids in developing countries throughout the Asia Pacific region. Carefully choosing what to put in each box based on the child’s age, they even

included personal notes to the kids. “Packing the boxes makes you really think about these kids. What would they really love, what would make them really happy this Christmas? It reminds you of what the holiday season is really about,” said Cleevely. With 100 lovingly packed Christmas boxes

now on their way to the kids, it’s smiles all around at NCH Australia, proving at Christmas time it really is better to give than to receive. NCH Asia 02 9669 0260 www.nchasia.com

FEBRUARY / MARCH 2020

COMMUNITY

HYDRAULICS SPECIALIST KEEPS FIRIES ON THE JOB WITH FREE HOSE FIXES

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Hydraulink Port Macquarie Director Simon Bell, right, and Hydraulink technician Andre Bouwer, left, with one of Lake Cathie Rural Fire Brigade’s trucks after they had repaired the rear water pressure hose

Late last year, while NSW battled one of the worst bushfire seasons on record, the community-minded Hydraulink Port Macquarie branch came to the aid of local firefighters to repair their broken hoses, so they could continue to protect the community. Blackbutt Engineering, which operates as an authorised Hydraulink dealer in Port Macquarie, has been repairing hoses completely free of charge for the Lake Cathie Rural Fire Brigade and Lake Innes Rural Fire Brigade. “These firefighters are going above and beyond the call of duty to protect families and their homes in a time of crisis. Being able to provide them with any amount of assistance was highly rewarding,” said Simon Bell, Director, Blackbutt Engineering.

that it could keep helping in the efforts to contain and manage the bushfires in local areas. Lake Cathie Rural Fire Brigade was highly appreciative of the service and posted to its social media pages, “Huge credit to Simon and the Boys at Blackbutt Engineering & Hydraulink Port Macquarie enthusiastically repairing our pumper live reel free of charge this morning. Absolute legends! Thank you.” For the Lake Innes brigade, Hydraulink efficiently fixed five hoses with holes in them, to get the firefighters ready for one of the worst predicted fire days the very next day.

For the Lake Cathie brigade, Bell and tradesman Andre Bouwer determined that the fire engine’s pumper live reel (the hose at the rear of the truck) had a leak on the reel end of the water pressure hose.

The Lake Innes Rural Fire Brigade also greatly appreciated the assistance, posting on social media, “A big thanks to Simon and the awesome team at Blackbutt Engineering & Hydraulink Port Macquarie. The guys have donated their time to make some emergency repairs on our firefighting hoses.”

The two trained hydraulic technicians got to work promptly and repaired the leak, to get the fire truck back on road as quickly as possible, so

Hydraulink 1300 36 37 34 www.hydraulink.com.au

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FORTHCOMING EVENTS

WHY IS IT SO? Explaining design innovations from everyday life you may have missed. The pen lid While you may have attempted to whistle through your pen lid either at school or in the office, this isn’t the function of the hole in the top or why it was introduced. It did, however, come about because of our tendency to put pen lids in our mouths, and was designed to stop children in particular from choking should they accidentally swallow it, with the hole preventing suffocation. The can ring-pull The primary function of the ring-pull on a can of fizzy drink is to open it, and that’s all right? Wrong. The reason there is a hole in the ring pull isn’t just to allow more purchase when opening it, it was actually designed and implemented to turn around and double up as a straw holder so you can enjoy your drink with greater ease. That odd piece of fabric with an item of clothing How often do you get a new shirt or blouse and it comes with a puzzling square of spare fabric? Many of us live our lives believing this is used to replace any holes, rips or tears in the clothing and this is its secondary use. However, you might not have realised it’s actually there so you can test washing the fabric with your chosen conditioner and temperature to ensure it isn’t damaged before you wash the item of clothing itself.

Wooden clothing hangers Another design innovation that may no longer be in wider use, but the original wooden clothing hanger was made using Cedarwood. Why? Cedarwood was a natural bug repellent and helped protect clothes from hungry moths.

Which is the most abundant element on earth?

2 What was the original name for the Australian dollar when plans were announced for it to replace the Australian pound in February 1966? 3 … and who was the federal treasurer who insisted on the name change to the Australian dollar? 4 Which rocking Nobel Prize winner was born Robert Allen Zimmerman on 24th May 1941 in Duluth, Minnesota, USA?

13-15 May 2020, Sydney Showground www.advancedmanufacturingexpo.com.au

The car fuel gauge When we start out driving we may spend a lot of time looking at our car fuel gauge, usually due to it being illuminated a lot of the time. We also spend as much time when first driving a car pulling up to the pump and then realising the fuel cap is on the opposite side. What you might not have noticed is that the majority of cars have a little arrow pointing at the fuel pump icon to indicate which side it is situated. Computer keyboards You’re probably sat at a computer right now. Check out the F and J keys. See those two little ridged lines? They’re there so that touch typists can find their place on the keyboard without having to look. The shirt Even the simple shirt has seen innovative design developments over the years. Ever wondered about that random loop between the shoulder blades? If you don’t have your moth repellent cedarwood clothes hanger to hand, this loop allows you to hang the shirt by a peg without creasing it.

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6 And which is Australia’s tallest? 7 Which swimmer holds the record for the most Olympic medals? 8 Which Australian state is home to the Big Bogan? 9 Which iconic movie set tool was invented in 1930 by Frank Thring Sr of Efftee Studios in Melbourne? 10 How many roads must a man walk down?

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With Australian manufacturing sitting at the crossroads between growth and contraction, what better way to make a bold statement of intent than to join us in the April/May 2020 edition of Industry Update.

5 What is the world’s tallest building?

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ARBS 2020 19-21 May 2020, Melbourne Convention & Exhibition Centre

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The issue is an important one, looking ahead to the biggest shows of the year with our previews for the all-new Advanced Manufacturing Expo in Sydney, as well as the Workplace Health & Safety Show in Melbourne. We’ll also be taking our annual in-depth look at the latest Welding and Cutting Technologies, putting Pollution Control in the spotlight, and checking out the latest developments in Industrial Lighting. There’s also our annual special feature devoted to Machine Building, bringing together all the latest developments in

mechanical hardware and control and automation technologies. And in the second of our regional features, we’ll be putting Queensland’s manufacturing industry under the spotlight. Add in all our regular features on Business and Finance, Waste Management and Environmental Matters, Industry Politics, Security, and Workplace Safety, and you have a magazine that we’re confident everyone will want to read. So, make your statement and come and join us by calling Scott or Glyn about advertising on 02 9439 1288. Or send your editorial to editor@industryupdate.com.au. But be quick. The deadline is 2nd April 2020.

1 Hydrogen, 2 The Royal, 3 Harold Holt, 4 Bob Dylan, 5 Burj Khalifa in Dubai (828m), 6 Q1 on the Gold Coast (322.5m including spire), 7 Michael Phelps (28, including 23 golds), 8 NSW (at Nyngan), 9 Clapperboard, 10 42 (allegedly) ANSWERS

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Number one manufacturing

Number Number one one manufacturing manufacturing publication in Australia Number one manufacturing Circulation ofAustralia 19,233 and readership of 76,932 publication publication in in Australia publication in Australia Audited by

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Industry Update February/March 2020 Issue 112

Articles inside

FUN & GAMES

COMMUNITY

PRODUCTS

100 Years of South Australian Engineering

ARBS PREVIEW

INDUSTRIAL DOORS & SECURITY

ENVIRONMENT, ENERGY & WASTE MANAGEMENT

FOCUS ON MANUFACTURING IN SOUTH AUSTRALIA & THE NT

WORKPLACE SAFETY

ROBOTICS & AUTOMATION

AMX PREVIEW

MATERIALS HANDLING

New HQ for Vega Australia

FROM THE EDITOR

BUSINESS & FINANCE

INDUSTRY NEWS

MACHINERY

INDUSTRY POLITICS

Lapp Group Celebrates Australia

A Brief History of Compressed Air