NZ Manufacturer September 2016 by Media Hawkes Bay Limited

September 2016 Award winning supplier of SOLIDWORKS in Australia and New Zealand

www.nzmanufacturer.co.nz

10 FoodTech PackTech MHL

Preview

Manufacturing Technology How 3D printing is revolutionising manufacturing.

Smart Manufacturing How do you get a job that doesn’t exist yet?

‘Protecting’ our FTAs or Waste-to-Energy supporting remaining local systems used manufacturers? in Europe will protect our water Widely used technology routinely ignored in New Zealand claims process engineer. European technology that converts milk and meat processing plant effluent into self- contained waste consuming and energy generating plants is now available in New Zealand. Napier industrialist Ken Evans said the technology allowed milk and meat processing plants to become their own standalone waste treatment units with the added advantage of these plants using the waste so consumed as their own source of energy. As an example he cited large scale milking centres in Europe that were self sufficient in power simply because all the waste they generated was converted into electricity. He said that the era in which factories could discharge their waste in any volume or in any proportion into the public domain should have ended many years ago. It was now time to apply a readily available

continued on page 21

Around mid-July 2016, Fairfax Media raised the spectre of NZ ‘steel dumping’ claims on imports from China. The response from our Prime Minister was to play it down, whilst MBIE would not even confirm or deny whether it had received two complaints from NZ producers. Trade Minister Todd McClay, whilst in Indonesia, said it was not appropriate for him to comment politically!

of clarity compromises sound forward planning.

Such reluctance from our Government and its officials to clarify what the true situation is has been further clouded by an “out of left field” rejection of very recent exports of Zespri kiwifruit by China, because of phyto-sanitary concerns - causing Zespri to further tighten its already stringent handling protocols.

As the CEO of an Australasian company with a chain of 46 branches, I am in a position to observe the different approaches by our respective governments (and in Australia, by their States too), and the Australian aluminium industry has taken on and won several anti-dumping cases on extruded aluminium and aluminium products (like ladders and platforms).

Comments from Wellington quickly denied that the rumoured steel dumping claims had any connection with a somewhat coincidental non-tariff barrier for NZ kiwifruit. All parties, including Zespri have been very circumspect in their response, seemingly to avoid any ramping-up of retaliation from Beijing, or the prospects of compromising the planned re-negotiation by MFAT officials of the existing FTA with China (originally commencing from October 2008). Such apparent reluctance by our nation’s political representatives to be transparent to its own business sector makes for less confidence, and the absence of clarity compromises sound forward planning. Such apparent reluctance by our nation’s political representatives to be transparent to its own business sector makes for less confidence, and the absence

You may ask why does an aluminium manufacturer and fabricator enter a debate on NZ steel dumping claims? Well, it’s quite simple.

However, in NZ, whilst the highest standards of design and strength are applied to our products, the same standards (or even border inspection) do not appear to be applied to say imported aluminium ladders. And failures with imported ladders have been a common problem as have rock bottom prices, because of cheap substandard materials! We are also well aware of substandard steel pile casings not meeting standards on bridges and overpasses on the road construction south to Hamilton, and serious concerns about the strength and flexibility of reinforcing mesh. So as someone who started work serving in the steel and manufacturing industries, including fabrication, welding and erection work in steel buildings, and

continued on page 34

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CONTENTS DEPARTMENTS

ADVISORS

4 EDITORIAL

Manufacturing growth seen in construction boom.

5 6 MANUFACTURING TECHNOLOGY BUSINESS NEWS

SESOC seeks to reassure homeowners on steel mesh.

How 3D printing is transforming manufacturing. Paperless manufacturing solution reduces engineering and operation effort. Autodesk introduces portfolio for the Future of Manufacturing Why modernise control platforms?

Craig Carlyle

Is Director of Maintenance Transformations Ltd, an executive member of the Maintenance Engineering Societyand the Event Director of the NationalMaintenance Engineering Conference.

Catherine Beard

Is Executive Director of Export NZ and Manufacturing, divisions of Business NZ, NewZealand’s largest business advocacy group, representing businesses of all sizes.

9 DEVELOPMENTS

NZ Certificates in Manufacturing now available. New industry award shines light on skilled apprentices.

10 FOODTECH PACKTECH MHL Preview

SMC offers stoppers for food and packaging market. Grease improves food and beverage industry bearing performance. Rexmoi controls temperature and humidity. Easi Recycling – Longopac Bagging Solution. Thermaflo and Trepko tackle market with new agency agreement. Improving OEE: Focus on the small things. Expo – Largest in a decade! Drying solutions made to suit.

Lewis Woodward

21 COMMENT

Wages, Inflation and Productivity. By Dieter Adam, Chief Executive NZMEA.

22 PROFILE

Make the world imagine.

23 SMART MANUFACTURING

Dieter Adam

Chief Executive, New Zealand Manufacturers and Exporters Association has a Ph.D. in plant biotechnology, consulting and senior management roles in R&D, innovation and international business development.

Is Managing Director of Connection Technologies Ltd, Wellington and is passionate about industry supporting NZ based companies, which in turn builds local expertise and knowledge, and provides education and employment for future generations.

Dr Wolfgang Scholz

Is HERA Director and a Fellow of the Institute of Professional Engineers NZ.

How do you get a job that doesn’t exist yet? Automating manufacturing processes with the help of Universal Robots.

28 FOOD MANUFACTURING

How to get Asia-savvy. Cell fusion discovery could improve agricultural production. Perishable exports to US on the rise. Mass flow controller performs at high volumes. Skills help keep horticulture thriving.

30 WORKSHOP TOOLS

A Tale of Two Cutting Tools – Rotary versus Indexable. Flexibility and power with multi-process welding machines.

33 ANALYSIS

The role of welding.

35 REAR VIEW

Protecting our FTAs or supporting remaining local manufacturers?

Garth Wyllie

Is EMA’s Executive Officer, Manufacturing & Industry Groups. He is a strong advocate for the manufacturing sector. In his 20-plus years with the organisation Garth has managed a range of sector groups, with manufacturing being a key focus.

PUBLISHER

Media Hawke’s Bay Ltd,1/121 Russell Street North, Hastings, New Zealand 4122.

Manufacturing growth seen in construction boom Economic growth in the last quarter has seen the manufacturing sector playing its role.

MANAGING EDITOR Doug Green T: +64 6 870 9029 E: publisher@xtra.co.nz

CONTRIBUTORS

It’s a pretty decent result when manufacturing in the construction sector grew by 9.5 percent and long may it continue with years of building to be done and completed, especially in Auckland and Christchurch.

Dieter Adam, Holly Green, Gilbert Ullrich, Ken Evans, Adam O’Neill, Dieter Adam, David Green www.mscnewswire.co.nz

ADVERTISING

Doug Green T: + 64 6 870 9029 E: publisher@xtra.co.nz

DESIGN & PRODUCTION

It is pleasing to see that locally manufactured products like concrete, cement and glass are favoured in the construction sector and overall the volume of manufacturing sales increased by 2.8%.

Kim Alves, KA Design T: + 64 6 879 5815 E: kim.alves@xtra.co.nz

WEB MASTER

Jason Bowerman E: jason.bowerman@gmail.com

PUBLISHING SERVICES On-Line Publisher Media Hawke’s Bay Ltd

DIGITAL SUBSCRIPTIONS

Manufacturing currently has some interesting statistics:

MEDIA HAWKES BAY LTD

• 250,000 people employed. Of which 175,000 are fulltime workers.

E: info@nzmanufacturer.co.nz Free of Charge.

T: +64 6 870 4506 F: +64 6 878 8150 E: mediahb@xtra.co.nz 1/121 Russell Street North, Hastings PO Box 1109, Hastings, NZ NZ Manufacturer ISSN 1179-4992

• An increase of 20% in plant and machinery investment between 2013-2015. (stronger growth than Japan, Australia, USA and Euro.)

Vol.7 No.8 September 2016 Copyright: NZ Manufacturer is copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed, nor facts stated in the advertisements, are necessarily agreed to by the editor or publisher of NZ Manufacturer and, whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information. NZ Manufacturer welcomes your contributions which may not necessarily be used because of the philosophy of the publication.

Affiliates

• Growth sectors include machinery, food and products, beverages and tobacco and machinery. • And this is a big one $450m invested in R&D by manufacturers in 2015. Keeping up with the world to assist gain entrance to new markets.

ASIA

MANUFACTURING NEWS

NZ Manufacturer September 2016

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• $12 billion in wages into New Zealand households each year. As manufacturers maintain this momentum a stubbornly high dollar continues to challenge them along with finding the right staff for their companies. Continuing to develop markets overseas and working closely with our largest, Australia, helps to maintain this momentum. The UK exiting Brexit can work in our favour as well. Australia is currently working closely developing markets over there with trade ministers visiting each other and looking to the future. The UK is seeking trade relationships with Canada, Australia and New Zealand in the future because of the mutual regulatory financial and government processes in place which each country adheres to.

Success Through Innovation

EDITORIAL

Doug Green

BUSINESS NEWS

I have never worked a day in my life without selling. If I believe in something, I sell it, and I sell it hard. –Estée Lauder, Co-founder of Estée Lauder Companies

SESOC seeks to reassure homeowners on steel mesh The Structural Engineering Society (SESOC) says homeowners should not become unnecessarily concerned about the ductility of steel mesh in their houses. SESCOC President Paul Campbell says SESOC has been prompted to make these comments following reports in the media that a law firm is proposing a class action in relation to mesh that may not meet The New Zealand Standard. Before changes to the Building Code following the Canterbury earthquakes, many residential slabs were unreinforced. Even if slabs were reinforced, they generally used mesh that was not very ductile. Ductility, or stretch, is a critical steel property for many commercial applications, particularly multi-storey buildings. Mr Campbell says: “Obviously engineers are concerned if mesh that is below standard has been circulated and used in residential buildings. But even if the mesh is only half as good as the current Standard requires, it is still at least 10 times better than what was used in the past, and infinitely better

Commercial & industrial growth

than unreinforced slabs.

to advise whether this is significant.

SESOC and the Institution of Professional Engineers New Zealand (IPENZ), which represent the majority of structural engineers in New Zealand, are concerned that unnecessary public alarm could be generated over this issue.

“For commercial developments and

“We are concerned that people, particularly homeowners in Christchurch who have been through years of emotional turmoil already, will experience unnecessary stress.

responsible for the design should be

“In virtually all residential construction where mesh has been used to reinforce slabs, the reduction in capacity due to the mesh not meeting the required standard will be insignificant.

regular reinforcing bars, which are not

“For a small minority of homes that have been specifically designed and engineered, there may be some potential impact, but the designers of those buildings should be quickly able

still perform significantly better than

larger

residential

properties

that

have used elevated concrete floors, there may be a very small number of cases where the mesh may affect the performance of the buildings in future earthquakes. The structural engineers able to advise whether this may be significant. In many cases where the strength of the mesh may be critical, it will have been augmented with generally affected by these issues. “We believe it’s important to point out that that the mesh supplied and used since the Canterbury earthquakes will the mesh that was used in the majority of floor slabs prior to the earthquakes, even if it does not fully meet the

“We are concerned that people, particularly homeowners in Christchurch who have been through years of emotional turmoil already, will experience unnecessary stress.”

Standard.”

Employment growth

Economic output

Crime rate East Tamaki is the largest industrial precinct in Auckland with 2000 businesses and a growth rate higher than the regional average.

getba

getba.org.nz

Greater East Tamaki Business Association Inc.

www.nzmanufacturer.co.nz

NZ Manufacturer September 2016

MANUFACTURING TECHNOLOGY

Leadership is the ability to hide your panic from others. -Lao Tuz

How 3D printing is transforming manufacturing Adam O’Neill, managing director, Australia, Y Soft

The transformative abilities of 3D printing are having a profound impact on industrial manufacturing. Despite 3D printing technology having existed in some form for several decades, it is only in the last few years, as printer prices have become more affordable, that it has started to take off. New research from IDC shows the global 3D printing market will exceed US$35 billion by 2020, double the US$15.9 billion forecast for 2016. A large portion of this growth will be spurred on by manufacturing innovation in parts prototyping, and new software and services to support the industry. The growth of 3D printing in manufacturing is of little surprise. Industrial manufacturing of finished goods is expensive and time consuming. The time it takes to design, test, and manufacture can take months. 3D printing, or additive manufacturing, changes the conventional definitions and mechanisms of manufacturing design and production, delivering quicker manufacturing times, greatly reduced costs, and faster time to market. 3D printing is disrupting and transforming manufacturing in a number of key ways: 1. Increased ability production

for

local

3D printing encourages production closer to the point of consumption. For example, car manufacturers tend to outsource manufacturing of most of the main car parts: the body, engine, wheels, brakes and so on. By using 3D printing technology to design and produce prototypes of these car parts, to test and then develop the final product, manufacturers can reduce the need to outsource so many processes. This helps foster stronger local production and improves manufacturing times. Even if the unit production cost is initially higher, it will likely be offset by the saving on shipping costs. 2. More customised products 3D printing can have a positive impact on every manufacturing business, large and small. Additive manufacturing increases the level of product customisation that a company can offer to customers. Manufacturers can work closely with customers to offer greater individuality in everything from cars

to home interiors. These technologies make it possible to develop complex designs in a single unit, and therein eliminate assembly requirements. Manufacturers can also achieve geometries that are not possible with traditional mould and cast techniques. This helps manufacturers compete more effectively, even against cheaper, overseas competitors.

eliminate the need for these safety and environmental processes but, by making initial mock-ups, testing, and development faster, the burden can be lessened in this area. In addition, the lighter weight of the materials used in 3D printing can have a positive impact on fuel consumption and shipping costs compared to their traditional counterparts.

3. Improved environmental impact

4. Changing nature of business

A unique concern to manufacturing is managing chemicals, recycling dissolvers and other liquids, and the impact on the environment. With traditional plastic mould methods used in a variety of manufacturing operations, each liquid, glue, and related chemical comes with the administrative and audit tasks of documentation: safety sheets; certificates of use; recycling processes; and a working procedure that includes proper ventilation, safety wear, and storage.

3D printing is likely to have a significant impact on how manufacturers do business, particularly in regard to shifts in material costs, incremental cost calculations, and assembly line and product pricing strategies. Manufacturing is changing from a ‘subtractive process’ where material is scraped away from a base, to an ‘additive’ process that helps manufacturers use the minimum material required to fabricate a part.

3D printing does not completely

Over time, and with increased scale of adoption, the costs of parts made on a 3D printer are also likely to cost less than those completed through traditional manufacturing. It can also facilitate greater assembly line flexibility. As assembly becomes a single operation and set-up time is reduced to nearly zero, production and sales teams will be able to push through orders faster and in a greater capacity, since they can be fulfilled almost immediately. Additive manufacturing, enabled by 3D printing technology, is changing the conventional definitions and mechanisms of manufacturing design and production, with faster manufacturing times, and greatly reduced costs. 3D printing systems offer much greater opportunities for customising and for manufacturers to maximise their engagement with customers to actively co-create the final product. Manufacturers who embrace this technology are likely to be able to compete more successfully.

NZ Manufacturer September 2016

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Making promises and keeping them is a great way to build a brand. -Seth Godin

MANUFACTURING TECHNOLOGY

Paperless manufacturing solution reduces engineering and operation effort Siemens has launched Version 6.1 of its SIMATIC IT eBR software, which is at the heart of its Manufacturing Operation Management for the life sciences industries. The new version of the software enables users to easily implement paperless manufacturing solutions by offering two main features: A new web-based MBR (Master Batch Record) module which facilitates the management of key process parameters, and native integration with the Siemens automation layer (SIMATIC PCS 7 process control system and HMI systems). The new version reduces the work involved in engineering and operation, helps users to enforce standardisation and makes for a more transparent production process, thereby shortening the time-to-market. Product quality and safety are the top priorities for the life sciences industry, especially in the pharmaceutical sector. At the same time, many companies need to cut costs and increase innovation. Siemens offers a paperless manufacturing solution for enhancing

both efficiency and product quality, while at the same time bringing down risk and costs. Adnan Abdul Rahman, Head of Automation & Engineering at Siemens Singapore, said, “Manual recording methods that involve large amounts of data and batch protocols put a strain on both the user and the business as a whole. Therefore, it is imperative that companies leverage on paperless manufacturing solutions such as the SIMATIC IT eBR to increase the efficiency of pharmaceutical manufacturing processes and to gain a competitive advantage.” Fully integrated communication is established between the automation level and manufacturing IT. This enables complete electronic recording

and documentation of quality-related production data, while eliminating time-consuming manual procedures and paper-based batch reports. SIMATIC IT eBR 6.1 facilitates the implementation of the paperless manufacturing. With a new Master Batch Record module and a “Project Startup” package, it provides a list of out-of-the-box deliverables to speed up project execution time. In addition, it offers native integration with Siemens PCS 7 Batch and new access to electronic work instruction lists embedded in SCADA/HMI clients. By accelerating the design, execution, review and release of regulated production processes and electronic batch records (EBRs), SIMATIC IT eBR helps both enhance product quality

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and lower production costs. Adnan added, “In Southeast Asia, especially in countries such as Singapore, Malaysia and Thailand, we are seeing increasing interests in paperless manufacturing solutions from the pharmaceutical sector. We look forward to working with our customers to identify and implement the best solution for their needs.” SIMATIC IT eBR 6.1 is based on the engine of the former XFP product developed by Elan Software Systems and acquired by Siemens in 2009. It combines 30 years of proven experience in the pharmaceutical industry and native integration with the rest of the Siemens portfolio for regulated and non-regulated industries.

NZ Manufacturer September 2016

MANUFACTURING TECHNOLOGY

Markets come and go. Good businesses don’t. -Fred Wilson

Autodesk introduces portfolio for the Future of Manufacturing

With the world of manufacturing undergoing major disruptions brought on by new market forces and technologies, Autodesk has unveiled its unified portfolio of solutions for additive and subtractive manufacturing. The portfolio lets manufacturers take advantage of technology disruptions and improve competitiveness by creating higher quality products in less time with lower costs. The new solution brings together industry-leading products historically offered from Autodesk, Delcam, Netfabb, Pan Computing and Magestic Systems—including HSMWorks, Inventor HSM, Fusion 360, FeatureCAM, PowerMill, PartMaker (now included in FeatureCAM), PowerShape, PowerInspect and Netfabb—into one complete set of hybrid manufacturing

solutions. Autodesk has long been a leader and innovator in 3D design, engineering and the technologies that expand the applications of industrial 3D printing, no product is really complete until it’s realised through physical manufacture. Autodesk has also become a leader in technologies that expand the applications of industrial 3D printing. Now, they are truly integrating the design, make and use phases of product development. This new set of solution goes big on the ‘make’ component— equipping manufacturers with all the software they need to go from digital design to real-world product. The portfolio spans computer aided manufacturing (CAM), additive manufacturing, composites, robotics fabrication, factory layout, inspection and modeling. It enables customers to solve complex manufacturing challenges and seamlessly connect design to machining. Within the portfolio offerings are cloud-connected capabilities designed to help users experience the benefits of a more cohesive manufacturing workflow and invest more time in product development. Cloud-capabili-

ties give customers improved support for global manufacturing operations with universal access to software and data, and the cloud also enables fast and frequent software upgrades.

What’s in the Autodesk portfolio for additive and subtractive manufacturing? • Autodesk HSMWorks: A fully integrated CAM solution for SOLIDWORKS, allowing users to get up to speed and become productive within minutes using familiar tools and workflows. • Autodesk Inventor HSM: Helps CNC programmers, designers and engineers rapidly produce machined parts designed in virtually any CAD system. • Autodesk 2017 CAM Products: With offerings for a multitude of advanced manufacturing applications, these new products combine the heritage of industry leadership in CAM software from Delcam with Autodesk’s 3D design and manufacturing prowess. Solutions include FeatureCAM for automating CNC programming; PartMaker for precision part manufacturing with Swiss-type lathes; PowerMill for

programming the most complex molds, dies and other components; PowerShape for preparing complex models for manufacture; and PowerInspect for inspection in every environment. • Autodesk Netfabb: All the software you need to reduce costs, increase efficiency and improve part performance in additive manufacturing and 3D printing. • Fusion 360: The centerpiece of Autodesk’s cloud-based product innovation platform, Fusion 360 combines CAD, CAM and CAE in a single package. It allows users to take their designs all the way to production with included 3D printing capabilities as well as HSM powered toolpath technology for 2 through 5 axis milling machines, turning centers and waterjets. This new integrated portfolio from Autodesk brings together technology Autodesk has been growing and investing in across the full manufacturing spectrum. This combination of solutions makes modular and scalable manufacturing solutions available to manufacturers of all sizes.

Why modernise control platforms? As products age and give way to new technologies, the need arises to proactively plan and manage the transition from existing equipment to leading-edge products and technologies Automation components, software and systems represent major capital investments that are instrumental to the success of industrial operations. In the face of rapidly changing markets and technologies, the industrial enterprise must keep step to remain competitive. Today’s contemporary automation systems offer unprecedented advancements in performance, flexibility, and security, with the potential to provide a competitive edge. Technology continues to advance at a rapid rate, accelerated by the emergence of the Industrial Internet

of Things and advances in enabling technologies, including data analytics, remote monitoring and mobility. Rockwell Automation continues to incorporate these latest technologies in control and automation platforms and although the PLC-5 programmable logic controller has been a valuable part of their portfolio for more than 30 years, no technology can last forever. Modern control systems provide a higher level of integration, driving improved asset utilisation, increased system flexibility and easy access to information. The high performance, Rockwell Automation ControlLogix platform delivers the capabilities to converge production disciplines (discrete, motion, process and safety), including extreme environments and high availability applications, into an

NZ Manufacturer September 2016

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integrated plant-wide architecture enabling a connected enterprise. Information shared between Information Technology (IT) and Operations Technology (OT) across a secure network enables: • Greater production visibility, for quicker response to customer demand • Higher profit margins through improved inventory management, cycle times and quality control • Improved capacity and asset utilization, leading to greater Overall Equipment Effectiveness (OEE) • Regulatory compliance and reduced exposure to security risks Migrating to the ControlLogix family of programmable automation controllers (PAC) provides the platform to leverage advancements in technology, including

improved access to information, more informed b u s i n e s s decisions, faster performance for more throughput and increased memory. This platform improves ease-of-use and enables scalability via a common control engine in a single development environment that helps eliminate the need for multiple discrete control systems. Whether a decision is made to migrate all at once or use a phased approach, Rockwell Automation provides migration tools for hardware selection, code conversion and hardware conversion that eliminate the need to modify any field device wiring.

DEVELOPMENTS

If people like you they’ll listen to you but if they trust you they’ll do business with you. -Zig Ziglar

New industry award shines light on skilled apprentices Thomas Forbes of Napier-based steel fabricator Red Steel took out Steel Construction New Zealand’s (SCNZ’s) inaugural Apprentice of the Year Award.

months. Finalists were invited to a face-to-face interview with the four-person judging panel, after which they were put through their paces during a practical skills exercise.

The Award was announced during a gala dinner following SCNZ’s AGM and conference in Napier on September 16th. Mr Forbes was presented with a trophy, certificate and $1,000. Runner up Louie Lumampao of John Jones Steel received a highly commended award and $500.

“We had two excellent finalists that highlighted the impressive ability of apprentices within our industry. The quality of both of their practical exercises was extremely high, which made it particularly difficult for the judging panel to determine the overall winner,” says judging panel spokesman Grant Simpson, Weldwell.

The SCNZ Apprentice of the Year Award, in association with Weldwell, acknowledges people whose skills, drive and willingness to learn and work hard has helped them to achieve outstanding outcomes. It recognises well-rounded apprentices who demonstrate not only talent in steel fabrication, but display traits important to the industry – commitment, innovation and ability. The judging process spanned two

The Award is part of SCNZ’s work to promote careers and training in the structural steel sector. “Over the last 10 years, New Zealand’s steel construction industry has undergone a renaissance and today its share of the New Zealand multilevel construction market is approximately 50%, and growing. This is not only thanks to the many beneficial properties of structural steel, but also

Skills Highway changing workplaces Smarter, safer, prouder kiwi workplaces feature in new Skills Highway success stories, showing the impact and effectiveness of investing in improving literacy and numeracy skills in the workplace. Whangarei’s Carter Holt Harvey Woodproducts and South Auckland’s Pacific Homecare showcase the difference literacy training has made to their businesses and the wider community. “This programme helped me to build my self-esteem and my confidence. I’m now looking forward to going to MIT to study more about the English language. This course has given me the courage to go further,” says Pacific Homecare support worker Tulai Luamanu. Improving adult literacy is an urgent challenge in New Zealand, with low literacy and numeracy affecting the home and working lives of hundreds of thousands of adults. Skills Highway is working to turn this around with the help of employers committed to improving the literacy, numeracy and communication skills of staff. Run by the Industry Training Federation (ITF) in partnership with the Tertiary Education Commission (TEC), Skills Highway connects employers with funding, resources and training providers to help create safer, happier, more productive workplaces. “Our most important resource is

our people,” says Doug Hallberg, Whangarei Site Manager from Carter Holt Sawmill. “If we invest the training in our people, we’ll get a return every single time.”

Thomas Forbes.

to substantial investment by local firms in new technologies and management systems, which are revolutionising the construction industry worldwide,” says SCNZ Manager Alistair Fussell. “Importantly, a steel structure is the

New Zealand Certificates in Manufacturing now available

Firms involved with Skills Highway report increased confidence and engagement, greater health and safety awareness, improved workplace culture, and competence on the job.

Manufacturing businesses across the country will now able to effectively handle operational issues and coordinate manufacturing operations through the New Zealand Certificates in Manufacturing qualifications launched last month.

“I’d like to see myself as a shift supervisor and go from there,” says Jamal Uiese from Carter Holt. “I wasn’t really one to learn from a book, but it’s made things a lot more interesting, and I can see a better future.”

The new manufacturing suite of qualifications has been designed to provide employees with the knowledge and skills to work safely and effectively in any manufacturing environment.

Hamish Crooks, Pacific Homecare Chief Executive, says English is a second language for 90% of his staff. “It’s a great workforce. Multi-lingual, multi-talented, and now it participates more than ever.”

The qualifications were developed in partnership with the manufacturing industry and the industry training organisation Competenz. Members of the manufacturing industry played a leading role in ensuring the new qualifications are fit-for-purpose for all New Zealand businesses.

The ultimate benefit is better health outcomes for their elderly and disabled clients. Skills Highway is a government funded programme supporting firms to deliver specialised literacy and numeracy support to workers and industry trainees. It delivers better business performance, and better working lives. We want to hear from more employers who want to build safer, smarter workplaces. www.skillshighway.govt.nz www.itf.org.nz

product of a highly skilled team, and each team member is essential to the overall success of the project. The structural steel sector boasts a wide variety of careers, and each offers challenging and rewarding

“The qualifications were developed through industry consultation to meet the needs of the employer and their employees,” says Mathew Vandy, Competenz Industry Manager for the manufacturing sector. “The National Certificates in Manufacturing qualifications no longer related to the requirements of the industry. These new qualifications have a suite of

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options that are very relevant to manufacturing businesses.” Training in the new qualifications allows for a more efficient and streamlined process. “Through the consultation process, we were able to narrow down the scope of the qualifications so it was more focussed, and people would Ahave a better understanding of it,” says Rick Smith, Operations Manager for Patience & Nicholson (NZ) Ltd and member of the industry governance group working with Competenz to design the new qualifications. “There’s an increased focus on health and safety which is crucial for the industry. The new qualifications are more about performance and on-the-job tasks.” Strong industry representation has helped the Competenz team to appreciate the technical skills required. “It gives learners and employers the flexibility to choose graduate outcomes that are relevant to their business,” says Vandy. The learning materials for the new qualifications are currently being adapted for online and will be available in early 2017.

NZ Manufacturer September 2016

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11-13TH OCT 2016

HEADING The shortest way to do many things is to do only one thing at once. -Samuel Smiles

Toilets

It’s easy to make a buck. It’s a lot tougher to make a difference. -Tom Brokaw

FOODTECH PACKTECH

3001 A & D Weighing

1051 Dematic Pty Ltd

3035 Mapei NZ Ltd

1015 Security Wholesale Limited

3119 Accolade Packaging Ltd

3092 Dexion NZ Ltd

2101 Accupak

2100 Drying Solutions Ltd

2014 Massey Institute of Food Science and Technology

2066 Selpak Automation Pty (NZ) Limited

2023 Ace Doors Ltd

3117 Dynamic Inspection Limited

1028 Master Equipment Limited

1010 Showcase Workshop

3178 Advanced Packaging Systems

3094 Dyno NZ

2047 MatMan Washing Soultions Ltd

3044 SICK NZ LTD

2037a AIP Austalian Institute of Packaging

2124 Dyson Appliances Ltd

3091 McLaren Stainless

2043 Sign node

3125 Air Solutions

3038 Easi Recycling

3124 Mercer Stainless Ltd

2078 Sika (NZ) Ltd

2025 Allied Lubricants

2088 Ecowize New Zealand

3005 Miltek NZ Ltd

2038 Simpro Handling Equipment

2091 Allproof

3176 Engineering & Compressor Services

3020 Minipack Quickshrink Ltd

2004 SMC Pneumatics (NZ) Ltd

2150 Altex Coatings Ltd

3160 Enpac Packaging

2082 MM Kembla NZ Limited

1015 Soar

3034 Amseal Closure Systems Ltd

2087 Envirowaste Services Ltd

3143 Southquip Industrial

3142 APC Technology

2046 MPM Marketing Services - Castaway food Packaging

2059 EPNZ Ltd

3149 Apex Environmental

3108 EQM Industrial

3010 Apex Printing & Packaging Eng.

3166 Mulcahy Engineering Ltd

1036 Equiptec

3096 Apollo Projects Ltd

1006 Multirack Storage Solutions

2001 ES Plastics

2057 Applied Instruments Group Ltd

3016 Multivac NZ Ltd

3000 Eurotec Ltd

2037b APPMA

3157 Munters Pty Ltd

3019 Fabri-Cell

2020 Ash Air

2080 NDA Group

3133 Ferrostaal NZ Limited

3155 Aurora Process Equipment

3120 Ngaio Diagnostics Ltd

3006 FF Instrumentation

3067 Autoline Automation

1058 Northern Forklifts Ltd

3129 Flexco (Aust) Pty. Ltd

3179 Balluff New Zealand Ltd

3065 NSK New Zealand Ltd

3007 Flight Plastic Packaging Ltd

3167 / Beijing Xinmei International 3156 Exhibitions Co Ltd

3106 Nukor Industries

2075 Food Processing Equipment

3127 Nuplex Industries Ltd

3136 Food Tech Solutions Ltd

3043 NZ Medical & Scientific Ltd

2086 Foodquip

2003 NZIFST

2032 Forbes Packaging

3039 O-I New Zealand Ltd

2030 Ford

2026 Oil Imports Ltd - Total lubricants

3085 Fort Richard Laboratories Ltd

2058 Omron Electronics

3111 Gala Solutions Ltd

3045 Oritain Global Ltd

1041 Gaprie

3040 Pac Food Pty Ltd

3031 Grain Tech Engineering Ltd

3032 Pacific Hygiene Ltd

3064 H D Process NZ Ltd

3180 Pack Fresh Limited

3165 Hayley Media Ltd

2031 Packaging Council of NZ (Inc)

3112 HCD Flow Technology Ltd

3018 Packaging Plus

2064 Heat & Control Ltd

2081 Pak World Ltd

3041 Tronics NZ Ltd

3099 Henkel NZ Ltd

3132 Panther Technologies

3184 Tru-Bilt Industries Ltd

2009 Hunter Filling Systems Ltd

2007 Plastics New Zealand Inc

3060 Ulti Group Ltd

1055 Hurricane Products Ltd

3097 Plummer Compressors Ltd

3063 Ungerer Australia Pty Ltd

3118 Hygiene Technologies

3115 Powder Systems

1083 Uni-Pak

3163 Idas group

3187 Presco Group

3110 Universal Packaging Ltd

3057 IFM Electronic

2008 PRIDE IN PRINT Awards

3087 UV Solutionz Limited

3177 IFP Group

3130 Propac Industrial Pty Ltd (NSW)

3028 Vemag NZ Ltd

3185 InControl

2063 PSP Building Brands & Plastic Sheets

3037 Viking Conveyor

2122 Industrial Lubricants & Services Ltd

2013 Reclaim Ltd

2076 Viscount Plastics Ltd

2110 Inspection Systems (NZ) Ltd

3004 Regal Packaging Ltd

1068 Voice Interface Design

2049 Integrated Packaging Ltd

1057 RetailQuip

2011 VPNZ

3088 Interfood Read Group Ltd

2022 Reynolds Group Ltd

3071 Wadding Solutions

3105 ITW Zip-Pak Australia

2027 Rhima New Zealand

3073 Walls Machinery Pty Ltd

3153 JL Lennard Ltd

2043 RML Engineering Ltd

3033 Warehouse Stationary

1033 JMP Engineering Ltd

2048 Rockwell Automation

3072 Waterworks Wholesale

3090 Johns Adhesives New Zealand

2044 Rollex Systems

3095 Watson-Marlow NZ Ltd

3148 Key Technology

3121 Romheld Automation Pty Ltd

3186 Wedderburn Scales Ltd

3175 KHS Pacific Pty Ltd

3122 Rotaform Plastics Ltd

2012 Wells Hygiene Systems/Food Safety

2000 KROHNE New Zealand Ltd

3132 Saito Group Ltd

2041 Westwick-Farrow Publishing

3109 Label makers NZ

2005 Sandvik New Zealand

3116 Workflow Ltd

3109 Label makers NZ

3113 Seal Imports Ltd

2060 Worley Parsons New Zealand Ltd

2085 Label Shop

3138 Sealed Air

1007 Youngman Richardson

2083 Linkplas Ltd

3126 Secureaload

2065 Ziemann Holvrieka Asia Co. Ltd.

2084 Bekon Media 3012 Bell Technology Ltd 3089 BelleTech International Ltd 3164 Blackwoods 3070 BOC 1014 Bondor 3042 Bonson Industrial Co Ltd 2123 Bucher-Alimentech Ltd 3158 Bulk Handling New Zealand Ltd 2028 Burns & Ferrall Ltd 2112 Busch Australia Pty. Ltd. 1038 Capital Racking 1039 CGP Industries 2050 Chart Industries 1075 CILT 3112 Clear Facilities 3003 Closurepac 3068 Codemark Limited 2015 Colourgrip Surfacing Ltd 3162 Columbit Australia Pty Ltd 3021 Competenz 2010 Compressed Air Maintenance 3154 Condor Pumps 3009 Confoil NZ 3168 Conqueror International Ltd 1035 Conslab New Zealand 2045 Coveris Australasia 1060 Crown Equipment Ltd 3174 CSE - W Arthur Fisher Ltd 2135 Cuddon Limited 3059 D & L Packaging Ltd 1077 Danfoss (NZ) Ltd 3161 Davey Water Products / Contamination Control Ltd 3013 Della Toffola Pacific

3054 SPM NZ Limited

3181 MST Packaging

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3131 Spray Nozzle Engineering Ltd 3182 Spraying Systems (NZ) Ltd 3008 Stainless Engineering Ltd 3079 Steam & Process 2102 Steel & Tube Stainless 1053 Storepro Solutions Ltd 3102 Stowers Containment Solutions Ltd 2024 Stratalign Ltd 3080 Supply Services Ltd 3183 Temprecord International Ltd 2062 The Dallas Group of America, Inc. 2018 The University of Auckland 3107 Thermaflo Limited 1074 Thermo Fisher Scientific 1034 TITAN CONTAINERS NZ LTD 3081 TNA New Zealand Ltd 1026 Toll 3036 Topcoat Specialist Coatings Ltd 1049 Tracecare 3002 Transportect ( NZ) Ltd 1075 Triton Commercial Systems ltd

NZ Manufacturer September 2016

FOODTECH PACKTECH

Forget past mistakes. Forget failures. Forget everything except what you’re going to do now and do it. -William C Durrant

SMC offers show stoppers for food and packaging industry SMC, the global leader in pneumatics and automation, will be showcasing their range of products which are particularly relevant to the food and packaging market. SMC has offices in 81 countries worldwide and twelve offices in the ANZ region alone, with four of these being specifically in New Zealand. SMC has a manufacturing facility in Auckland which offers customers greater flexibility in terms of customization and shorter lead times for delivery. “Offering High Quality Products at Low Cost with Rapid Delivery, has enabled SMC to retain a high market share in Japan and compete overseas as a leading global integrated manufacturer of pneumatic equipment as it evolves into an automatic control equipment manufacturer. In the ANZ region SMC has a market share of 40%” comments Nick O’ Connor, Sales Director for SMC New Zealand.

SMC Australia | New Zealand

“SMC prides itself on being customer centric and our products are developed based on customer feedback. The large sales force of 7900 sales people, are in constant contact with customers all over the world and because of this we

have a greater understanding of the food and pack market and the specific requirements to assist customers obtain good level of productivity and a serious bottom line. “In New Zealand we bring this global knowledge home to local implementation” adds O’Connor. One of the products on exhibit will be the CG5 and CJ5 stainless steel cylinders. These include a rubber rod wiper to keep potential contaminants from penetrating the cylinder. This wiper helps increase life by up to 5 times. The smooth exterior surface reduces the potential number of particle trap areas. The CG5 Series comes with plugs for the unused mounting holes to prevent residue collecting in the threads. Mounting brackets are Electro-polished to make them smoother, which prevents build-up of liquids and foreign matter. A perfect hygienic solution for the food industry. Other products on display will include the range of vacuum saving valves. The ZP2V is particularly adaptable to vacuum zoning. This offers the restriction of vacuum pressure even when there is no workpiece and multiple vacuum pads can be operated

from one vacuum generator. This means no need for switching operation when changing workpieces EtherCAT solutions can be applied to anything from simple to complex applications with the help of our engineers. The EX600 Fieldbus System, which covers not only EtherCAT but a wide range of communication protocols, will be on show. Recently an EtherCAT solution for an abattoir won an industry award in the Water and Wastewater category. The award shows that out of the box thinking can be applied to EtherCAT. New simplified and enhanced solutions are available through the use of technology. EtherCAT really is for everyone.

discuss their particular automation requirements. SMC offers “Simple Specials” this is R&D without the large associated costs which often goes hand in hand with the request for something out of the norm. No problem is too big or too small to solve” concludes Nick. SMC energy specialist, Bill Blythe, will deliver a presentation on “Energy Efficiency through the effective management of compressed air” on Wednesday 12 October at 11:45 in Seminar Room 2 at the ASB Showgrounds.

#doyoureallyknowSMC – visit us as stand 2004 at the Foodtech Packtech Exhibition in New Zealand from 11 – 13 October 2016.

The LEY range of electric actuators which offer high precision control in an option for IP65 specifications, will be available to view and discuss. “Customers are invited to visit the stand and meet up with our team to

LEY Electric Actuator from SMC

5 countries R&D Centres

1450 Engineers

88 ANZ Sales People

28 Production Locations

5 Local Production Facilities

36% Global Market Share

81 Countries

18 Engineers in ANZ

7 900 Sales People

40% Market Share in ANZ

12 000 Products

700 000 Variations

12 ANZ Branches

Let the facts speak for themselves... Through our commitment to Japanese Quality, Customer Centric Design, Local Manufacturing and Unmatched Commercial Support, SMC has managed to make it to the Forbes Top 100 Most Innovative Companies for three consecutive years. The Group’s Strengths of offering High Quality Products at Low Cost with Rapid Delivery are experienced by our customers not only in Australia and New Zealand but the world over.

positiv/graffictraffic/NZManuf/0916-HP

The facts speak for themselves.

Visit us from 11–13 October 2016 at Auckland | Stand 2004

doyoureallyknowSMC Join the conversation:

www.smcworld.com

SMC Pneumatics Australia | New Zealand Group

SMC_ANZ_NZManuf_0916-HP.indd 1

NZ Manufacturer September 2016

Global Leader in Pneumatics and Automation

2016/09/19 09:47:17 AM

www.nzmanufacturer.co.nz

FOODTECH PACKTECH

The world hates change, yet it is the only thing that has brought progress. - Charles F Kettering

Grease improves food and beverage industry bearing performance Schaeffler Australia is introducing to Australasia a leading range of rolling bearing grease for the food and beverage industry, its FAG Arcanol FOOD2 grease, which is designed to be softer, sturdier, more energy saving and produce less friction than other lubricants. FAG Arcanol FOOD2 grease is fully NSF H1 compliant, which means it has been certified by the National Sanitation Foundation (NSF). The NSF a globally recognised public health protection agency based in the US, with its certifications recognised in America, Europe, Africa, Asia and Oceania. H1 accreditation indicates the specific lubricant is acceptable for incidental food contact and can be used in food processing areas. The latest FAG Arcanol FOOD2 grease not only meets strict sanitation

standards, but also copes with high stresses and ambient conditions as well as being kosher and halal certified for food preparation areas that have these requirements, which extend beyond the food to include the machinery and environment where they are produced. “Bearings typically used in the food and beverage industry are tapered roller bearings and angular contact ball bearings. These are bearings that are subjected to the most extreme stresses, so reducing friction is a big advantage which improves the bearings’ starting behaviour and reduces power consumption,” says Mr Mark Ciechanowicz, Industrial Services Manager, Schaeffler Australia. “The other major advantage of the FOOD2 grease is that it maintains its fluidity in cold environments, as low as -30 degrees Celsius. This is important

Schaeffler’s FOOD2 grease, left, is part of a larger range of Arcanol greases and lubrication products, right

comprehensive range of FAG Arcanol greases. To eliminate any lubrication issues and further optimise the performance of the bearings, Schaeffler’s Arcanol greases provide rolling bearings with a longer operating life, favourable running behaviour and high operational safety – all contributing to a favourable price to performance ratio. Only the best greases are given the Arcanol seal of quality after passing a comprehensive series of stringent tests.

for food and beverage manufacturers working with refrigerated environments,” said Mr Ciechanowicz. Typical applications of FAG Arcanol FOOD2 grease include: • Filling plants • Sealing machines • Meat and fish processing machines • Freezing plants • Many other plants in the food and beverage industries FOOD2

complemented

the

Rexmoi controls temperature and humidity The units are sealed enclosed chambers which allows control of the atmosphere within, using smart controls and refrigeration technology.

Rexmoi® has now become a multipurpose tool with the ability to control temperature and humidity with applications such as drying various products, cooking at low temperatures, and controlled cooling of products.

Air flow around the product is an important factor of how well the system works. There are different trolleys and trays and variable air flow to optimise this. Filters are used to control product particles in the chamber. An air sanitising system can be added. The Rexmoi® technology is not limited to our current units. It can be used to control the atmosphere in an existing environment, designed to suit your

requirements. The existing units can be used for trials to obtain the information necessary to design a unit or environment to suit your product or situation.

FoodTech PackTech on Stand 2100.

The Rexmoi® technology is not limited to food products. We have supplied a unit that heats and cures a material product at various temperatures for a certain length of time. The reason for choosing the Rexmoi® method is it a safer method of heating volatile products as there is no exposed electric elements or gas fire. This technology is available from Drying Solutions Ltd who are appearing at

REXMOI® is now a multipurpose tool • Product drying • Temperatures range -5oC to 60oC • Low temperature cooking • Cooling tunnel controlling temperature, humidity, and time • Cool room • Precooler • Can run below 0oC (freezing) • Is a standalone unit, just plug unit in to electrical source

• Varying trolleys and trays allowing different airflow patterns • Enclosed chamber • Energy efficient • Portable • Electronic controls for accuracy and monitoring, setting recipes for different products • Uses refrigerant technology

Drying Solutions Limited • Phone 027 544 2980 • Email admin@dryingsolutions.co.nz

www.nzmanufacturer.co.nz

See us at Stand 2100

NZ Manufacturer September 2016

FOODTECH PACKTECH

Today I will do what others won’t, so tomorrow I can accomplish what others can’t. - Jerry Rice

Easi Recycling - Longopac Bagging Solution base plate and cassette holder made from PP plastic & blue metal detectable material, with stainless steel legs and wheels.

As recycling becomes more popular in New Zealand, the manufacturing industry is increasingly taking ownership of their waste, realising the benefits of recycling and that clever waste management reduces waste costs and helps the environment. Understanding the waste management needs and requirements of business’ within New Zealand, in 2016 Easi Recycling, a leading supplier of waste recycling equipment, has added a new range to their portfolio. Easi Recycling is appearing at FoodTech PackTech on Stand 3038. The Longopac system, manufactured in Sweden for over 30 years, is a highly developed waste management system

supporting and focussing on the hygiene and safety of those who use it. The endless bag technology and sealing options minimises the risk of waste exposure to employees, a perfect solution for the food and manufacturing industry where exposure to offensive waste throughout the disposal process can be avoided. The Longopac waste management range, www.longopac.co.nz, is a flexible continuous bagging system that is efficient, hygienic and an environmentally friendly alternative to standard bagging systems. The ‘Longopac Maxi Food’, purposely designed for the food industry, has a

Highly visible in food preparation areas, the transparent or food blue bag cassette options accompany the stand. The food bag cassette is certified by Normpack (Swedish coding for food packaging materials), the black odour control cassette is an extra airtight bag cassette to control odours associated with waste, and biodegradable bag cassettes are available for either the disposal or composting of food waste. They are produced from organic material that is certified according to EN 13432:2000-12, with the material degrading within 6 months at 23°C / 73°F. The Longopac bag cassette technology allows for the waste bags to be replaced and sealed from the outside, with plastic ties, containing odour’s and eliminating user contact with the waste. Spillages around the opening are collected by the next bag,

helping to provide a cleaner working environment. All food grade bags are supplied with blue plastic ‘metal detectable’ ties. The variable bag sizes ensure they are 100% fully utilised and of course the minimal contact with waste is ideal for factory environments with high volumes. Clear perforated cassettes are also for the Maxi range, these are ideal for bagging valuable ‘shrink wrap’ plastic at source, available with adaptor to maximize the weight of every bag. Easi Recycling, a leading supplier of waste recycling equipment in the UK, opened a business in New Zealand in 2013, advising companies on recycling processes, equipment and strategies to maximise benefits. The company has implemented over 3,000 solutions worldwide, they have exclusive partnerships with European manufacturers and offer excellent value and quality recycling equipment. To find out more about Easi Recycling and the Longopac system please visit www.longopac.co.nz or contact them on 0800 342 3177

A great frozen product requires more than fresh ingredients. At BOC, we understand the knowledge, expertise and process needed to succeed in the food industry, and we’re proud to play a small but important role. Whether you’re talking chilling or freezing, modified atmosphere control, extending shelf life, safety equipment and training programs — we’re there. You can count on our reputation and commitment to service and safety because your business is important to both of us. To find out more, visit boc.co.nz or call 0800 111 333.

Visit us at FoodTech/PackTech between October 11-13 2016 at stand 3070. BOC Limited 988 Great South Road, Penrose, Auckland, 1061 New Zealand boc.co.nz | 0800 111 333 BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2016. MP15-0341|VS|NZM|0916 /bocsouthpacific

NZ Manufacturer September 2016

www.nzmanufacturer.co.nz

/bocsouthpacific

/user/boclimited

Come for a demonstration on this great innovation See us on Stand 3038

Savings and Benefits

Changing to the Longopac system is a sustainable bagging solution offering the following overall savings and benefits

Material

Food grade 110m cassettes

Saving on wasted plastic No double bagging

Hygiene

Reduced cleaning Improved housekeeping

Labour

Quick bag changes Reduced cleaning

Recycling and Environment

Improve Recycling Reduce general waste costs Less Plastic used and thrown away

Food Grade Maxi and Mini stands

Freephone: 0800 342 3177 â&#x20AC;˘ info@easirecycling.co.nz â&#x20AC;˘ www.longopac.co.nz 15 www.nzmanufacturer.co.nz

NZ Manufacturer September 2016

FOODTECH PACKTECH

Definition of Statistics: The science of producing unreliable facts from reliable figures. -Evan Esar

Thermaflo and Trepko tackle the New Zealand market with new agency agreement Every single day thousands of milk, juice, and water bottles are filled along very sophisticated assembly lines in and around New Zealand. With that, there are very strict regulations in place that help ensure the products that end up on your supermarket shelf are safe for human consumption. Thermaflo have always employed best practice engineering principals as part of their design policies. This insures that they meet all of their client’s expectations as well as adhering to any local regulations relating to food safety. With the above in mind Thermaflo have been associating themselves with other world leading equipment suppliers. For many years they have been building relationships with companies not only in New Zealand but into other countries such as Italy, the UK and Denmark. These companies include Filmatic from South Africa who are a leading manufacturer of bottle, tub and jar filling lines and Trepko from Denmark, who specialise in high speed horizontal form fill seal, and other tub filling applications as well as butter wrapping and end of line packaging plant. It has been fortunate that Trepko and Filmatic have formed a joint venture and now together they are supplying

complete filling and packaging lines, thus Thermaflo’s clients benefit from two world leading suppliers being represented here in New Zealand. With a large client base within the Australasian market it made sense for Thermaflo to partner with another company that had experience in these markets, but who were also looking to increase their market share. Recently, Thermaflo and Trepko signed a new agency agreement that has allowed Thermaflo to expand their product offering, while also assisting Trepko in their efforts to increase their client base in the New Zealand, Australian and Southeast Asian markets.

complex processing sites worldwide, the team at Trepko know there is no ‘one size fits all’ approach to food and beverage processing. It is this global experience that has challenged Trepko to design and overcome many processing obstacles, but what has ultimately provided them with unique opportunities to develop new, cutting edge equipment. It is this innovation that has allowed Trepko to respond to changing trends ain the food and beverage industry and adapt their product offering to meet the customers ever evolving requirements.

With over 65 years of manufacturing experience Trepko are placed at the forefront of the packaging industry and today have many loyal customers in more than 120 countries across the world. Their dynamic range of equipment is fabricated out of highest quality materials that meet the most stringent quality and hygiene standards worldwide. Their performance combined with flexibility offers individual and optimized solutions designed specifically for the customers’ needs.

With such a sophisticated range of filling and end of line packaging solutions, Trepko have the ability to provide a cost effective solution for new start-up businesses, all the way t h r o u g h to fully integrated process lines for larger international food and beverage p r o c e s s companies.

Having integrated many of their filling and packaging lines into

It is this flexibility that

has allowed Trepko to become one of the world’s leading suppliers of filling and packaging equipment and has laid the foundations for their future growth. Thermaflo has a strong track record in designing and fabricating process plant and Trepko recognise that Thermaflo’s quality supply matches their level of quality expectation, therefore Trepko feel Thermaflo know exactly what it takes to succeed in the food and beverage industry and that the quality of their gear will complement Trepko moving forward. Trepko are excited by the opportunity to work with Thermaflo and if you have any inquiry please get in contact with Thermaflo today. www.thermaflo.co.nz

Improving OEE: Focus on the small things When trying to improve OEE, efficiency or productivity most manufacturing companies start off by tackling the big things that stop the machine or line. Why? Easy to see, low hanging fruit, big impact, easy to see the benefit of resolving, etc. In reality though, often these things don’t get resolved as fast as thought, or at all. Why? Too expensive, take too long, don’t have resources, too busy firefighting, long shutdown times, etc. The result is not a lot happens despite best intentions. Workflow Ltd, appearing on Stand 3116, specialises in assisting New Zealand and Australian manufacturing companies “see” and improve how their production machines and lines are running. Once you can see this, you can then start to improve. Over the years it is clear that those companies that focussed on frequently fixing the small things, actually do

NZ Manufacturer September 2016

better at lifting plant productivity, than those that primarily focus on the big issues.

on performance. With no ongoing software licence fees this is a very cost effective tool to start with.

The first challenge however for these companies was how to “accurately see” the smaller downtime events, and how to present them into a usable form without lengthy manual collection, data input and spreadsheet analysis.

LineView

Workflow has two products well proven that help monitor and visualise the performance of machines and lines in real time, automating the identification of smaller stops and downtime. XL Visual Productivity Manufactured in the US, this robust LED display hardware device is made for factories, it simply bolts on to any machine or line, takes a count signal from a sensor, plugs into your network, and is fully self-contained. The team on the floor are still involved in collecting downtime reason data using a simple barcode scanner interface, and they can see live data

www.nzmanufacturer.co.nz

Takes things to another level with fully automated monitoring of multiple machines on a line, and relates stops on any machine back to the effect on the constraint machine. This automated “causal downtime” is a feature unique to LineView, and takes masses of complex data and simplifies it visually and in real time. With fully auto PLC fault code tracking, LineView also allows real-time visibility to operators, electrical, and mechanical support teams of what faults are occurring. Once you have the ability to see your small down events by using XL or LineView via a web browser, you then realise that the smaller problems are often easier to fix, need less money to fix, can be fixed often by the team on the floor, and the results are seen immediately. This then motivates the team to find and solve more small

problems. The result is that it is easy to start now, and lots of small fixes add up to real sustainable improvement in productivity. In the Timber Processing industry, the XL Visual Productivity tools have seen a marked improvement. A Business Improvement Manager of one company confirmed “Since we implemented this on one of our Moulders on the 8th of August, we have seen an increase of 25% productive time. For the same period another Moulder has seen an increase of 13% in 6 weeks. We haven’t focussed on any one big thing, it’s been lots of little things, and the fact that the team on the floor can see real-time how they are going” Another timber processing production manager confirms

plant

“we have seen 14% lift in 2 months, and now there is space for more orders for production”

The worldâ&#x20AC;&#x2122;s leading suppliers of packaging solutions for the food industry

Working alongside Thermaflo to service all of the New Zealand market www.thermaflo.co.nz

17 I 06 353 3640 I sales@thermaflo.co.nz www.nzmanufacturer.co.nz

NZ Manufacturer September 2016

FOODTECH PACKTECH

Sales are contingent upon the attitude of the salesman - not the attitude of the prospect. -W.Clement Stone

Logistics, Warehousing, Food Manufacturing and Packaging Technology Expo - Largest in a Decade! More than 4,500 visiting industry professionals from both New Zealand and around the world are about to converge in Auckland to attend the sectors largest (and free to attend) combined trade only industry event the Materials Handling & Logistics Expo (MHL) running alongside Foodtech Packtech (FTPT). Held at the ASB Showgrounds from 11 to 13 October organisers, XPO Exhibitions are pleased to confirm a very full exhibition floor, featuring products and services from over 220 industry suppliers showcasing the very latest product innovations and new technologies entering the market. Whilst FTPT has been in existence for over 30 years, this is the first time since 2000 that MHL has featured alongside FTPT. This year’s event will be the largest for over a decade and it’s certainly a must attend event for anyone in the warehousing, transport or logistics industries! Under new ownership, MHL is set to outperform all previous events with 50 of the exhibiting suppliers offering solutions specifically to the Materials Handling, Warehousing and Logistics industry. We’ve got everything

from forklift providers to the latest palletizing and handling systems right through to 3PL providers. The event includes three full days of free seminars arranged in conjunction

with the Chartered Institute of Logistics & Transport (CILT) and the New Zealand Institute of Food Science and Technology (NZIFST). Topics include ‘Health and Safety - What the New Legislation Means to the Supply and Logistics Industry’, ‘Opening the Waterview Tunnels in 2017 Transforming the Auckland Network’ and ‘Risk Management for Business Continuity – critical for sustainable business success’. A full seminar schedule can be found at www. mhlexpo.co.nz “MHL and FTPT are arguably the most important national sector events in this country,” says Tony Waite Sales Events Director of XPO Exhibitions. “It’s a platform where the industry gets to review and procure world leading technology, discover the latest innovations and share best practice and knowledge. In addition, the

materials handling and logistics side of things completes our ‘New Zealand pasture (or sea) to plate’ capability story which is so important to realise our $30+ billion food and beverage export market potential.” says Waite A combined audience across FTPT & MHL Expo of 4,500+ industry professionals and 220+ exhibitors showcasing the very latest innovations and technologies, 3 days of industry lead seminars, special features, show specials, visitor prizes including the chance to win a brand new Ford and exclusive VIP networking events, the MHL Expo is an event not to be missed. The Materials Handling & Logistics Show and Foodtech Packtech runs from 11-13 October at the ASB Showgrounds, Auckland. Industry professionals can register to attend for free at www.mhlexpo.co.nz

Drying solutions made to suit Cuddon Freeze Dry products are the benchmark for quality in sublimation solutions. With over 50 years’ experience and expert consideration of all the factors necessary for optimum freeze drying results, our products are highly respected around the world.

Visit us on Stand 3116

NZ Manufacturer September 2016

www.nzmanufacturer.co.nz

the product range from 5.5kg to 1500kg, there is a drying solution for your needs. And because Cuddon manufacture everything, they are able to build to your specifications.

The company’s turn-key projects are managed in house from the delivery, onsite installation to commissioning, staff training and supply documentation.

The company understands Freeze Dry and how to integrate in to your systems and factory process. With technical support, process design and onsite installation and management, the transition is made as seamless as possible.

Clients expect quality and support when looking at freeze drying. With

Cuddon Freeze Dry is appearing at FoodTech PackTech on Stand 2135.

If you want to live a happy life, it T tie E T to a goal, not to people or RKEthings. SA - Albert Einstein T A MIPSHE . O T T GR 2 W OU 300 E N ECK ND H text STA â&#x20AC;&#x201C;C

title

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NZ Manufacturer September 2016

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COMMENT

Our work is the presentation of our capabilities. -Edward Gibbon

Wages, Inflation and Productivity There have been a number of discussions recently around wage levels, annual increases, productivity and the Living Wage, and we have recently received requests from NZMEA members for information on what average increases have been and the level of inflation to inform wage discussions. So I wanted to share some up-to-date information on wage increases and inflation, as well as discussing the link between wages and productivity.

increase of 1.7%. For manufacturing as a whole, salary and ordinary time wages increased 1.6% in June 2016 compared June in 2015.

manufacturing companies can be hit by these rising costs without any corresponding increase in revenue and productivity.

speculative sector of our economy –

Firstly, looking at inflation, annually for June 2016 (June 2016 quarter compared to June 2015) was at 0.4% on the Consumer Price Index measure. Tradeable inflation has remained in the negative, at -1.5% annually. The Sectoral factor model for inflation, which the Reserve Bank of New Zealand has previously described as their preferred model, was at 1.6% annually in the June quarter. Source: RBNZ http://www.rbnz.govt.nz/ statistics/m1.

Below is a table of the year on year wage increases across the sub-sectors of manufacturing.

The Living Wage concept is another factor that is being discussed, largely around local council and government workers. It comes from a perception that especially in high-cost places like Auckland the minimum wage is not enough to pay for a decent standard of living. If we are willing to pay for this from our rates, that is one thing.

compete to hire and retain quality

In terms of average wage increases over the last year, private sector ordinary wages (which excludes overtime) saw an annual increase of 1.6%. Private sector overtime wages had an annual

However, there can be external factors which add to wage pressure – resulting in the link between wages and productivity being broken. When this happens, the viability of

For businesses, particularly those in manufacturing, the vital link for wages is productivity. As workers and businesses become more productive, through increased skills and worker capability, capital investment in more efficient and capable equipment and process innovation, profits and margins can improve and worker wages can increase as a result.

But wages paid in one sector of the economy tend to impact on wage expectations in other sectors, and unless it’s accompanied by real increases in productivity, it will raise the cost of manufacturing in New Zealand and makes us less globally competitive. It is in effect loading the consequences of uncontrolled development in the

housing – onto the productive sector. Skills shortages can also lead to increasing wages, as more companies highly skilled staff. This happens not only within New Zealand, but globally, as overseas companies also compete to hire skilled Kiwis. The other side of the equation currently for many manufacturers and exporters is the pressure the exchange rate is putting on margins and competitiveness. The current strength of our currency against the Australian dollar is particularly relevant for many manufacturers,

hitting

profitability

and the ability to improve wages. However, jobs in the productive sector of manufacturing continue to provide weekly wages that are higher than the average of all industries, both in average and median terms. Creating

environment

where

productive industries can prosper is a vital way to improve wages generally, through

higher

value

output.

Conversely, increasing our reliance on service jobs, particularly in lower productivity areas such as tourism, which have lower average wages, brings down wages generally. -Dieter Adam, Chief Executive, New

Zealand

Manufacturers

and

Exporters Association

Table Source: Statistics New Zealand – Labour Cost Index - http://www.stats.govt.nz/browse_for_stats/income-and-work/employment_and_unemployment/LabourMarketStatistics_HOTPJun16qtr-incl-HLFS.aspx

continued from page 1

Waste-to-Energy systems used in Europe will protect our water a readily available solution, and one widely used internationally, he said. The problem he said was that there had not been the concerted nationwide will to do something about process waste finding its way into the water system. This he said was itself a by-product of uncertainty about the ability of technology to cope with the problem. “You look at the situation today in which vehicles that drive themselves

are now on the roads. Yet we still have copious amounts of concentrated waste matter allowed to penetrate the nation’s water system.” He said that waste-to-energy plant technology in primary processing had been allowed to be placed in the “too hard” basket. He said that the conservation lobby had allowed itself to become over-focused on international issues at the expense of seeking solutions to problems in what he described as the nation’s

“back yard.”

now readily available in New Zealand

He said that he would now ensure that milk and meat processors in New Zealand were acquainted with this waste-to-energy solution that was so widely used in Europe. His objective he said was to make New Zealand’s processing plants their own waste consumers, and thus their own energy suppliers.

backed by his specialists with the

It was he said a relatively low cost solution, and one with its own pay-back. This proven technology was

ken-evans.html#sthash.ewS246Ie.dpuf

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experience to install it. -

See

at:

http://www.

mscnewswire.co.nz/reporters-desk/ item/2682-industrial-waste-to-energysystems-used-in-europe-will-protectnew-zealand-s-water-says-napier-s-

NZ Manufacturer September 2016

PROFILE

The results you achieve will be in direct proportion to the effort you apply. - Denis Waitley

Make the world imagine Tristan McCallum’s favourite movie as a kid was Alien. “It was the first movie that had a big impact on me: I got to sit up with Dad and watch that when I was about eight. And that was life changing, you know? It was like, ‘Wow, I want to make stuff like that’.” Fast forward to adulthood, and McCallum was standing next to Alien star Sigourney Weaver on the set of Avatar. “I was like, ‘I can’t believe this is happening!’ I gave her her mask at the start of the day. You are as close to the storytelling at some times as the camera and the director. You are just one step out of frame.” McCallum, 34, has had many job titles, from propmaker to mechanist to the very epic “swordsmith”. In short, he’s responsible for making actors look cool. Whether he’s helping create Matt Damon’s mechanical exoskeleton in the sci-fi blockbuster Elysium, or the giant swords in The Hobbit - McCallum is there to make sure film and television stars have the tools they need to kick ass. But after years of working at Weta Workshop as a technician, he realised he needed more. “The moment I realised I wanted to be an engineer was when I was working on a project over in China. I was there with a very talented mechanical engineer who was basically MacGyver.” With MacGyver at the front of his mind, McCallum dived straight into a New Zealand Diploma in Engineering (Mechanical Engineering), realising it would push him onto even bigger and better things. “I didn’t even know what engineering was! And I think if you ask a lot of people, ‘What does the word engineering mean?’, they can’t tell you. Well, it comes from the same root as ingenuity or ingenious”. He pauses.

NZ Manufacturer September 2016

“What engineering does is it qualifies you to understand things about the real world more completely than pretty much anybody else. That puts you in a really good position, no matter what you find yourself doing.” His main fear going into the diploma was something that had haunted him back at school: Maths. “I didn’t really take it past the age of 15. As soon as I could drop it, I did.” But he quickly found his studying groove. “I loved it - it was very liberating. I’d been working for six years at that point, and I hadn’t really had a chance to relax and be on my own time. I was on my own terms when I started studying, and I loved that.”

And along the way, he found out Maths wasn’t such a horror-show after all. “It turns out I was really good at it! It was just hard work at school... and I was quite lazy. That’s the honest truth. The thing about Maths is that you just have to work at it. It doesn’t come naturally for anyone. It’s like doing weights or long distance running - the more you do, the better you get at it.” With the NZDE in hand, his career went from strength to strength. Despite being terrified of Maths at school, his new skills went straight to use, whether it was using Calculus to figure out how much film gear could be loaded onto a plane in Kazakhstan, or simply finding a better way to make a sword. “I did a lot of work on the hero swords that were used in The Hobbit, and

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some of the dwarf weapons. They just got so much screen-time! And with all of the posters, you had the sword right in front of the actor’s face,” McCallum laughs. “When you see that, and it’s 220 feet tall on a billboard down the end of Cuba Street, it’s just like, ‘Wow’.” For McCallum, working with Peter Jackson was simply another childhood fantasy fulfilled. “When I was about nine, I played my grandma Bad Taste. I said, “This guy is going to be really famous one day” and she said, “No, I don’t see that happening!” and then a couple of years later, there was a newspaper article about how he’d picked up the contract for King Kong and my grandma wrote me a letter saying, “Oh, this is that man that made that horrible movie you played to me!” After working on everything from King Kong to Superman Returns, McCallum made a bold move - leaving his home at Weta Workshop. He and his fiance Mary Pike moved to Ireland to set up their own studio, The Workhouse. Jobs have been non-stop, from blockbuster films to huge new TV shows. “I am just off the back of a couple of jobs with Netflix - Marco Polo season 2. We were in locations all around Eastern Europe!” Reflecting on his career to date, he says studying was one of the best decisions he ever made. And he can’t stop, currently completing his Honours in Mechanical Engineering. “The Diploma

in Mechanical Engineering I did in New Zealand is so well thought of over here that students can go straight into an Honours degree.” And while business at his own studio is booming, he’s already looking to the future. Recently, those exoskeletons he worked on during Elysium have been playing on his mind. “It’s funny you mentioned Elysium, because next week I am going to a surgery where they are actually implanting a device to straighten up a scoliosis.” It’s a case of the skills he learnt working on a sci-fi film being used in an entirely different field - medicine. “A lot of the design engineering stuff that I have learnt is really applicable across the board. You are making a product, the product has a purpose, and what engineering does is help you identify the purpose really specifically and then figure out how to make it do that right. That philosophy applies if you’re designing a vehicle or if you’re designing a spinal implant for someone.” For McCallum, the importance of engineering is all-encompassing. In his mind, not only do engineers make the world, they could be responsible for saving it. “The next 20 to 30 years are going to be pretty tough on the human race. And they need people who are basically prepared to commit themselves to some pretty big problems. At the end of the day it’s engineers who are going to save the world.”

ADVISORS Mike Shatford is an expert in the field of technology development and commercialisation. His company Design Energy Limited has completed over 100 significant projects in this vein by consulting for and partnering with some of New Zealand’s leading producers. Among Mike and his team’s strengths are industrial robotics and automated production where the company puts much of its focus.

Chris Whittington

Senior Lecturer at AUT, Chris Whittington is a versatile Engineer, Educator and Researcher. Chris has had many years experience in senior engineering and product management. Chris has a strong background in computational modelling, 3-D scanning and printing, and a strong interest in engineering education.

Sandra Lukey

Sandra Lukey is the founder of Shine Group, a consultancy that helps science and technology companies accelerate growth. She is a keen observer of the tech sector and how new developments create opportunity for future business. She has over 20 years’ experience working with companies to boost profile and build influential connections.

Katalin Csikasz

Katalin is a highly knowledgeable engineer with strong capabilities in; industrial design, quality assurance, product compliance, technical expert support, troubleshooting and process improvement.

Phillip Wilson

Phillip Wilson of Nautech Electronics has over 25 years of experienced in the development, commercialisation and implementation of advanced manufacturing technology, robotics, automation and materials. Serving companies operating within the aerospace, automotive, offshore, defence, medical and scientific industries on a global basis. More recently specialising in change management and business re-alignment for a range of commercial entities from medium sized SME’s to divisions of large corporates.

Work hard, be kind, and amazing things will happen. -Conan O’Brien

How do you get a job that doesn’t exist yet?

It’s almost impossible to anticipate which occupations will thrive in years to come. The parents of today’s social media managers and search engine evaluators – openings currently advertised in the New York Times – couldn’t possibly have known those roles would exist when they were helping their children decide which subjects to study at school.

But whole ecosystems are also emerging. Advertising on Google used to be something a small business owner could do herself, but has now become so complex and specialized that millions of consultants make a living from managing online advertising services. Facebook, meanwhile, created the social media consulting advisory business.

So how do we prepare for jobs that don’t yet exist?

Video games gave rise to gold farming and the increasingly massive eSports industry. There are even students earning their rent cheques by walking people’s smartphones around to hatch Pokemon Go eggs.

As a legendary hockey player once said: success comes not from skating to where the puck is, but to where it will be. The following high-level trends can give us an idea of where to focus our attention.

Shock of the new Jobs seem to be becoming more abstract. As we spend more time in the virtual digital world, we see more new occupations arising. Making Creating and operating those very digital platforms, for one, for instance.

NZ Manufacturer September 2016

And if you think these aren’t proper jobs, ask yourself what someone growing up in the 19th century would have made of the fact that, in 2016, some of the world’s highest-paid people are running around after footballs. What would they have made of job titles such as psychologist, space lawyer, personal trainer or brand consultant? At the same time, there’s a movement in the opposite direction, towards the tangible and authentic. The food industry is abuzz with enterprises that extol the virtues of local, seasonal, farm-to-table products and services – among them pop-up restaurants, street-food trucks, microbreweries, urban farms and cooperative shops.

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Much like the Arts and Crafts movement, born as a reaction to industrialization in the 19th century, the resurgence of artisanal, “old world” values signals not only a nostalgic desire for handcrafted goods, but a desire for a different model of social and economic progress. From man or to machine No one really knows which jobs will be automated in the future. But one thing is clear: as machines become more pervasive, so too do the humans who teach and interact with them. As we’ve already seen in the airline business, autopilot didn’t put pilots out of a job; instead it foreshadowed an increasing collaboration between human and machine on complex tasks. As automation gains ground, the human workforce has the intriguing possibility of further developing uniquely human skills that machines cannot match or replicate. In an unusual twist on industry practice, automotive giant Toyota is removing robots from its factories because human workers can, unlike their machine counterparts, propose ideas for improvement. Machines, it seems, are not very good with innovation. They’re not very good at certain types of agility, either. Watch Parisian waiters in action and ask yourself how long it would take for robots to put them out of a job. Then there’s empathy, creativity, leadership, intuition and social intelligence. If I were to give younger people an idea of the skills they’ll need, these would be on the list, as well as advice to pay attention to how machines function and think. A piece of wisdom I gleaned from the

father of a friend who once fled from the USSR was: “Learn your enemy’s language.” If machines are coming for us we need to understand how they function. Lessons from history The problem with the changing world of work is not so much the loss of opportunities as the period of transition. A few years ago, I sat down with the CEO of a 40,000-people company and asked him to list the skills he thought would be needed in a digital, data-driven future. He mentioned programmers, designers and online marketing specialists. I then asked him to list the skills his company had on the payroll. The difference was painfully obvious. For those whose training is becoming obsolete, and organisations needing completely new skills in a short amount of time, the transition will be complicated. As the author Alvin Toffler once predicted, the future belongs to those who can unlearn and relearn. History tells us that technology creates more opportunities and jobs. The state of the world might look confusing and worrying, but it is not. Virtual or tangible, automated or humanised, work is changing in many ways, but the fundamentals remain: acquiring skills and doing things that people need. Skating to where the puck will be is much easier than it seems, as long as you stick to a few basic rules: being curious, open, and ready to experiment and to follow the direction the world is moving in.

When youâ&#x20AC;&#x2122;re at the end of your rope, tie a knot and hold on. - Theodore Roosevelt

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NZ Manufacturer September 2016

Making the beginning is one third of the work. - Irish Proverb

Automating manufacturing processes with the help of The significant labour costs and geographic isolation of the New Zealand manufacturing industry has meant that in order to compete with international players, local manufacturers must look to innovate with new technologies and automate their production processes. To compete with global manufacturing hubs, leading Auckland based injection moulding company, TCI New Zealand (TCI) were looking for an automated solution that would offer a more cost effective means of producing its customer’s products. TCI found the solution in Universal Robots, a global developer and manufacturer of 6 axis industrial robots. TCI has now deployed two of Universal Robots’ industrial robotic arms, the UR3 and UR5 to perform labelling and assembly tasks for the company’s EasiYo Yoghurt Maker line, as well as its storage bins. With a Universal Robot assisting, several key processes in the manufacture of these products have been automated, relieving employees of repetitive assembly processes and ensuring smooth production flow.

this return on investment, TCI then decided to purchase the UR5, with the payback period expected to be under 12 months.

The UR3 was the first machine to be implemented by TCI, with the costs of the robot recouped six months after it was first purchased. Satisfied with

TCI is one of the largest privately owned plastic injection moulding companies

NZ Manufacturer September 2016

Finding a solution

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in New Zealand, based in Avondale, Auckland. For more than 20 years, TCI has manufactured a vast array of products, including building products, components used in instrumentation, as well as a range of retail products, including homewares, garden products and outdoor furniture for companies

across New Zealand and the rest of the world. “Previously we were paying two employees to work in 12 hour shifts to ensure around-the-clock production of our EasiYo Yoghurt Maker. If one employee didn’t turn up for work it

The trouble with talking too fast is you may say something you haven’t thought of yet. - Ann Landers

Universal Robots meant the entire production line would be halted. This wasn’t really financially sustainable for us so we were looking for an automated solution that would guarantee quality assurance and help us to reduce costs,” said Quinton Fowler, Manager Director at TCI. During its search for an automation solution, TCI came across Universal Robots’ technology at a trade show and made contact via Design Energy, Universal Robots’ New Zealand distributor. “Design Energy were fantastic. We were initially considering an off-the-shelf robot from China, but I’m glad we were able to find a customisable solution,” said Quintin.

UR3 in action The UR3 is a compact table-top robot that weighs just 11 kg and is capable of handling payloads up to three kilograms. The robot has a reach radius of up to 500mm and features 740-degree rotation on all joints. TCI uses the UR3 to help label and place rubber feet on its EasiYo Yoghurt Makers. After a product is moulded, the UR3 aligns and passes the product though a label printer, then it adheres the label to the base of the product. The UR3 then inverts and places the product onto a mandrel, then picks

up rubber feet from a bowl feeder and places them on the base of the product. A pneumatic press is then activated, which presses the feet firmly on the product. The UR3 then picks up the finished assembly and places it on a conveyer belt for delivery to the next process. The UR3’s controller provides control for all ancillary equipment including the label printer, bowl feeder, pneumatic press and conveyor.

UR5 in action The UR5 helps manufacturers automate repetitive and dangerous tasks with payloads up to five kilograms and a reach radius of up to 850mm. The UR5 is suitable for collaborative processes such as picking, placing and testing. The success of UR3 gave TCI the confidence to implement a Universal Robots’ UR5 robot to help assemble several different sizes of storage bins, from 40L up to 112L. “We use the UR5 to put wheels on storage bins and we programmed the robots to be able to place wheels on multiple sized storage bins. The robots are so easy-to-program that we can quickly change from one size to the next by pressing just a few buttons,” said Quintin.

Flexible Quintin noted, “Both the UR3 and UR5 went beyond our expectations in what we were looking for in a robot. These robots have the ability to perform the tasks that we need without being overly expensive or difficult to program. The robot can also operate safely alongside our staff without the need for guarding.” Easy to program All UR robots can be completely reprogrammed and deployed for other tasks in a matter of minutes. A graphical user interface with a teach function enables an operator to simply grab the robot arm and show it how a movement should be performed. The user-friendly interface then allows staff to drag and drop the routines to do their programming. “The UR3 and UR5 are very flexible robots. We use the UR5 to help assemble all of our storage bins. The robot can be reset to perform different jobs depending on the size of the bin,” said Quintin

Safe to use In contrast to traditional industrial robots in the market, Universal Robots’ small and lightweight robotic arms are able to work safely alongside staff (subject to a risk assessment).

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The robots’ state-of-the-art force limit safety feature automatically stops the robot from operating when its movement is obstructed. The robot will not exert a force greater than the limit specified in the adjustable safety settings. “One thing I loved about Universal Robots was that we didn’t have to worry about guarding. Whereas a lot of the other robots in the market guarding was an issue because you’d have to use safety barriers for all the machines which just complicates the situation,” said Quintin.

The pay-off According to TCI, the company has been able to significantly reduce expenditure by using robots at a time when labour costs can be 10 to 20 times higher that of other markets. “We paid off the UR3 within 6 months, which means we can reinvest in further product development and innovation. We also saved around 75 percent on yearly product assembly labour costs. “The robots are easy to set up and reprogramming can take just a few minutes. However one of the biggest selling points for us is having that guarantee that the robots aren’t going to call in sick - production can go on 24/7 without us worrying about human related factors that might stop production,” said Fowler.

NZ Manufacturer September 2016

FOOD MANUFACTURING

The shortest way to do many things is to do only one thing at once. -Samuel Smiles

How to get Asia-savvy Want to break into an Asian market? New Zealand businesses need to think big but start small and get “Asian-savvy”, an expert in Asian business networks says. And that will take a shift in mind-set among some of our businesses as well as serious investment in upskilling. Professor Natasha Hamilton-Hart, the new director of the New Zealand Asia Institute, says New Zealand is “behind the curve” in developing a workforce with the skills and knowledge needed to succeed in Asian markets. “We’ve increased sales to the region, but we can’t rely on the low-hanging fruit to grow in the longer term,” she says. She says the $34.5 million government funding announced in June to set up new Centres of Asia-Pacific Excellence is welcome but overdue. “Australia is way ahead educating for Asia engagement, and even Singapore - which is squarely in and of the region - has recognised since the 1980s that it needs to actively develop the skills and mind-sets for expanding in the region.

It won’t happen automatically.” Professor Hamilton-Hart has previously held positions at the National University of Singapore and the Australian National University. She introduced the Asia Savvy Conference at the University of Auckland Business School on Saturday 27 August. The conference, in its sixth year, is student-driven and supported by the institute. Speakers shared their experiences of doing business in Asia, emerging market trends and opportunities for New Zealand entrepreneurs. Being Asia-savvy not only helps entering a market, it means you’re less likely to be blindsided by predictable events, Professor Hamilton-Hart says. Her advice to businesses wanting to take on an Asian market: • Really get to grips with your market. Beyond standard market research, businesses need to understand the wider culture and politics at play. • Share stories of failure as well success. “There could be a lot more knowledge-sharing among

companies about their experiences in Asia. They only want to talk about the good stories, no one wants to talk about failures.” • Use our 1.5ers. Kiwi Asians who were born in Asia but educated in New Zealand offer a valuable resource, with their bilingualism, cultural knowledge and personal connections to Asia. • Start small. Pick one or two Chinese cities, or a smaller Asian country such as Singapore. Professor Hamilton-Hart points to companies doing well in Asia. “Some of the newer players like Comvita and Smartfoods have made big inroads in export sales. Both are on record saying they learnt the value of having staff who speak the relevant local language and have local knowledge. And what was formerly AWT, a water technology and consulting company, shows the value of starting small. It has upped its regional business significantly since merging with Mott MacDonald, a large multinational.” We

should

also

remember

one of our much-touted strengths – New Zealand’s “clean green” brand, is a double-edged sword, she says. “If this is what we rely on, we’re vulnerable to consumer distrust if we get hit by an actual or even just rumoured food safety issue. And it doesn’t particularly help our engineers, high-tech niche manufacturers or service exporters. “We do have a strength in a diverse and multicultural population, but we could make much more of this.”

Some of the newer players like Comvita and Smartfoods have made big inroads in export sales.

that

Cell fusion discovery could improve agricultural production An international research team has observed cell fusion in flowering plants for the first time in more than a century. The discovery demystifies how plants prevent the attraction of excessive pollen tubes after a successful fertilisation.

Earlier research found that the role of synergid cells is to attract or prevent pollen tubes from reaching a plant’s ovule. If the initial fertilisation fails, the second synergid cell attracts a new pollen tube for another attempt of fertilisation.

Reproduction of flowering plants occurs within a plant’s ovule by the fertilisation of both the egg and a larger central cell by two sperm cells. Sperm cells are carried into the ovule by a pollen tube and discharged into one of two “synergid” cells located next to the egg cell.

In the case of a successful fertilisation, the second synergid cell – also known as the persistent synergid cell – is inactivated to avoid multiple pollen tubes entering the ovule. This prevents more than one sperm cell from fertilising the same egg, creating a genetic imbalance. However, the mechanism behind synergid inactivation remained unknown.

During this process, the synergid cell dies and degenerates, and the sperm cells migrate to the egg and central cell. Once fertilised, the egg cell becomes the embryo while the central cell becomes the endosperm that nourishes the embryo.

Led by Daisuke Maruyama of Nagoya University’s Institute of Transformative Bio-Molecules, a team of international researchers from Singapore, Germany, Saudi Arabia and Austria has discovered

that, following fertilisation, the persistent synergid cell fuses with the endosperm, triggering its inactivation. Cell-to-cell fusion in plants is rarely seen due to their relatively tough cell walls, according to the researchers. Their study is only the third report of plant cell fusion being observed and the first observation since the initial reports in the late 1800s. Using live imaging techniques, the team found that cell fusion, which is induced by the fertilisation of the central cell, rapidly dilutes the contents of the persistent synergid cell. Meanwhile, fertilisation of the egg cell activates its “ethylene signalling” pathway, which degrades the nucleus of the persistent synergid cell. As a result, the persistent synergid cell completely loses its ability to attract pollen tubes.

Dr Maruyama says their discovery could ultimately be useful for improving the success rate of plant fertilisation in agricultural production, for example. Optimising the fusion of synergid cells with endosperm, he explains, would reduce the chance for multiple pollen tubes to be accidentally attracted following a successful fertilisation.

Perishable exports to US on the rise Wasps, live eels and capsicums are just some of the perishable export products driving New Zealand’s rapid growth in the US market.

data from Hawaiian Airlines.

New Zealand exports of short shelf-life goods to the US have increased by up to 150 percent over the past few months according to new industry figures and

Tim Strauss, vice president of Hawaiian Airlines’ cargo division, says the market demand for a diverse range of products is increasing rapidly as Kiwi producers fill seasonal gaps in the northern hemisphere, and are expanding the market for live produce in the US.

NZ Manufacturer September 2016

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Strauss says analysis of data from their NZ cargo shipments shows significant growth, particularly for niche and time sensitive products such as horticultural produce, frozen serum and live animals. Already year-to-date fresh fruit exports to the US mainland in 2016 are up by

50 percent to $136 million compared to the same time last year according to industry export figures. Live animal exports are also up 53 percent* over the same time period.

FOOD MANUFACTURING

Don’t take the wrong side of an argument just because your opponent has taken the right side. - Baltasar Gracian

Mass flow controller performs at high volumes A new mass flow controller with its highest top flow rate suitable to a wider range of applications. The MCRH can accommodate flow rates of up to 5000 slpm, without compromising speed or precision of gas control. The highly stable controller manages industrial processes with more chaotic upstream fluctuations, such as control of industrial combustion gases, or mass flow into food and packaging processes. The MCRH 5000 slpm precisely and

Skills help to keep horticulture thriving Primary ITO, the industry training organisation for the primary sector, is supporting the current growth of New Zealand’s horticulture industry by inspiring people to upskill through the launch of their Let’s Grow initiative. “New Zealand horticulture is enjoying quite a boom at the moment and we’re on a roll. The question is, how do we stay there? A vital element moving forward is ongoing upskilling through the education and training of the staff within horticulture. People are the lifeblood of the industry, and consistent training programmes are a must,” explains Mike Chapman, Chief Executive of Horticulture New Zealand. “We’re proud to launch our Let’s Grow initiative, focused on training the next generation of superstars in the viticulture, fruit and vegetable production industries. Let’s Grow actively promotes a range of our high quality and relevant horticulture programmes, including General Skills, Effective Supervision and Horticulture Apprenticeships,” says Mark Jeffries, Primary ITO Chief Executive. One rising star, and Primary ITO advocate, is Northland orchardist Patrick Malley, winner of the 2014 Young Horticulturalist of the Year award. Patrick has recently initiated an innovative solution to the traditionally seasonal nature of the horticulture workforce by marrying up multiple different crop types, including kiwifruit, avocado, raspberries, figs and tamarillos. His company, Onyx Capital, has also looked at expanding into kumara. This results in his staff remaining in employment all year round.

rapidly controls mass flow rate, volumetric flow rate, or back pressure of gases in high flow processes. To overcome the poor turndown ratio and slow response of existing methods (such as interlinking a meter with an external valve) Alicat designed a new flow geometry. This new design accommodates the higher flow rates, with a low pressure drop of 14.1 psig at full scale. A dual valve design enables a fast 100 millisecond control response time without significantly raising instrument power requirements.

The instrument’s Gas Select firmware includes a library of up to 130 preloaded gases, user selectable in the field. The MCRH 5000 slpm can be programmed with the instrument’s push button menus and onboard display, or via remote connection. Digital communications options include RS-232 or RS-485 serial, Modbus, or PROFIBUS, as well as analog 0-5 Vdc,

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WORKSHOP TOOLS

If you don’t drive your business, you will be driven out of business. -B. C. Forbes

A Tale of Two Cutting Tools – Rotary versus Indexable In the early industrial days of cutting tool development, metalworking was very limited. It was a slow task until the nineteenth century when the industrial age brought the availability of machine power from the steam engine and, later, electricity. Machine tools developed considerably in response and with the introduction of High Speed Steel (HSS) in the twentieth century, the modern metal cutting era began. Today, there are two types of cutting tools, rotary and indexable. Rotary, also known as solid round tools, forms one entire piece made up of the cutting edge and shank. It is typically associated with drilling, threading and milling applications. Indexable tools are predominantly made of inserts or tips, where the cutting edge is a replaceable shaped piece which is welded or clamped on to a tool body. These are generally used for turning, milling and hole-making operations. Fabio Sala is product manager for round tools and Lukas Pavlis, product manager for indexables, at global manufacturer Dormer Pramet. Both discuss the key elements which make up the differences between the two types of cutting tools, including the material, performance and versatility. Material – indexable At the beginning of the twentieth century, cutting tool material was sometimes only slightly harder than the material being cut. Therefore tool-life was poor and cutting speeds had to be kept very low. As cutting tool materials developed, they allowed for increased machining parameters and the ability to withstand higher temperatures while maintaining hardness. The harder the tool substrate the more wear resistant the cutting tool, resulting in longer tool life. The compromise here is that harder tool substrates are more brittle and more

likely to fracture or break under adverse operating conditions. Softer tool substrates mean the tool will be tougher, allowing successful machining even under adverse conditions. Although, tougher substrates are less likely to fracture or break, they operate at lower performance parameters and so tool life is not as long. An ideal cutting tool material should resist flank and point wear, as well as deformation, be tough to resist breakage, does not chemically interact with the work piece material, resist oxidation and diffusion and have good resistance to sudden thermal changes. Inserts are made from tungsten carbide, which is the most commonly used material for indexables. Other available material used for inserts includes cermet (CT), ceramics (CC), cubic boron nitride (CBN) or polycrystalline diamond (PCD). CT has good flank and crater wear resistance and is not prone to built-up-edge. Because of this, the cutting edge maintains its sharpness over a longer time. CC has a wide application area in cutting hard materials (45-55 HRc) and has high resistance to abrasive and thermal conditions. CBN is an excellent cutting tool material and offers extremely hard high thermal resistance. CBN is utilized in materials such as hardened steels and cast iron. PCD exists in two types (natural diamond or industrial diamond) and is utilized for non-ferrous materials, such as high silicon aluminum due to its high resistance to wear. As PCD is extremely hard and brittle, it is not a good choice for high hardness or impact applications. Material – rotary Round tools are traditionally made from High Speed Steel (HSS), High Speed Cobalt (HSCo or HSS-E) or Solid Carbide. Carbon, Chromium, Tungsten, Molybdenum, Vanadium and Cobalt all make up the main alloy elements used within high speed steel cutting tools. HSS is a medium alloy that has good machinability and performance. It offers toughness and is a cost-effective option for a wide variety of large scale drilling and threading applications in multiple materials. However, it is not very wear resistant and so not suited to demanding, difficult conditions.

A Dormer milling cutter.

NZ Manufacturer September 2016

Cobalt high speed steel offers a good combination of toughness

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and hardness, providing good machinability and wear resistance. This makes the material suitable for drills, taps, milling cutters and reamers. Solid Carbide is the most widely used and wear resistant cutting tool material today and is suitable for both round tool and indexable applications. Performance & versatility – indexable From a cost perspective, indexable inserts and tool holders represent a significant investment, however, they have the potential to last for longer periods of time. Also, when a replacement is needed, this is more time and cost efficient because of the need to only rotate or change the insert. To support the long-term investment of indexable inserts, they are also interchangeable and versatile. Machinists have the ability to keep the cutter (or tool holder) in place while easily switching the inserts with varying alternative grades more suited to machining different work-piece materials. Indexable cutting tools offer greater versatility in terms of performance than rotary tools, providing stable results even in adverse conditions and are able to perform multiple operations. For example, the operational versatility for milling inserts includes plunging, helical interpolation, profiling and enlarging a hole. Indexable cutting tools can also offer much larger diameter capability than round tools. Performance & versatility – rotary Although round tools generally involve a large initial investment compared to inserts, this investment can be spread over the long-term with the added possibility of regrinding. This is not an option with inserts. The geometry, substrate and coating of a round tool determine performance. Application specific tools have the potential to produce greater accuracy than general purpose tools. Also, the overall design allows the machine operator to achieve much smaller diameters.

Dormer Pramet has an extensive assortment of round tools and indexables available.

designs for a wide variety of hard and soft materials. It can be applied to a variety of drill point angles, the most common being 135°. This highlights the evolution of round tools where key features, developed for specialist and unique applications have, in time, expanded for use in a wide number of applications and materials. A key benefit of the split point is easier and more precise self-centering and to prevent the tool from “walking” before penetrating the work-piece. The web thinning or split point greatly reduces thrust and adds a positive rake cutting edge that extends to the center of the drill. In many materials the point will also act as a chip breaker to produce small chips which can be ejected more efficiently through the flutes. This is a distinct advantage in most applications, but especially when portable drilling or in a drill press where bushings cannot be used.

The four-facet Split Point geometry, for example, used on rotary drills, was originally developed for deep oil holes in automotive crankshafts. Today, it The Dormer brand of round tools provides options for milling, is used on many drill drilling and threading.

WORKSHOP TOOLS

A little more persistence, a little more effort, and what seemed hopeless failure may turn to glorious success. - Elbert Hubbard

Flexibility and power with multi-process welding machines WIA (Welding Industries of Australia) has announced the expansion of its industry leading Weldmatic range of MIG and multi-process welding machines, which now includes three new inverter models; the 250i, 350i and 500i. With all three welding machines utilising inverter technology, they feature sophisticated electronic controls, high frequency switching and high frequency transformers, to achieve consistent and controlled weld output for the professional welder. The Weldmatic 250i is a 240V multi-process industrial welder, suitable for everyday use by vehicle smash and exhaust repairers, fencing contractors and general maintenance applications in workshops and factories as well as on construction and mine sites. Capable of handling MIG, Stick and Lift-TIG welding, the 250i is a versatile and portable machine capable of gas shielded welding of aluminium, mild and stainless steel, as well as gas shielded cored wires and gasless flux-cored wires. Designed for every-day use, the control panel allows easy selection of gas and wire type, with infinitely variable voltage and wire speed, indicated on the digital display. However, unlike other similar machines on the market, the Weldmatic 250i features a 4-roll wire drive which improves wire feed consistency, plus it can accommodate 15kg wire spools. Using a 15kg spool means the machine

suits the light industrial user as 15kg spools work out far cheaper per kg than smaller 5kg spools; in short the 250i can improve the welder’s productivity while reducing operating costs at the same time. The Weldmatic 250i is also supplied with a tradesman quality MIG gun with 3.6m cable complete with euro connector for easy fitting and removal, plus a 3m work lead, an industrial twist lock electrode holder, gas regulator, a range of tips and suitable drive rollers. Weighing in at just 25.5kg, the 250i comes supplied with two handles, making it an easy two-person lift and suitable for onsite maintenance applications. At the top end of the Weldmatic range are the 350i and 500i multi-purpose machines designed for MIG, Stick and Lift-Arc TIG welding in medium to heavy fabrication and all general industrial applications. Offering 60% duty cycles, the 350A and 500A three phase machines are designed to meet the professional welder’s demands for flexibility and power, and are ideal for long run welding work. Built to perform, these are the machines welders turn to when they don’t want to compromise on quality and results. With optimal weld characteristics, the machines provide high quality results on steel, stainless steel and aluminium, plus the power to comfortably run all popular sizes of solid and flux cored

wires. With the capacity to run 1.6mm flux cored wire, the 350i and the 500i machines can handle a wide range of applications. Both machines suit gas shielded and flux cored wire as well as offering variable arc control, with infinite Voltage and Arc Control to adjust arc harshness and Arc Start to control the wire starting speed. As well as being supplied with a 32A supply plug, the machines feature digital Volt and Amp meters which retain last weld information and allow precise set-up. The 350i and 500i machines come with a four roll drive wire feeder (heavy duty on the 500i) and a trolley with a drawer specifically designed for the machines, as well as high quality US-manufactured consumables. Both the welding torches and the Bernard Centerfire 0.9mm welding tips are of premium quality and designed for long life and quality welds.

As well, the machines offer built-in operator safety, with the power sources featuring thermal protection devices that activate if the machines are operated beyond their safe thermal operating zones. When it comes to warranty issues, all Weldmatic machines are supported by an Australia wide service network covering parts and labour as standard, so customers can be guaranteed they’re buying reliability and performance. While the 250i features a two-year unlimited warranty on its power source, the 350i and 500i offer an industry-leading full three-year gold-shield warranty on all the components of the welding machine.

The package also includes a 3.6m gun cable, a 10m work lead, an industrial twist lock electrode holder, a 10m interconnecting lead, a gas holder and suitable drive rollers. With safety a very important issue for WIA, all three machines feature built-in VRDs (Voltage Reduction Devices), which deliver added safety when operating in stick or lift-TIG mode and meet the requirements of site work to AS60974.1 and AS1674.2 CAT C.

New SilverPlus technology for plasma cutting at 400 amps Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, is introducing SilverPlus electrodes for its HyPerformance HPR400XD® plasma cutting systems. Thorough laboratory testing shows SilverPlus electrodes last 50 percent longer than standard copper electrodes in most cutting applications. Instead of replacing the electrode at a pit depth of 0.040 of an inch as recommended with standard copper electrodes, SilverPlus electrodes are designed to last to a pit depth of at least 0.080 of an inch. In addition, the electrode delivers a very consistent range 4 and 5 cut quality throughout its life. This allows owners to lower their operating cost with no impact on cut quality or speed. SilverPlus electrodes are differentiated from other silver electrodes on the market in the way they are manufactured. By fusing the silver tip

to a copper blank, using a patented process prior to electrode machining, Hypertherm electrodes have the best life and consistent performance. When used with an oxygen plasma gas on mild (carbon) steel, SilverPlus electrodes can burn deeper than copper electrodes extending the life of the electrode. Additionally, silver electrodes help to preserve the size and shape of the nozzle orifice increasing nozzle life as well.

includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and consumables.

In addition to the new 400 amp electrode introduced today, Hypertherm also offers 130, 200 and 260 amp versions with similar performance. Please contact Hypertherm or an authorized partner to request samples of SilverPlus electrodes. Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line

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ANALYSIS

The way to get things done is not to mind who gets the credit for doing them. -Benjamin Jowett

The role of welding Even though manufacturing is changing, welding still has a role... explain. Welding remains a fundamental activity within many manufacturing operations as it is a unique and proven technique in providing rapid, effective and high quality finish results at relatively low cost levels. This is particularly the case when it is compared to other techniques such as industrial gluing, which may be available in some metal joining applications and materials. Where are new opportunities for welding in manufacturing? It’s really more a matter of where welding technology needs to be adapted and developed to meet the challenges associated with new manufacturing processes, particularly with regards to developments in new metallic materials to improve existing industrial applications. More importantly, there is growing demand by industry globally for welding technologies which improve both productivity and quality management within welding production operations, and at the same time, ensure evidence of compliance with welding procedures and standards. These demands are being met by Kemppi through the development of easier to use and precise inverter based welding power sources coupled with software to produce optimised welding arcs (for different applications/ situations), and also external cloud based systems. These systems assist in welding documentation production and the monitoring and management of multiple machine and multi-site welding operations to ensure quality management is achieved in real time. The name of the game now is about achieving high quality and highly productive welding performance at the lowest cost; while ensuring that all welding parameters are monitored, managed and captured to make collation of welding documentation quick and accurate. So the 4th Industrial Revolution does not make welding obsolete? Quite the opposite, Industry 4.0 is becoming an implicit part of the developments within contemporary welding technology, and the capture of ‘big data’ in welding is already here. This is related to the growing demand for real time monitoring and management of welding data during the welding process, along with the automated capture and collation of welding documentation. Welding data is captured and processed

David Green ,Managing Director, Kemppi Australia Pty Ltd

to provide a real time view of the welding operation. Each weld can be monitored against its own WPS in real time and ultimately the total welding operation has full weld traceability. The potential impacts on quality management and cost management are immense. In particular, the implicit benefit of enabling quicker, more accurate welding and the ability to avoid costly re work. Being cloud based, this technology can be implemented over individual and multiple machine welding operations, and multiple site operations. There are no restrictions on brands of welding equipment as any can be integrated within this type of system and there are no geographic limitations. We already have integrated welding systems monitored using cloud based technology deployed over several countries - the only criteria is a sound browser connection to the net from any device with an appropriate password access to the system. Safety around welding is a big issue. What changes are being made in this regard? Clearly industrial safety is a major issue in any field, driven by societal expectations, workplace legislation and organisational ethics. Welding is no exception in this regard. Safety design is a prominent feature in the development of welding equipment itself; where design and manufacturing standards are strictly adhered to in most markets where welding equipment is manufactured. With respect to welding equipment this mainly applies to compliance to national electrical standards and local regulations. Recent advances have been made using software within the welding power source to control and optimise the welding arc in Mig welding. This maximises control of both welding fusion and penetration, whilst significantly reducing the welding filler material and shielding gas required. This is known as RGT –Reduced (welding)Gap Technology. Apart from reducing material costs and increasing speed of welding, it also has the collateral benefit of reducing welding fumes - a major potential hazard source to personal health, implicit within any welding operation. Other developments in safety within the welding environment relate to PPD – Personal Protection Devices specifically welding masks. Standard welding masks, designed with either fixed shade lenses for a specific welding duty or automatic transition lenses for multiple duties with varying levels of light intensity, are an inherent part of

the welder’s personal protection. These are used by all welders to protect the welder’s eyes from the intensity of light emitted from a welding arc and include a visor to protect the face as a whole from spatter and other metallic debris However, standard welding masks do not provide protection against the potential harmful effects of welding fumes, produced as a normal part of the welding process and the associated effects on the lungs. They also don’t give any relief against heat discomfort experienced during prolonged periods of welding activity. The development of PAPR welding masks provides a filtered protection system against both welding fumes and any micro particulates which may be inhaled. This is in addition to creating a cooler more comfortable environment within the welding mask around the welder’s face. Some versions also include an impact design which is compliant with Australian standards for use in ‘hard hat’ areas. Do you foresee a shortage of skilled welders in the future? It is evident from both observation and feedback from organisations engaged in welding activities that there is already a shortage of highly skilled and qualified welders, particularly in higher end structural fabrication operations. It can only be concluded that given the reduction in welder training opportunities within the public training sector this situation will be exacerbated in the future. How do you attract youth to welding? People will have different views on this, but for me it’s all about changing the perception of the welding role and bringing about awareness of the high technology changes which are already an important part of the welding operation. Welding as a skill is now, as it has always been, a unique combination of art, science and engineering. Contemporary developments enhanced mainly by software and cloud based enabling technologies, further enrich the role and bring the industry right into the information age.

The global trend is very clear on this, whilst welding as an industry follows the general manufacturing trend, which is currently negative in most developed markets, automated welding systems are certainly growing at a greater rate than manual systems as a specific technology - and for good reason. Reverting back to the point made earlier on the focus upon quality management coupled with improving welding productivity - in many cases this can be achieved with the automation of a welding process – and this is influenced to a great extent by the application concerned. What will be the role of the welder in automation? Due to the nature of many applications and the geometric challenges of certain welding tasks, welding automation cannot replace ALL welding activity. Therefore, the skills required for manual welding will remain. However, since the demands for manual welding are similarly being driven towards increasing levels of productivity and quality, within stricter levels of compliance, and considering the developments in new materials and processes which are partially provided for by new developments in welding equipment and welding software management technology, this also underlines the ongoing need for highly skilled and qualified welders. Where an automated welding operation is involved, the role of the welder is enhanced to include the skills necessary to set up, operate and control the automated welding system. What are the benefits of automation for both the welder and management?

Where do you see the use of welding automation heading?

Clearly for management, the automation of an existing welding operation will potentially provide significant improvements in both quality and productivity.

Welding automation involves welding processes including ‘mechanised’ rail, orbital pipe semi-automated systems and fully automated robotic welding systems, dependent upon the applications involved and the investment appetite of the organisation.

For the welder involved with automated welding systems, there is the implicit benefit of enabling upskilling requirements around a higher tech welding role, without losing the high level manual welding skills always required in other areas of the welding operation.

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REAR VIEW

A brand for a company is like a reputation for a person. You earn reputation by trying to do hard things well. -Jeff Bezos

continued from page 1

‘Protecting’ our FTAs or supporting remaining local manufacturers? now running an Australasian-wide company, I can relate to such challenges from firsthand experience. Where has the importance, prestige and benefits of local manufacturing, i.e. “manufactured in NZ”, to NZ Inc. gone? Not to mention the value-added benefits of our exports for jobs, taxes, local economy, education, career development, etc.? And if trade commentators often mention that NZ needs to “export more value-added products”, then to achieve that expectation NZ exporters of NZ-made goods need to have a reasonable-sized home market as a “springboard”, from which to support the initial costs of exporting to new markets. So therefore, substandard imports are an impediment to creating that very crucial local market as a “beachhead” to export markets!

NZ, the Bluff smelter is totally powered by carbon-neutral hydro-electricity, as are our own extrusion presses in Hamilton - and the relative lightness of aluminium makes for lower fuel use in transport per Kg of product. It is also more resistant to the elements. And carbon footprints are being increasingly considered by society, with more and more commercial buildings being described as Green Buildings equipped with even roof-top gardens - along with solar power panels.

…can the NZ Government and the Local Councils and Authorities make a conscious effort to not only consider the economies of cost, but the social benefit of jobs for New Zealanders? So, with the large building boom ahead of us in NZ, particularly in Auckland, can the NZ Government and the Local Councils and Authorities make a conscious effort to not only consider the economies of cost, but the social benefit of jobs for New Zealanders, and of course meet our environmental commitments that our Government

has signed up to in Paris? Enlightened accountants and companies refer to it as the “triple bottom line” in annual reporting. And like so many developed countries do, the Government talks and acts free trade, but at the same actively supports retaining contracts within their borders for the local companies based on the balanced decision making criteria – it’s pragmatic politics within the Rules!

This, of course, brings me to the next point and that is, in a country prone to “seismic activity” (like Christchurch recently, and Napier and Murchison much earlier), such factors as robust ties, bolts, rivets, and fastenings must be totally compliant, with independent stringent testing - along with the pillars, beams, claddings, and glass (and of course the foundations, where steel piles are involved). And on the point of claddings (these must be fire-proof, as not all metals are), and glass (where toughened safety glass is essential for balconies, and certain doors and windows). Finally, environmental factors are increasingly entering into large buildings and other structures, like bridges. In the case of aluminium from

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