NZ Manufacturer May 2023

NZ start-up Fabribotics poised to revolutionise metal manufacturing

Fabribotics, a new manufacturing start-up based in Tauranga, New Zealand, has developed technology in large-scale metal additive manufacturing. The company’s proprietary technology allows for the production of custom metal parts ranging from 1kg to 1000kg in size, using a variety of weldable materials, including stainless steel, aluminium, steel, and bronze.

Founders Mike Fry and Ben Jackson began working on the 3D printing (Wire-Arc Additive Manufacturing, or WAAM) technology during an MBIE-funded research program at TiDA Ltd. The start-up has secured pre-seed investment from KiwiNet to further develop the technology and business.

The applications for Fabribotics’ technology are vast with the ability to produce custom, large metal parts applicable across many industries, with 1kg to 1 tonne being the target size. Industries include heavy industry, power generation, marine, mining, agriculture, food processing, transport, and architecture. The technology offers a cost-effective solution for creating complex shapes and reducing the costs of machining.

Using additive manufacturing to produce near-net-shape billets, the technology minimises material waste and maximises the efficiency of the manufacturing process.

The technology also eliminates the need for expensive tooling required for traditional casting methods, making it an attractive option for replacing one-off cast components.

Furthermore, the technology enables extensive repair options for broken metal products, offering a sustainable and economical alternative to replacing entire components.

New Zealand is ideally placed to benefit from Fabribotics’

technology due to its long supply and logistics chains, high cost of labour and low value of metal waste. The ability to produce custom and niche metal parts on-shore will provide a much-needed solution for industries that currently have limited options for prototyping, spare parts and repairs.

Commenting on the launch of Fabribotics, newly appointed Commercialisation Director Iain Hosie says “The potential for Fabribotics’ technology to revolutionise metal manufacturing in New Zealand is immense. With the ability to produce custom metal parts on-shore, this technology could provide a much-needed solution for industries that currently rely on overseas suppliers. This is an exciting time for manufacturing in New Zealand, and Fabribotics is leading the charge.”

With the potential to transform the way custom metal parts are produced, this start-up is poised to make a significant impact in the industry. For more information, visit their website at www.Fabribotics.nz or see them at Booth #184 at SouthMACH.

quality components and products to industrial markets

Treotham Automation is the exclusive distributor for many world class international product lines. As a leader in automation control, Treotham have a broad capacity to provide systems and custom-built solutions using a diverse range of products and components. Contact our technical engineers for more information.

The leading supplier of high

DEPARTMENTS

LEAD

NZ start-up Fabribotics poised to revolutionise metal manufacturing.

BUSINESS NEWS

Engineering worth up to $18b a year to economy.

SMART MANUFACTURING

Industry 4.0 transforming manufacturing processes for increased efficiency.

Tech at the edge – Trends that need to reshape NZ.

New Zealand research to fly on International Space Station.

SOUTHMACH 2023

Prioritising functional and machine safety with EIS.

A great opportunity for manufacturers to pick up new ideas.

Solutions for dust problems.

SHAPE energy providing SouthMACH a breath of compressed air.

ANALYSIS

Increasing interest in ZLD driven by costs and environment.

WORKSHOP TOOLS

Cost-effective automation: igus presents the world’s lightest cobot.

Kemppi launches new portable welding machines for Master M series.

CIRCULAR ECONOMY

Mitigate or adapt? With climate change it’s both.

Battery power plus product stewardship fir a brighter future.

DEVELOPMENTS

Aotearoa diverts two million kgs of e-waste from landfill.

Propelling EV charger deployment in NZ.

DEVELOPMENTS

HERA recognises leading Metalminds at Future Forum.

LAST WORD

Interview: Computer Recycling Ltd.

Is Chief Executive of BusinessNZ, New Zealand’s largest business advocacy body He has held a range of senior positions at Westpac and is a barrister and solicitor

Ian is a Partner, Argon & Co. NZ, a master black belt improvement specialist and global lean practitioner. He is passionate about improving productivity and helping to create world class New Zealand businesses.

CEO thinkstep-anz

Barbara’s passion is to enable organisations to succeed sustainably. She describes her job as a ‘translator’ – translating sustainability into language that businesses can act on.

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.

EMA chief executive Brett O’Riley has a background in technology and economic development.

Brett actually grew up with manufacturing, in the family business, Biggins & Co. He currently holds board roles with Wine Grenade and Dotterel Technologies and is also on the NZ Film Commission board.

Insa’s career has been in the public and private sectors, leading change management within the energy, decarbonisation, and sustainability space. Insa holds a Chemical and Biomolecular BE (Hons) from Sydney University. She is a member of the Bioenergy Association of NZ and has a strong passion for humanitarian engineering, working with the likes of Engineers Without Boarders Australia.

Insa is a member of Carbon and Energy Professionals NZ, been an ambassador for Engineering NZ's Wonder Project igniting STEM in Kiwi kids and Engineers Australia Women in Engineering, increasing female participation in engineering.

Kirk Hope

Brett O’Riley

Ian Walsh

Lewis oodward

Insa Errey

Dr Barbara Nebel

PUBLISHER

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

MANAGING EDITOR

Doug Green

T: +64 6 870 9029

E: publisher@xtra.co.nz

CONTRIBUTORS

Holly Green, HERA, EMA

Business East Tamaki, Ian Walsh,

Doug Marsh, Matt Hale, Dominic Salmon, Patrick Moynahan

ADVERTISING

T: + 64 6 870 9029

E: publisher@xtra.co.nz

DESIGN & PRODUCTION

:kim-jean:

E: kim.alves@xtra.co.nz

WEB MASTER

Julian Goodbehere

E: julian@isystems.co.nz

PUBLISHING SERVICES

On-Line Publisher

Media Hawke’s Bay Ltd

DIGITAL SUBSCRIPTIONS

E: publisher@xtra.co.nz

Free of Charge.

MEDIA HAWKES BAY LTD

T: +64 6 870 9029

E: publisher@xtra.co.nz

121 Russell Street North, Hastings

NZ Manufacturer ISSN 1179-4992

Vol.14 No.4 May 2023

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.

SouthMACH 2023 where manufacturers and innovators meet

NZ Manufacturing enjoys sharing with readers news of innovative company start-ups. In this issue, on Page 1, we introduce you to Fabribotics, based in Tauranga, developers of technology in large-scale metal additive manufacturing. The company’s proprietary technology allows for the production of custom metal parts ranging from 1kg to 1000kg in size, using a variety of weldable materials, including stainless steel, aluminium, steel and bronze.

SouthMACH, the bi-annual technology trade fair returns to Christchurch Arena from 24-25 May

In these times of on-going change in products and services for the manufacturing sector, some of it quite profound, it is important to visit trade fairs like this one to see the latest technologies available and mix and discuss business and opportunities with your peers with your peers.

Ideally, visitors will come from Canterbury University, progressive members of the chamber of commerce, industry leaders, engineers, technical specialists, operations managers, company leaders and all who have a stake in the future of manufacturing in the South Island and from further afield. Regional manufacturers from Invercargill and Gore, can drive up the road and spend a couple of days updating their knowledge bank and have a good time.

There is a new Advisor in the Smart Manufacturing department of NZ Manufacturer, Iain Hosie, a Director and Founder of Nanolayr Ltd, Director for the NZ Institute for Minerals and Materials Research, Commercial Director for Fabribotics Ltd, and Executive Council of BiotechNZ. Welcome aboard Iain!

Engineering New Zealand has released a report showing engineering contributes between $14.6 and $18.1 billion a year to New Zealand’s GDP – and that we will need almost 2,500 more engineers every year just to keep up with demand. Full story Page 6.

The heavy engineering industries’ top innovators and changemakers were recognised at the HERA Future Forum Nation Dinner on 5 May 2023 at the Christchurch Art Gallery Te Puna o Waiwhet. Sponsored by New Zealand Steel, the awards celebrated the significant impact that individuals and teams are making across Aotearoa, honouring outstanding projects, innovations, and research that demonstrate leading vision and contribute to success within their respective industries. Full story Page 28.

Dr. Barbara Nebel, Frank Baldrighi,

Business

Engineering

worth up to $18b a year to economy

Engineering New Zealand has released a report showing engineering contributes between $14.6 and $18.1 billion a year to New Zealand’s GDP – and that we will need almost 2,500 more engineers every year just to keep up with demand.

The report by PwC shows engineering positions produce an average of about $228,000 of GDP per employee per year – nearly twice as much as the average New Zealand worker.

Engineering New Zealand Chief Executive Richard Templer says, “It’s great to have an estimate of what engineering is worth to New Zealand.”

“To understand how engineering contributes, PwC had to look inside every industry. Engineering spans the whole economy, from the things that most people associate with engineering, like structural and civil projects that build the infrastructure all New Zealanders rely on, to more niche areas, like food-processing engineering, artificial intelligence and biomechanical implants.”

PwC estimates about 77,000 engineers are currently employed in New Zealand – around 3 percent of the workforce.

The report says New Zealand will need almost 2,500 engineers every year assuming long-term economic growth of 3 percent. This doesn’t include the new engineers we need to replace those who retire, leave the profession or go overseas.

Templer says, “In many ways the report has confirmed what we know – that engineers are of immense value to New Zealand’s economy, and that there’s a

need for more engineering talent in New Zealand.”

Templer also recognises the need to support diversity within the profession. “Only 18 percent of Engineering New Zealand’s members are women, and Māori and Pasifika are also underrepresented. In order to serve our communities effectively, engineers need to be more representative of those communities.”

He points to initiatives like The Diversity Agenda and The Wonder Project, which aim to foster a more inclusive environment and show that engineering is for everyone.

“Engineering is an incredibly varied profession,” says Templer. “If you enjoy solving problems there’s bound to be a career path in engineering that excites and interests you.”

Templer says engineers are on the frontlines of some of the most pressing issues of our time. “Taking action to mitigate and adapt to the worst effects of climate change will rely on innovations in almost every sector.

Efforts like rolling out more renewable energy, upscaling alternative transport options and developing new methods of food production are vital contributions to our collective futures.

“Engineers do amazing mahi and we need more of

them, and Engineering New Zealand Te Ao Rangahau is here to support you no matter where you are in your training or career,” he says.

Helping

is here to make it easier to do business; working alongside business leaders and property owners in the region on security, advocacy, development and growth.

* Engineering New Zealand Te Ao Rangahau has 22,000 members.

* In 2020, 9.4% of New Zealand’s graduates studied engineering. The OECD average is 13.7%1.

* International agreements enable New Zealand engineering qualifications to be recognised overseas and valid overseas engineering qualifications to be recognised here.

businessET.org.nz

build sustainable business, and sustained success.

The report says New Zealand will need almost 2,500 engineers every year assuming long-term economic growth of 3 percent.

Productivity – the only economic way forward.

-Ian Walsh, Argon & Co

New Zealanders are at a crossroads. Surely it is now apparent that continuing to do what we always did will not cut it in the next twenty years? Last month I shared that Ireland (once comparable to NZ) is now almost twice as productive as we are, whereas we now find ourselves in the bottom half of the OECD with our quality of life heading the wrong way.

Just look at our nearest neighbour who can recruit our best and brightest, pay wages which match employee’s worth, and provide better work conditions and futures. How can this be? What are they doing differently? Why is their economy vibrant, enabling them to continue to recruit, attract, reward, and grow talent?

We are now struggling to pay nurses, teachers, police officers and defence force the sustainable wages which encourage them to continue in the vital roles we need. Our infrastructure is not meeting the climate change challenge and we have major investments to make to future proof the country and help the global drive to curb the impacts of climate change. We have done many of the things that advanced economies have done to provide the environment to meet these challenges, including regulatory, taxation (still a work in progress, I note), committees, working groups and suchlike, yet we have not embraced the approaches larger more competitive economies have.

The lower levels of competition due to distance, market size and cost to serve have been a barrier to entry, but since Covid this has changed. So, if we want to achieve the sustainable growing economy we need, then we must be internationally competitive. This means being world class. It means adopting proven best practices and relentlessly improving.

What would it mean for your business to be able to double your output with the same overhead cost? What would this do for profitability and business value? What would happen if you had the ability to add new services or products and grow? And with a broader lens, what would this do for the national economy?

Imagine if we had 10 F&P’s or 100! We could sustainably pay the rates needed, generate enough tax and reduce our debt, invest in infrastructure and secure our futures. Further taxing unproductive businesses through imposed holiday rules, minimum

wages, levies and suchlike only accelerates their decline, leads to failures (as we are starting to see, especially in construction), reduces available jobs (also seeing job availability at a very low level and reducing), leads to unemployment, higher social costs and therefore a higher need to fund…this is a cycle of despair and economic folly.

The imperative is to support our business leaders to be internationally competitive through the adoption of proven methods and practices, supported by enablement (where applicable) with a goal to drive high quality high paid jobs.

So why do so few leaders know what these practices are? Even in large corporations there is a dearth of thorough understanding and little sustained adoption. I’ve found pockets of excellence, but the uptake is too slow.

It is interesting that construction companies who had not embraced best practice approaches when asked how good they thought they were, 55% thought they were highly efficient.

For those who had been in a company actively embracing this approach, 62% recognised they were highly inefficient. This speaks to the lack of understanding and awareness….and the lost opportunity, as the drive to improve anything is very low when you believe you are the best at it – after all we don’t know what we don’t know.

This is the same mindset the US auto industry had in the 1970’s regarding Japanese cars. They believed they were the best, had nothing to worry about. They have spent the last fifty years trying to catch up, with two of the big three declaring chapter 11 bankruptcy in 2009.

Let’s not repeat history, let’s build our understanding and knowledge to we can double and triple our performance. The time is now.

Want some help with this…drop me a line.

ian.walsh@argonandco.com

ADVISORS

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.

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.

Sean O’Sullivan Has a B Com (Hons) Otago University. In 2000 - 2001 introduced PCs on the workshop floor and job and staff tracking and a productivity software App to Fletcher Aluminium Group and 100 manufacturers NZ nationwide.

In 2001 – 2022 Founding Director Empower Workshop Productivity & Scheduling Software App. 236 manufacturing and engineering clients mainly throughout NZ and Australia, also UK and US.

Iain Hosie

Iain Hosie is a respected figure in the NZ Advanced Manufacturing and Materials sectors, with extensive experience in product development, research projects and commercializing tech products. Iain is a Director and Founder of Nanolayr Ltd, Director for the NZ Institute for Minerals and Materials Research, Commercial Director for Fabribotics Ltd, and Executive Council of BiotechNZ.

Industry 4.0 transforming manufacturing processes for increased efficiency

Frank Baldrighi, business development manager – Australia and New Zealand, GETAC

Thanks to digital transformation powered by artificial intelligence (AI), automation, and machine learning (ML), manufacturing processes are becoming smarter, more efficient, and safer.

This transformation is often referred to as industry 4.0, or the fourth industrial revolution, and marks the beginning of a new era of digitalisation, data-driven decision-making, and smart automation.

In the manufacturing industry, digitising certain crucial key performance indicators (KPIs) has long been a challenge. Among these persistent issues is the need to reduce downtime and enhance worker productivity. Industry 4.0 promises to change this for both process and discrete manufacturers.

By leveraging data as its core resource, Industry 4.0 delivers a ‘smart’ factory that is not only efficient but also capable of self-correction and self-optimisation. Mobile devices on edge have a crucial role to play in this modern data-driven landscape. These devices serve as a central access point for all data-driven decision-making processes. Their sturdy build and portability also make them highly reliable tools on the plant floor of a smart factory.

Here are some ways in which Industry 4.0, through edge devices, can deliver results: Improve worker productivity

To enhance the productivity of workers, mobile devices can serve as a valuable tool for completing administrative tasks effectively. This includes clocking hour sheets and signing off on completed tasks, which can be easily accomplished through the convenience of a digital device compared to manual and paper-based processes that often lead to inaccuracies and lack real-time visibility into production processes.

Through the use of a mobile device, workers can access the company’s manufacturing execution system (MES), which offers centralised information and real-time updates.

This delivers a more collaborative approach to work, ensuring that every worker is on the same page and working towards common goals. And, the ability to access data from all plants provides a more holistic view of the manufacturing process, regardless of geographic location.

The availability of this data can help plant managers and workers make informed decisions to fine-tune their actions based on KPIs. This can lead to more efficient processes, improved production outputs, and ultimately, increased productivity.

Decrease machine downtime

The traditional run-to-fail model of equipment maintenance is wasteful and potentially catastrophic. It involves running machines until they break down or replacing parts after specified periods, regardless of whether they show signs of wear and tear.

This approach can tie up capital in unnecessary parts and cause production delays, leading to lost revenue and reduced customer satisfaction.

Industry 4.0 takes a more proactive approach to maintenance, using rugged mobile devices with sensors to detect potential issues and faults in machines in real-time. By continuously monitoring the health of machines on the production line, workers can fix problems before they become critical, and plant managers can quickly resolve issues, leading to an increase in machine uptime. Furthermore, when alerted to potential machine issues, workers can use their mobile devices to pull up manuals, access augmented reality (AR) applications to overlay diagrams of parts against what they see on the floor, and even call-in remote experts to troubleshoot more complex equipment.

Staying ahead of the curve

Digitisation and automation in manufacturing processes through industry 4.0 will bring a new era of efficiency and productivity. This transformation is crucial for manufacturers to remain competitive in a rapidly changing market.

Companies can purchase as much digitisation as they can afford, and incremental positive changes can add up quickly, leading to real gains.

In today’s manufacturing environment, where every second counts, the importance of mobile devices, purpose-built for ruggedness and portability, cannot be overstated.

These devices are not just tools that let workers access critical information on the go; they are also a means to increase efficiency and productivity, reduce downtime, and provide real-time insights into production processes.

By embracing industry 4.0 and mobile edge devices, manufacturers can achieve digital maturity, optimise their production processes, and stay ahead of the curve in a rapidly changing market.

Tech at the edge -Trends that need to reshape NZ -*Doug Marsh, JP

Efficiency, productivity, and profitability via Wright’s and Moore’s scale Law has been the quintessential mantras for global manufacturing industries. There is a lot of haze around the benefits of AI in digital manufacturing in NZ and how it has been key in driving transformation from conventional manufacturing to digital.

Entrepreneurship Innovative AI Technology is the creator of insane economic growth from the early 2020’s.

But NZ was slow, even complacent, to the onslaught of new technologies hitting world markets.

But reflective thought of some of the more relevant tech AI trends lays out a convincing, even exciting, state that something significant is happening.

It is the magnitude of these changes that is opening the door to new innovations - business growth transition, business model productivity gain and PEG Many AI-based solutions give agility responsiveness to changing conditions in real-time for greater confidence safety, profitability, and sustainability. The use of AI is to increase throughput and yield and to reduce conversion costs.

One of the biggest hurdles for many manufacturers is to scale effectively. This is the fundamental purpose to fully benefit from the impact of AI. Difficulties arise from a lack of AI capabilities/

The “Fish Rots From the Head” and NZ manufacturing, it is said, is “cast” in the lower quartile of global competitiveness productivity and advanced technology take upa clarion call for NZ to do better. Exploring realistic scenarios, implications, and opportunities to forge competitive advantages increase exponentially in terms of profitability scaling and innovative Tech at the edge Research reveals innovation develops faster by virtual connectivity with global peers making it cheaper easier to test, launch, and scale innovations. 90’s strategic thinking cannot hope to keep pace on it’s own.

Companies need to be much more involved in global digital networking outside their organisation’s day to day routines to tap opportunities and acquire innovative and execution know how.

They will also benefit from government monetary incentives.

it is a major contributor to South East Asia’s economic superiority through semi conductor innovation.

South Korea business through Government collaboration resulted in incentivising and manufacturing for:

* Technology take up

* Productivity growth

* Innovations and competitiveness globally commercialised delivering export incremental growth

*Doug Marsh

Life Fellow IMNZ, Fellow IoDNZ (Rtd)

40 year Chair Director

Manufacturing Entrepreneur

Consul South Korea (Rtd)

Founding President Business NZ

NZ Past President Inst. Management

New Zealand research to fly on International Space Station

A research facility prototype developed in Christchurch will soon orbit Earth aboard the International Space Station (ISS) under a partnership between the Ministry of Business, Innovation and Employment (MBIE) and US space company Axiom Space.

The facility for studying protein crystal growth in space, developed by Senior Lecturer at the University of Canterbury’s School of Product Design Dr Sarah Kessans, in collaboration with teams from Arizona State University and Christchurch companies Asteria Engineering Consultancy and Intranel, was one of two projects selected for initial feasibility studies in 2022.

“We signed a Memorandum of Understanding with Axiom last year and agreed to two feasibility studies, one of which led to Dr Kessans’ project,” MBIE Director of Innovative Partnerships Joe McKay said.

“This facility could lead to major advances in medical, biotechnological, food science, and agricultural innovation and we are excited to support the next step.”

Sarah’s research facility is scheduled to fly on Axiom Mission 3 (Ax-3) later this year, which will be the third private astronaut mission to the ISS.

“Being able to conduct this research on the ISS is such a huge opportunity and really is critical to what we’re trying to achieve in terms of scientific innovation and future commercial outcomes,” Sarah said.

“When protein crystals are grown in microgravity, they can develop into larger and higher quality crystals than what we can grow on Earth. These crystals can then be used to

create high-resolution pictures of the protein’s structure. If we have a detailed picture of what virus proteins look like, for example, we can develop things like antiviral drugs and vaccines.”

Current facilities for protein crystal growth on the Space Station require significant time and resources for astronauts to mix samples, set up experiments, observe growth and adjust settings as needed. By developing a facility that is self-contained, autonomous, and allows for on-orbit analysis of thousands of experimental conditions, Sarah hopes even more research can be conducted at a lower cost into the future.

“We can do a lot of analysis up in microgravity and can gain a great deal of information from the real-time data that we will be able to downlink during the experimentation on the ISS,” Sarah explained. “But the real value is in being able to get those experiments back to researchers on Earth for further analysis.”

“That’s why we’re excited to be sending the first prototype of our facilities to the International Space Station with Axiom Space. This initial project represents just the beginning of what we hope to develop into an entirely new industry in New Zealand at the interface between aerospace and biotechnology.”

Aotearoa New Zealand’s partnership with Axiom Space, especially as they transition to operation of their future commercial space station in low-Earth orbit, will create opportunities for commercial microgravity research. Under the partnership agreement, New Zealand has also joined

Axiom Space’s Access Program, an initiative to grow space ecosystems alongside governments from around the world. “This membership is a natural move for New Zealand, which is already contributing to projects that will fly on future Axiom Space missions,” Joe said.

Other local research set to fly to space includes a new superconducting magnet technology demonstrator, developed by Paihau—Robinson Research Institute, Te Herenga Waka - Victoria University of Wellington and hosted on Nanoracks’s (Texas, USA) test facility on the outside of the ISS.

The experiment is a key milestone which will lead to the development of an extremely efficient in-space propulsion system. This research is expected to fly in 2024.

OSMA Board Director Dr Sarah Kessans.

SMART FACTORY SHOWCASE

Featuring

The Smart Factory Showcase

Your chance to experience the future of advanced manufacturing by immersing yourself in the Smart Factory Showcase.

Transform your business

Understand how Industry 4.0 can transform a business and see first-hand what a high level of maturity in Industry 4.0 technologies looks like, based on a real ‘smart factory’ in New Zealand.

The sessions

Feature a digital twin of Nautech Electronics’ Auckland facility which enables us to deliver real content and stories directly to you. The interactive session examines how Nautech integrated smart technology to enhance efficiency, connectivity, and processes. They also highlight how you can engage and improve employee experiences and enhance manufacturing agility.

Get started

Our aim is that you will leave the showcase feeling inspired by the solutions offered and armed with the knowledge needed to kick-start your own Industry 4.0 journey

Questions or feedback? Please contact - manufacturing@ema.co.nz

NETWORK SITE VISITS

The Network Site Visits is a programme to encourage sharing of Industry 4.0 knowledge across the sector. Whether you are well into your Industry 4.0 journey or just starting out, the programme provides a range of opportunities to expand your understanding of Industry 4.0 technologies and learn from others who have already embarked on their Industry 4.0 journey. Join us for events, undertake an assessment or expand your knowledge through resources and case studies.

eadiness Assessment

Companies can apply for a fully funded Smart Industry Readiness Index (SIRI) Assessment process to help accelerate their own journey towards Industry 4.0, the result of which will be a benchmark against other companies in their sector and a high level prioritisation roadmap.

Apply for the assessment

Factory Tour

The tours provide an opportunity to see first-hand what businesses have implemented as a result of the SIRI Assessment. They will showcase developments, specific technologies and learnings on their Industry 4.0 journey. Targeted at local manufacturers, these events are delivered across New Zealand and are a great way to network and connect with others in the region.

Upcoming events

Webinars

The webinar series is an opportunity to hear stories from all stages of the Industry 4.0 journey, focusing on the benefits of implementing these technologies, what challenges you may need to overcome along the journey and specific examples of Industry 4.0 technologies, all based on the experience of New Zealand companies.

Upcoming events

Case Studies

Documented as part of the SIRI Assessment, the case studies provide an opportunity to understand a specific example of how Industry 4.0 technology has been implemented in a manufacturing environment. They will provide you with key learnings to take away and inform your own journey.

Resources

PROUDLY SUPPORTED BY

Christchurch Arena

REGISTER YOUR TICKETS HERE TO BE IN TO WIN AN EINSCAN HX HYBRID LASER 3D SCANNER

Prioritising functional and machine safety with EIS

Compliance can feel like it’s heavy on resources and effort. Navigating the complex world of compliance can be a daunting and expensive task for any business. But you don’t know expensive until you’re not compliant…

You don’t want to spend your time on compliance. We’re the experts! Let us do it for you, allowing you to focus on the bigger picture of your business.

Functional and machine safety are critical components of any workplace involving equipment, industrial processes or machinery. Injuries and accidents resulting from the use of machinery or equipment can lead to lost productivity, financial loss, and legal liabilities for both employees and employers.

EIS understands how crucial it is for businesses to prioritise functional and machine safety to ensure the wellbeing of their employees and equipment.

Functional safety involves ensuring process and mechanical systems operate as intended, minimising potential failures that could lead to harm. This includes identifying hazards, evaluating their risk and reducing that risk to tolerable levels using automated safety systems. Machine safety focuses on identifying and eliminating hazards associated

with machinery or equipment, provide solutions incorporating state of the art technologies such as ensuring fit for purpose guarding both mechanical and optical electric , training employees on safe operation procedures, conducting regular maintenance and inspections and compliance documentation.

Investing in functional and machine safety has numerous benefits for businesses. Reducing the risk of accidents and injuries in the workplace can minimise downtime within the business, reduce absenteeism, and in some cases with automated safety systems increase productivity, reliability and higher efficiencies.

Additionally, prioritising safety can help businesses avoid costly legal liabilities resulting from workplace accidents.

Functional and machine safety should be a priority for any business that values the safety and wellbeing of its employees and equipment. Investing in safety measures and protocols means businesses can protect their employees, their bottom line, and their reputation.

Come and chat with us at SouthMACH on 24-25 May for your chance to win a free compliance audit of your business and systems.

www.eis.co.nz

INVENIO provides total industry solutions, from software sales to engineering services and even to talent and placement services. Established in 1986, Invenio aspires to build lasting, sustainable partnerships. Our team of experienced industry experts can provide quality, actionable consultations to help you pinpoint ways you can improve your workflow and productivity and to support your digital transformation journey.

SouthMACH 2023 Christchurch

24-25 May

SouthMACH, the bi-annual technology trade fair returns to Christchurch Arena In two weeks time.

-Doug Green, Publisher, NZ Manufacturer www.nzmanufacturer.co.nz

In these times of on-going change in products and services for the manufacturing sector, some of it quite profound, it is important to visit trade fairs like this one to see the latest technologies available and mix and discuss business and opportunities with your peers with your peers.

Ideally, visitors will come from Canterbury University, progressive members of the chamber of commerce, industry leaders, engineers, technical specialists, operations managers, company leaders and all who have a stake in the future of manufacturing in the South Island and from further afield.

Partake in “Make NZ’s ‘Listen and Learn’ manufacturing industry conference on May 24, as part of SouthMach which will focus on peer-to-peer learning opportunities for manufacturing leaders.

It’s a one-day conference with presentations from well-known and exciting manufacturing leaders across three sessions,” says Aad van der Poel, exhibition sales and event manager for Xpo Exhibitions, organiser of SouthMach 2023. Sessions during Listen and Learn will include a focus on the local and global environment that New Zealand manufacturers operate in, innovation for profit – as well as products, processes and business models.

Reducing waste and carbon footprint will be covered and many are looking forward to MESNZ’s James Neale with his presentation ‘If you want to reduce your carbon footprint, do your homework first’. Van der Poel says that the wide variety of key industry people with crucial information will help manufacturers meet customer expectations, become

www.southmach.co.nz

an employer of choice, and retain a social licence to operate, Industry 4.0, to name but a few.

“You will walk away with plenty of new ideas for making the boat go faster in your factory, and future-proofing you manufacturing business,” says van der Poel.

“It’s a chance for the industry to do as the name suggests and listen and learn, through such experienced and varied presentation speakers, and then implement what they have learnt into their own businesses and operations,” says van der Poel. The programme of events begins at 9am and concludes 5.30pm, followed by a social hour where networking is encouraged.

For more information or to buy tickets visit www.makenz.org/

A great opportunity for manufacturers to pick up new ideas

We all know SouthMach as an action-packed event where manufacturers - and all others with a passion for manufacturing – get to see and try out latest developments in manufacturing processes and technology.

This year manufacturing business organisation MAKE NZ (https://www.makenz.org) is adding another attraction to the show. Responding to the often-raised desire to have an industry conference that talks about opportunities and issues shared right across manufacturing in New Zealand. “Our Listen and Learn manufacturing industry conference on May 24, as part of SouthMach, will focus on peer-to-peer learning opportunities for manufacturing leaders. It’s a one-day conference with presentations from well-known and exciting manufacturing leaders across three sessions,” says Dieter Adam, Community Champion for MAKE NZ.

SouthMach 2023 will take place over two days at Christchurch Arena in Addington, Christchurch, May 24-25, and is the South Island’s premier technology trade show celebrating the heartland of New Zealand manufacturing.

Sessions during Listen and Learn will start with an overview of the local and global environment that New Zealand manufacturers operate in. In its main session, it will focus on Innovation for Profit – hearing from manufacturing leaders about innovation of products, processes and business models that have improved their profitability.

The final session will present examples of how manufacturers are mastering ‘external contributors to success’ – expectations of customers and employees and meeting sustainability criteria, thus retaining a social licence to operate.

“You will walk away with plenty of new ideas for making the boat go faster in your factory, and future-proofing your manufacturing business,” says

Dieter Adam. “It’s a chance for the industry to do as the name suggests and listen and learn, through such experienced and varied presentation speakers, and then implement what they have learnt into their own businesses and operations.” says van der Poel. The programme of events starts at 10 am

and concludes at 5.30pm, followed by a social hour where networking is encouraged.

For more information or to buy tickets visit MAKE NZ’s conference webpage: www.makenz.org

Griffin’s successful recipe for producing great people

For over 150 years, New Zealanders have been enjoying Griffin’s ‘bikkies’. Founder John Griffin and his team created a culture of continual improvement back then, and today it is as strong as ever. Proud to produce a continuous and innovative range of biscuits, crackers, chips and nutty bars, Griffins also invests heavily in continually upskilling their staff.

Olga Duncan is Training and Development Advisor - Supply Chain and Operations, working across both Griffin’s manufacturing plants in South Auckland. With around 700 staff nationally, Olga says that, like many businesses today, hiring staff is one of the biggest challenges they face. A company-wide commitment to developing staff has benefitted the business over the years, particularly in the engagement and retention of their staff, but also the number of staff actively wanting to step up and apply for other internal roles.

Over twenty years ago, the company first implemented a staff training programme that offered a formalised career pathway. Partnering with Competenz Te P kenga, they have seen nearly 900 programmes completed by staff in that time. Programmes range from traineeships to apprenticeships, with the majority being in Food or Beverage Processing, but also New Zealand Certificates in business-related qualifications and mechanical engineering.

Once on-board, new recruits can expect a formalised plan to further their knowledge and job competency. New machine operators initially undertake a 3-4 month Limited Credit Programme in Food or Beverage Processing before progressing to level 2 and 3.

The Griffin’s Snacks Training Team deliver many of their training programmes in-house and is a registered Competenz Te P kenga Workplace Assessor, with the ability to assess a broad range of qualifications.

Olga says the training is tailored and reviewed regularly by Griffin’s and Competenz Te P kenga, ensuring it is always relevant.

“Many of the assessments are directly related to their real work and take place using the machinery they would use at their workstations – the familiar environment helps to create meaningful learning connections.

“We try to engage the staff right from the start, and we work hard to create a supportive culture to help them complete their training.”

As well as staff gaining knowledge and qualifications, the company has seen an increase in staff confidence where they will apply for higher roles and actively inquire about other development opportunities available to them.

Competenz Te P kenga Account Manager Bill Fisher has worked with Griffin’s for over ten years. He has been impressed by the manufacturer’s commitment to continuous improvement of their inhouse training.

“The Griffin’s Snacks workplace assessor and training team have an incredible assessment scope across many qualifications and have written training and assessment material closely aligned to the business.

“The training team is very focused and over the past five years has added a framework around their internal training to produce many successful outcomes for their learners,” said Bill.

With 54 active enrolments from a wide range of ages and nationalities, Bill says he and Griffin’s Snacks training communicate almost daily to process enrolments and completions, and to provide ongoing technical support. During the COVID-19 period, when no visitors were allowed on-site at Griffin’s, Bill and Training Team developed an excellent online working relationship. They both found it so efficient that online meetings have continued.

Olga’s background has been working with large companies specialising in quality assurance and lean manufacturing, underpinned with training programmes. In her current role, Olga says she enjoys being part of a team where the company culture is focused on supporting the development of their people.

“It is so rewarding to be part of people’s learning journeys.”

Solutions for dust problems

Dust and fume extraction problems can cause serious health and safety issues for workers in a variety of industries. Exposure to harmful dust and fumes can lead to respiratory problems, lung disease, and other health issues. In addition, it can impact the quality of the products being produced and can result in damage to equipment.

AtSource understands the importance of clean air in the workplace, and we have the expertise and world-leading products to provide engineered solutions to these problems.

Our 20 years of experience in the industrial ventilation industry has allowed us to design and install extraction systems for a wide range of industries. Our team has worked with vehicle workshops, dental laboratories, emergency vehicle stations, chemical processing plants, food production plants, schools, universities, boat builders, steel fabrication shops, and many others.

No matter the industry, if there are workplace dust and fume emissions, AtSource can provide a solution to overcome the problem and achieve clean air in the workplace.

Our engineering expertise, along with products by Nederman, SEAT, and other global industry leaders, ensures that the systems we design and install are made to last. We take pride in designing and installing systems that are sufficient for your needs and stand by our systems with full service and

support NZ-wide. We provide only well-engineered, safe, and compliant systems to help you meet your health and safety requirements.

At SouthMach, we will be showcasing a new product – Drying Systems by Pronomar. These systems are designed for a better work environment where the use of Personal Protective Equipment (PPE) is a necessity.

Instead of donning wet gear for the next shift, Pronomar drying systems safely and efficiently dry all kinds of clothing from jackets to boots and gloves. This not only means greater comfort and sustained health for workers, but it also increases the lifetime of the PPE gear.

If you are facing dust or fume extraction problems in your workplace, come and talk to the AtSource team at SouthMach. Our expertise in the industry and world-leading products mean we can provide engineered solutions to meet your specific needs. We stand by our systems with full service and support NZ-wide, and our commitment to safety and compliance means that you can trust us to provide well-engineered, safe, and compliant systems.

SHAPE Energy providing SOUTHMACH a breath of compressed air

Compressed air systems are often overlooked as a significant contributor to an industrial business’ electricity bill, with up to 10% of the total cost being attributed to this service. However, for some sectors, this percentage can be even higher. In light of this, SHAPE Energy will be demonstrating the importance of tailored compressed air solutions for the manufacturing and engineering industry at SOUTH MACH 2023.

Energy Saving Systems

SHAPE Energy’s 7.5kw high-pressure compressed air system will provide exhibitors with the necessary air to showcase their products and services at SOUTH MACH. By offering reliable and efficient air compressors, piping, hosing, filters, and accessories, SHAPE Energy aims to optimize the energy consumption of the compressed air system while enabling exhibitors equipment to operate quietly and effectively during the show.

Take targeted action

To reduce costs and improve equipment reliability, productivity, and production output, targeted action is crucial in reducing compressed air waste. While the compressor unit accounts for the largest energy consumption in the system, it is essential to consider the overall demand on the system, its design, and maintenance.

These factors can significantly impact the energy

For example, even the most efficient compressor on the market is of little use if connected to a system with a 40% leak rate, resulting in more effective waste production.

Tailored Solutions

SHAPE Energy’s tailored compressed air solutions aim to reduce waste and lower the carbon footprint of the manufacturing and engineering industry, easing its impact on the natural environment.

By optimising compressed air usage and reducing energy costs, SHAPE Energy highlights the importance of reducing energy waste with customized compressed air solutions.

SHAPE Energy’s compressed air services will showcase the significance of tailored compressed air solutions in the manufacturing and engineering industry, emphasizing the importance of reducing energy waste, lowering carbon footprints, and optimising energy consumption to drive productivity and reduce

FUTURE OF ADDITIVE METAL MANUFACTURING IN NEW ZEALAND IS HERE.

Neil Beeslaar, SHAPE Energy, Manager Compressed Air & Gas, Stands with SHAPE’s range of NUKOR Air compressors.

SOUTHMACH 2023 REVIEW

INDUSTRY 4.0 CONSTRUCTION WORKSHOP TOOLS THE

CIRCULAR ECONOMY

A LOOK AT: AI

Advertising Copy Deadline – 8 June 2023

Editorial Copy Deadline – 8 June 2023

Advertising – For bookings and further information contact:

Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay

Email:

Editorial material to be sent to :

Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay

Email: publisher@xtra.co.nz

Tel: 06 870 9029

At NZ MANUFACTURER our aim is to keep our readers up to date with the latest industry news and manufacturing advances in a tasty morsel, ensuring they do not get left behind in the highly competitive and rapidly evolving manufacturing world.

Opinion

Increasing interest in ZLD driven by costs and environment

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

In 2021 the global market for zero liquid discharge (ZLD) technology was estimated at US$1 billion and is forecast to grow at almost 12% over the next ten years1. The rise is being driven in particular by an increase in adoption of the technology by the food and drink and textile industries as a growing world population puts greater pressure on fresh water supplies.

What is ZLD?

Zero liquid discharge (ZLD) is a liquid waste stream treatment which involves transforming liquid waste streams into clean water (which can be reused) and a minimum volume of solid residues.

One of the advantages of ZLD over other treatment techniques is its theoretical ability to separate unwanted materials from water, whether they are benign, hazardous or toxic. The resulting solid residue is often more stable, making it suitable for recycling or landfill.

However, poor management or handling of the remaining residue can result in unintended environmental consequences. For example, storage ponds may leak or affect local wildlife while there is the potential for toxic chemicals to leach into groundwater from landfill.

It is therefore important that when implementing a ZLD system, full consideration is given to the entire process, including the ultimate fate of liquid and (semi-)solid waste streams. A well-designed ZLD system should minimise or even eliminate liquid waste streams, resulting in clean water for reuse or environmentally-friendly discharge, and a solid residue suitable for further processing (often to recover valuable components for use elsewhere) or for safe disposal.

The factors driving ZLD uptake

According to Transparency Market Research1, ZLD is being implemented across a wide range of industries, including chemical and petrochemical production, food and drink production, textiles, energy and power, and pharmaceutical manufacturing.

These industries are being driven to adopt the technology due to growing environmental awareness of the hazards of toxic wastewater and increasing environmental regulation. In turn this has increased the costs of handling and disposing of such waste streams, and in some cases has made such disposal impossible. As a result, companies are looking for more sustainable alternatives, and ZLD is one of the leading technologies in this area.

up its waste processing systems. ZLD methods are already widely used in industrial wastewater treatment to recover useable and profitable minerals and by-products from waste streams, and the success of such systems is encouraging their take up by other businesses. In 2015 the Indian government issued a draft policy requiring all textile plants generating more than 25 cu. m. of wastewater effluent a day to install ZLD facilities2.

ZLD technology has been utilised in various markets around the world, including Europe, Australia, Canada, the Middle East and Mexico, but the biggest markets, and the biggest potential for expansion, can be found in the United States, China and India2.

The benefits and challenges of ZLD

In general terms, the use of ZLD reduces water pollution and augments water supply, but this is sometimes offset by high costs and energy consumption and in the past these factors have limited the uptake of the technology.

Wastewater reuse minimises the volume and environmental risk of discharged wastewater, but also alleviates the pressures associated with the abstraction of freshwater, but these benefits have to be balanced against the economic and energy costs of implementing ZLD systems.

As water scarcity and environmental pollution around the world intensifies, ZLD becomes more feasible and widespread, and the relative costs of ZLD technology versus the alternatives (assuming alternatives even exist) are lowered.

Increasing the efficiency of ZLD

Diary

Profiles

www.nzmanufacturer.co.nz

The specific factors driving uptake are different for each industry. For example, in the energy and power sector (historically the largest user of ZLD technologies), access to clean water suppliers is an increasing concern.

Pollution control is also a major driver, and the US EPA considers zero discharge as the preferred treatment option for fly ash and bottom ash transport water, and wastewater from flue gas mercury control systems2.

Elsewhere, growing awareness of the toxic effects of petrochemicals and petrochemical waste products is driving efforts by the industry to clean

Separating all of the water out of the product requires large amounts of energy. It takes roughly 6 times more energy to evaporate water (latent heat) at its boiling point then the energy needed to actually bring it to that boiling point (sensible heat).

continued on Page 29

HRS Unicus Series scraped-surface evaporators are used to maintain thermal efficiency and remove fouling during evaporation in ZLD installations.

In nursing, in dispensing machines, in the field or in factories, collaborative lightweight robots can help automate monotonous tasks. To enable interactive service robotics concepts to be implemented quickly and inexpensively, igus has developed the new generation of the ReBeL. The lightweight plastic robot has a fully integrated tribo strain wave gear with motor, encoder, force control and controller. Electronic components in the fully integrated strain wave gear allow human-robot collaboration to be possible (HRC). This is because the encoder technology enables forces and torque to be determined and limited via the motor current in combination with the angle measurement. For this, igus relies on a double encoder, in which a measurement is carried out in front of and behind the joint. This detects forces and torque levels and responds accordingly.

Plastics is a game changer in automation

The use of plastic in the ReBeL results in an extremely compact, lightweight design. With a net weight of

Workshop Tools

Cost-effective automation: igus presents the world’s lightest cobot

Automation made very easy: with the new ReBeL, Treotham now presents a plastic cobot from igus that weighs only ten kilograms. Together with low costs, low maintenance and simple operation, the ReBeL makes new innovative ideas in service robotics feasible for smaller companies and start-ups – from installed use on agricultural drones up to mobile support as household help.

less than ten kilograms, the robot is the lightest cobot on the market. Its payload is two kilograms and it has a reach of 700 millimetres.

Thanks to the low starting price, the ReBeL can even be used in areas where the use of robotics was not previously worthwhile. Many new innovative ideas are now becoming feasible: from use in an automated guided vehicle system to use as a bartender.

Many young companies are currently showing what is possible with low cost automatio. An example, in the textile industry, as at ADOTC. Here an igus articulated-arm robot undertakes the automatic feeding and removal of textile pieces to and from the sewing machine. Since energy prices for robots are comparable worldwide, this automated product is worthwhile.

Entry barriers for robotics continue to fall

In addition to the price, igus also lowers other entry hurdles such as complexity. For example, the new ReBeL, like the other articulated-arm, delta or linear

robots from igus, can be tested and operated very easily.

For this purpose, igus offers free control software. It is easy to define and simulate the movements of the robot quickly. This saves companies commissioning costs and makes them less dependent on integrators. Those who require further support can also make use of the new RBTXpert service, which helps in the selection of the right low cost automation solution. After a free online consultation with the RBTXpert, the suitable automation system can be tested. Based on the tests, the RBTXpert can then quote the customer with a price. This is made possible by the low cost automation marketplace RBTX.com where components, hardware and software from different manufacturers can be found.

Among them are various robot kinematics, cameras, GUIs, grippers, power electronics, motors, sensors and control systems. In line with the “Build or Buy” approach, customers can configure individual components for their robot or ready-made robotics solutions and order them from Treotham.

Workshop Tools

Kemppi launches new portable welding machines for Master M series

Leading international welding equipment manufacturer, Kemppi, has released two new portable and versatile welding machines for MIG/MAG welding – the Master M 205 and Master M 323.

Part of the popular Master M series, the Master M 205 and Master M 323 are perfectly suited for site work, boat building and repair shops, as well as dedicated hobby welders. Their small size and transportability, make them an ideal choice for repair welding. Both models deliver excellent usability, best-in-class welding performance, and a smooth parameter setup.

Developed in collaboration with professional welders and manufactured in Finland, the M 205 and M 323 let users weld quickly and easily for quality results.

The Master M 205

The Master M 205 has been created specifically for welding tasks that require lightweight, easy-to-move welding equipment, but also high-quality welds.

Highly portable and powerful, the Master M 205 is a MIG/MAG welding machine for manual, synergic, and pulse MIG/MAG welding of stainless and light steel, and aluminum.

Delivering true grunt and convenience, the Master M 205’s 200 A, 1-phase power source operates with a 40 percent duty cycle. Plus, the Master M 205 comes with 17 welding programs for pulse MIG and 20 welding programs for 1-MIG. These include welding

programs for Fe, Ss, AlMg5, AlSi5, CuSi3, and CuAl8 filler materials.

Very easy to use, the Master M 205 features a large LCD screen that is bright and easy to read. Self-charging LED lights can be turned on to improve safety, particularly in dim and confined spaces, and they work with or without mains power. The machine is also hassle-free to operate. The new model can be quickly set up thanks to Weld Assist. This feature saves time and makes welding easier with automatic parameter settings. Just select the material thickness, joint type, and welding position, and start welding

The Master M 323

This model is ideal for sheet metal welding, and thanks to its portable size and versatile accessories, it is also well suited for welding environments with challenging spaces.

A high-performance, portable MIG welding machine, the Master M 323 delivers 320 amps of power at a 40% duty cycle. To help improve welding quality and save time, it comes with 28 built-in welding programs for Fe, Ss, AlMg5, AlSi5, CuSi3, CuAl8, and FC-CrNiMo filler materials. Plus, the Master M 323

includes 4 welding programs for the MAX Cool arc welding process.

Equipped with 6 memory channels, both models also let users save chosen parameters for fast retrieval. The ability to save customised settings means welders do not have to go through an initial setup for every job, saving precious time while helping to boost productivity.

Like the Master M 205, the Master M 323 also comes with Weld Assist, a large LCD screen that is easy to read and use, and self-charging LED lights. For greater convenience, both models also feature a safe-lift handle design. The handle has been reinforced with metal so that it can be lifted by crane.

A powerful, lightweight welding machine that can go anywhere on site, the Master M 323 is perfect for high-performance industrial welding.

HRS Heat Exchangers operates at the forefront of thermal technology, offering innovative and effective heat transfer products worldwide, focusing on managing energy efficiently

Master M 205 and 323 models complete the Kemppi Master M series.

Mitigate or adapt? With climate change it’s both

If you’re dealing with the aftermath of the weather events, as many are, we wish you well.

Adapting to climate change. Since the disastrous weather earlier this year, it’s a term we’ve heard regularly in the mainstream media. What does adapting involve? Why does it matter? As a manufacturer, do you need to keep reducing (mitigating) climate change as well as adapting to it? (The answer to that last question: an emphatic yes!) This article explains why mitigating and adapting to climate change must go hand-in-hand for New Zealand manufacturers.

But first, the science

Let’s start with the global picture. The Intergovernmental Panel on Climate Change is adamant: a 1.5°C increase in global temperatures over pre-industrial levels will adversely affect the world’s climate. A 2°C increase will be more serious still. The cause of this warming? Greenhouse gases (GHGs).

Zoom in to Aotearoa New Zealand. Scientists at the National Institute of Water and Atmospheric Research (NIWA) and University of Waikato are convinced that Cyclone Gabrielle’s devastating rainfall is an example of climate change. The cause? Global warming, due to GHGs, increases air temperatures. Warmer air holds much more water vapour. When this vapour cools, it rains.

What does mitigating climate change involve?

Think of mitigation as the fence at the top of the cliff. Mitigation is about addressing the causes of climate change by reducing the GHGs we emit. If you’re a manufacturer, it could involve reducing the carbon in your products or moving your factory to renewable electricity.

To date, governments and businesses have focussed on mitigation – with good reason. We all benefit when we reduce climate change.

What does adapting to climate change involve?

If mitigation is the fence, adaptation is the ambulance. With a poorly maintained fence (an atmosphere damaged by GHGs), we need to invest

Battery power

plus

in a fleet of ambulances to manage potential falls (the impacts of a changing climate).

At a national level, adaptation could involve moving vulnerable communities away from the coast (‘managed retreat’) and building infrastructure like bridges to withstand extreme weather. For a manufacturer, adaptation might mean planning how you’ll run your factory if extreme weather disrupts your power supply or if you can’t get your raw materials delivered.

It’s both/and, not either/or

Mitigation and adaptation go together. We must continue to mitigate – hammer in those fenceposts, plug up those holes. If we stop, the holes will get bigger. Bigger holes mean a weaker fence (less chance of meeting that crucial 1.5°C target), more falls (extreme weather and rising temperatures), more investment in our fleet of ambulances (adaptation), and so on. It’s a vicious circle. We need to adapt too. Some of the holes will be hard to fix or may take longer to mend than we’d hoped. We need to put some ambulances on standby. The good news for manufacturers: the activities involved in both mitigating and adapting will help you manage your risks and costs, engage your team in your sustainability work, and strengthen relationships with suppliers and customers. Here’s what you need to do.

Continue to mitigate (mitigate, mitigate!)

1. Reduce the carbon footprints of your products and packaging. A Life Cycle Assessment (LCA) provides science-based data to help you measure your footprint and understand how to improve it.

2. Reduce the carbon footprint of your business Get your house in order, maybe by upgrading to a more fuel-efficient boiler. Then work with your suppliers to help them reduce their carbon footprints too. Set a science-based target to reduce your emissions

3. Spread the word. Enlist support from climate-conscious customers. They’re hungry for credible information to help them choose lower-carbon products. (If you supply building products, ‘green building’ products will be in

demand.) Consider Environmental Product Declarations (EPDs). They tell the environmental story of a product over its life cycle in a simple format, and they’re independently verified.

Start (or continue) adapting

1. Identify and act on your climate risks. Physical risks result from extreme weather like Cyclone Gabrielle and gradual changes in climate like rising temperatures. Could a flood damage your main supplier’s factory? What will you do if your supply chain is disrupted for months on end? Transitional risks occur as we move to a lower-carbon economy. Some, like a carbon tax, are outside your control, but there are many you can manage. For example, you can invest early in lower-emissions equipment or end an agreement with a supplier who refuses to reduce their carbon. Planned changes are disruptive and costly but a sudden transition is worse.

2. Disclose your climate risks. Large NZX businesses must disclose these risks in the 2023/24 reporting year. The guidance of the Task Force on Climate-related Financial Disclosures (TCFD) and requirements of the External Reporting Board (XRB) explain what this involves.

3. Identify and act on climate opportunities. For some manufacturers, climate change brings opportunities. For example, redesigning a product to reduce its carbon may help you enter new markets.

Taking climate action is both/and. Keep mitigating. Make sure you adapt too.

www.thinkstep-anz.com

product stewardship for a brighter future

By Dominic Salmon, 3R Group Business Development – Sustainable Solutions

The transition away from fossil fuels will rely heavily on large batteries – it’s estimated that EVs and stationary energy storage batteries can enable 30% of the emissions reduction needed in the transport and energy sectors.

The conversation can often steer towards electric vehicles, but large stationary batteries are just as important.

Large batteries are not yet widely used in New Zealand outside of EVs and hybrid vehicles. However, the potential applications for stationery storage are huge. These range from use in homes to store excess solar power, to national power grid stabilisation, upgrading old, inefficient battery systems and even as back up for key infrastructure in the event of natural disasters such as Cyclone Gabrielle.

The range of stakeholders in this area is wide, from EV and home solar system owners (and potential

owners) to energy generation companies, vehicle and battery importers, recyclers and, well, just about anyone who has energy needs.

Like all solutions though, thought needs to go into preventing unintended consequences. In the case of batteries, it’s ensuring they are ethically and sustainably produced and don’t become a problematic waste stream at end of life. While small markets like New Zealand, which don’t mine the minerals or manufacture large batteries, can’t have a direct impact on their production, we can ensure they are used as efficiently as possible. Importers, retailers and consumers can also use tools like the Global Battery Alliance’s battery passport to track battery health and environmental impact and create demand for ethically and sustainably manufactured batteries.

Making this transition obviously isn’t straight

of

Photo credit: Kelly Sikkema on unsplash

forward but there is a significant amount

work being done, including in Aotearoa New Zealand by the Battery Industry Group (B.I.G).

Circular Economy

Batteries in the Land of the Long White Cloud

One of the biggest perceived sticking points for batteries is concerns over what happens to them at the end of life. The majority of large batteries are not simple to recycle, and detractors often point to their end of life as a major obstacle. That’s where product stewardship comes in.

In New Zealand, legislation has been passed for all e-waste, including batteries, which requires regulated product stewardship schemes to be developed for these ‘priority products’.

B.I.G. is currently designing a product stewardship scheme for all non-lead acid batteries over 5kg, which will give certainty to users that they will be recovered, and repurposed or recycled.

The scheme is guided by circular economy principals, so keeping the batteries in use for as long as possible, utilising used EV batteries as second life storage before recycling them is a primary focus. Beyond managing the actual product, stewardship of the batteries can enable emissions reduction and create energy security.

Surging advancements and demand

Batteries are far from a new technology, but it’s one which is seeing fast-paced advancements. The development of solid-state batteries, for example, could see EV ranges exceed ICE vehicles and take the same amount of time to ‘refuel’.

The co-inventor of the lithium-ion battery, John Goodenough, recently announced his team has developed a solid-state battery which charges in

minutes, lasts longer, and holds three time as much energy as his old invention. These same advancements would mean stationary batteries can perform far better than they currently do.

The rapidly increasing demand for batteries means they have become a valuable commodity after their initial useful life has ended. As a result, the focus is less on simply keeping them out of landfill and more on enabling their continued use through innovation and collaboration.

An EV battery, for example, may only be useful to power a vehicle until it reaches the ability to hold around 70% charge, but can still serve for many more years as a stationary energy storage unit.

Modern battery technology is relatively new, so a battery’s secondary life is somewhat unknown. Many EV batteries are already far exceeding their expected life span as vehicle powerplants, so their secondary life as a static power storage unit could be another 10 to 20 years. The life of units built specifically for power storage, using the latest technology, could be even greater still.

While there is currently a demand for batteries at end of life for the rare earth metals they contain, as battery technology changes, that might not always be the case, so the stewardship scheme design must take this into account.

Current batteries are metallurgic in nature, which gives them value at end of life. Further advancements by moving to cellulose and plastic, which is currently being developed, will present new end of life challenges which scheme design needs to take into account.

Product stewardship

Unlike most other products, an end-of-life solution is being created for large batteries before they become a problematic waste stream. This forethought means there can be push back up the pipeline to the design and manufacture stages so batteries can last longer and be easier to reuse, repurpose or recycle.

Leading the charge in New Zealand is B.I.G, which kicked off in 2019 with a working group. In July 2020 the Government declared e-waste, along with five other product categories, as a priority product under the Waste Minimisation Act 2008.

In the same month the B.I.G working group submitted the first milestone report of it phase one work to the Ministry for the Environment – a testament to the pre-emptive approach around batteries. In 2021 the final milestone report for phase one was submitted, which explained how a potential product stewardship scheme could work for large batteries in New Zealand.

In 2022 governance of the B.I.G project transferred to the not-for-profit product stewardship organisation Auto Stewardship New Zealand.

Phase two work is now underway, including improved data sets on chemistry and weight of batteries, a non-EV battery stock take, progress on a

battery traceability platform, expanded stakeholder database, awareness and engagement, and the development on a business plan and financial model for the scheme.

The business plan is due to be submitted to the Ministry later this year. This second phase will take the scheme through to the point of implementation.

There’s little doubt batteries will play a big part in how we store and use energy. Through product stewardship, we can use them to create a far cleaner energy system without creating a new waste problem for future generations to deal with.

For more on the work B.I.G is doing I encourage you to visit big.org.nz

Developments

Dominic Salmon is the Battery Industry Group (B.I.G) Project Lead at 3R Group.

3R accelerates the circular economy through the design, implementation and management of product stewardship schemes and other sustainability services. They are the project managers for Phase Two development of the product stewardship scheme for large batteries. Find out more at www.3r.co.nz

Aotearoa diverts two million kgs of e-waste from landfill

Aotearoa’s leading e-waste recycler, Computer Recycling, has reached a remarkable milestone having processed over 2 million kilograms of e-waste for the year to March 2023.

Estimates suggest New Zealanders produce up to 100,000 tonnes of e-waste per year, with only 2% of it being recycled. Through enhanced recycling capabilities, Computer Recycling is now capturing 2% of the country’s e-waste on its own.

Through sustainable recycling and reuse practices, Computer Recycling has brought the nation one step closer to eradicating e-waste from general landfills. The scale of this waste reduction plays an important role in helping Aotearoa deliver on its future waste minimisation goals.

This milestone has come on the one-year anniversary since Computer Recycling’s launch of the world’s eighth, and New Zealand’s only, BLUBOX e-waste shredder and MSS optical sorting machine.

Patrick Moynahan, Computer Recycling’s Managing Director, says the implementation of the world leading BLUBOX technology has been an integral move forward in helping the company reach this point.

“BLUBOX has played an important role in helping us achieve this incredible milestone, having processed hundreds of thousands of kilograms of e-waste since its launch. Combined with the great work of our team and the existing processing systems we have in place, we’re now capturing the equivalent e-waste produced by 80,000 Kiwis .

“In March alone, we received 300,000 kilograms of e-waste for processing, a figure which continues to grow month on month. As we enter a new phase of growth, it’s exciting see what we’ve accomplished and get a taste of what lies in store for the months ahead,” says Patrick.

Since establishing in 2018, Computer Recycling has been committed to helping Kiwis reduce their carbon footprint and be more environmentally conscious, offering a range of services to help individuals and businesses recycle e-waste responsibly.

“Aotearoa is one of the worst offenders when it comes to e-waste, with the average Kiwi producing 20 kilograms of e-waste per year, one of the highest amounts per capita in the developed world.

“It’s clear New Zealand has a lot of room to grow with sustainability, and the nation’s waste production

Propelling EV charger deployment in NZ

Tritium DCFC Limited a global developer and manufacturer of direct current (DC) fast chargers for electric vehicles (EVs), has announced a strategic partnership with Jump Charging, a green energy charging and fuel infrastructure business, to expand access to fast charging infrastructure in New Zealand. The rate of EV adoption continues to grow in New Zealand and charging infrastructure will need to grow to meet the increasing demand. Nearly 20% of the 100,000 light vehicles sold in 2022 in New Zealand were battery electric, and the country is on its way to achieving its 2050 net-zero emissions reduction goals.

However, as of December 2022, there were only approximately 350 public charging stations in the country, or just one charging station for every 200

EVs registered in New Zealand. To address this gap, the New Zealand government has plans to expand on its initial vision for nationwide coverage of DC fast chargers every 75 kilometres along state highways. As part of this investment, the government is prioritising high-powered public charging hubs to match the rapidly growing number and increased requirements of electric vehicles and their drivers.

Jump Charging, a new Tritium distributor and service partner for New Zealand, is committed to further expanding access to publicly available charging in the country to accelerate decarbonisation of the transport sector.

The company is developing their network with Tritium fast chargers at its core and is planning to implement an initial 20 fast charging hubs at key locations followed by the rapid deployment of further sites nationwide.

Tritium CEO Jane Hunter emphasised that EV charging installation, maintenance, and education are crucial steps to helping New Zealand reach its 2050 net-zero emissions reduction goals, which were announced last year in the country’s first Emissions Reduction Plan.

Focused on the development of a reliable, purpose-built charging network of strategically located infrastructure, Jump Charging’s mantra of “fast, accessible, and visible” illustrates their commitment to ensuring all electric vehicle drivers have adequate access to charging.

The company offers its customers flexible purchase, lease, and partnership models, and they manage and

figures are testament to this. But we’ve recently seen a huge shift at Computer Recycling, having received a record- amount of e-waste.

“This suggests New Zealanders and Kiwi businesses alike are showing more consideration towards their waste and looking for alternatives, rather than sending unnecessary waste to landfill.

“It’s great to see to see this behavioural shift, and with climate-related reporting becoming mandatory for listed organisations, we expect local businesses will be focusing on sustainability even more this year,” Patrick concludes.

maintain all sites on the Jump Charging network to ensure a reliable and consistent level of service for all electric vehicles. The first of these sites is an EV charging hub at the new Agritech Business Park in Rakaia, Canterbury. The first stage of this project will include two of Tritium’s modular 150kW fast chargers, each capable of simultaneous vehicle charging to service both passenger and fleet vehicles on site.

In addition to expanding their network, Jump Charging is creating innovative solutions to solve charging demand issues. The company has created a portable, skid-mounted solution for charging station installation, that is designed to be used with Tritium’s 75kW award-winning modular fast charger, enabling swift deployment in service locations experiencing increases in EV charging demand due to seasonality, specialist events, construction projects, or emergency situations.

Adding to its flexibility, the design enables connection to either a standard 400V system or alternatively a high voltage 11kV supply through the inclusion of an onboard transformer.

The Low Emission Transport Fund (LETF), administered by the Energy Efficiency & Conservation Authority (EECA), provided co-funding for both the Agritech Business Park EV charging hub and for the development of the portable, skid-mounted fast charging solution. The EECA was established under the Energy Efficiency and Conservation Act 2000 to encourage and support energy efficiency, as well as provide co-funding for technology development like Jump Charging’s skid-mounted charging station.

Developments

HERA recognises leading Metalminds at Future Forum

The heavy engineering industries’ top innovators and changemakers were recognised at the HERA Future Forum Nation Dinner on 5 May 2023 at the Christchurch Art Gallery Te Puna o Waiwhetū. Sponsored by New Zealand Steel, the awards celebrated the significant impact that individuals and teams are making across Aotearoa, honouring outstanding projects, innovations, and research that demonstrate leading vision and contribute to success within their respective industries.

Dr Troy Coyle, HERA’s CEO, says, “I would like to congratulate the winners, finalists, and scholarship recipients for 2023. All of the work they do across the country invaluably contributes to the success of the industry and nurtures the values that will ensure we are servicing a better tomorrow. It is a privilege to acknowledge longstanding dedication, alongside new leaders and up and coming talent.”

The 2023 award winners are:

Keith Smith Memorial Award – Geoff Bird, Structural Technical Development Manager at Beca. Geoff’s contribution to the industry is a longstanding one, supporting HERA’s Structural Division in 1983 and moving on to become the Structural Manager of New Zealand Steel in 1992, where his work became instrumental in the widespread use of structural steel in multi-story buildings.

Geoff is a significant knowledge benefactor for the industry, participating in HERA’s Steel Research Panel and SCNZ technical working groups. He is also an honorary lifetime member of the Structural Engineering Society (SESOC) and a Fellow of Engineering NZ.

Whanake Scholarship – Lydia Frater was congratulated as the 2022 scholarship recipient. She is at the University of Canterbury, studying towards an honours degree in engineering, with the intention of completing a bachelor degree in civil engineering.

Steel Research Student of the Year Award –University of Auckland’s Fanqin Meng. Fanqin’s research is important to understanding structural steel’s performance in severe fire, in particular the performance of beam to column sub assemblages in gravity resisting systems of steel structures which has led to more realistic strength reduction factors for columns in fires.

Fab 4.0 Award – Farra Engineering (Welding Technology). Quality work and improving supporting processes and systems have been a strong focus for Farra Engineering. As a result, this has led to a reduction in the number of hours required to complete the fabrication of complex machines, and more importantly a significant reduction in rework cost.

Fab 4.0 Award – MJH Engineering (Welding Skills Development). To combat the shortage of trained, skilled, and competent welders, MJH Engineering developed an inhouse training programme to recruit, train, and employ skilled welders in conjunction with the utilisation of CNC technology to improve productivity.

This has led to a significant reduction in the time it takes for graduates to receive their welding tickets and become qualified with the main welding accreditations.

Innov8rerehua (steel is beautiful) Award –McConnell Dowell, Aurecon and Eastbridge McConnell Dowell, contracted by Waka Kotahi NZ Transport Agency, replaced the 105-year-old Mangere Bridge with a new 260m long stunning piece of structural engineering that is a focal point that reflects its local landscape. Designed by Aurecon and predominantly fabricated by Eastbridge, Ngā Hau Māngere connects the communities of Onehunga and Māngere Bridge on either side of the Manukau Harbour.

Next Gen Leadership, Leading Metalmind Award – Mike Ryan, GM of Operations at Farra Engineering. Mike impressed the judges with the breadth of projects for which he was able to achieve the seemingly impossible, as a result earning the informal title ‘guru of solving crazy engineering problems for the hydro industry’.

His problem-solving work at the Burrinjuck Hydropower Station in Australia avoided a costly shutdown, saving 15 million dollars and extending its life by a further 15 years.

Innov8impact Award – Dr Shahab Ramhormozian for his project “Sustainable Earthquake Resilient Buildings for a Better Future”. This $9.47 million Endeavour funded research program will develop systems so that buildings will suffer no structural damage under severe earthquakes or associated fires, therefore significantly reducing the cost of earthquakes on the built environment and improving intergenerational wellbeing.

Innov8changetAward - Ti-ra for exporting spiral welding innovations. Received in memory of Wayne Taylor who was the inventor of spiral welding, this innovation reflects a business on a path of automation and innovation.

This reshaping of Ti-ra has opened it up to new markets and expanded their footprint offshore when it comes to their novel automated spiral welding technology, and unique expertise in process vessels.

Innov8resilience Award – WSP and Waka Kotahi NZ Transport Agency. The “Steelwork Durability Documentation Suite” relates to the coating of steelwork on highway structures such as bridges, and will be integral in raising the quality of the protective coatings industry in Aotearoa New Zealand and the durability potential of structural steel in the built environment.

Innov8taiao (steel is sustainable) Award – Beca. The project “Adaptive reuse of steel in the Civic Administration Building” resulted in 100 percent reuse of the 1900 tonnes of structural steel frame and gave it a new lease of life as high-end central city apartments. The resultant reduction in carbon footprint was 6,150 tonnes of CO2 equivalent emissions.

The HERA Industry Awards recognise those who have significantly contributed to the industry’s success. The awards were aligned with the Future Forum Conference, which is about building a tribe of metalminds and casting a collective gaze to the future so the industry can prepare for disruption.

Whanake Scholarship Recipient, Lydia Frater.

Mike Ryan, GM of Operations, Farra Engineering.

Innov8taiao (steel is sustainable) Award.

Last Word

Computer Recycling Ltd

Patrick Moynahan, Managing Director

E-waste, is this proving to be a successful business for Computer Recycling?

Yes, e-waste recycling has been very successful for us. Over the past five years we have grown significantly, and reached the milestone of processing more than 2 million kgs of e-waste in the 22/23 financial year. In March alone we received 300,000kgs of e-waste for processing, which is a clear indication of the increasing demand for e-waste recycling and ITAD services.

How much of the componentry are you exporting overseas?

There is no end-of-life recovery processing available in Aotearoa New Zealand, therefore 100% of the commoditised material processed through our BLUBOX and MSS machinery are exported overseas via EPA permits, for final recovery.

And to which countries and companies?

We have developed relationships with suppliers in various countries, including South Korea, Japan, and Belgium. These countries have some of the most advanced technologies and facilities for processing e-waste materials.

Which components are most sought after?

Items that are most sought after are those that can be refurbished - or harvested for parts - and resold, such as data-bearing IT equipment. Prioritising the recycling of these items allows us to give as many tech items as possible a second life in the community.

Do you think companies could benefit by keeping

continued from Page 22

some of the components in-house? After all, society’s approach to buying new may not always be necessary?

Absolutely. Keeping components in-house can be a cost-effective way for companies to extend the lifespan of their IT equipment and reduce e-waste. In fact, this is a big part of our business and accounts for 50% of our revenue.

What percentage of the e-waste is a metal component and how much is plastic?

The percentage of metal and plastic components in e-waste can vary greatly depending on the product type. For example, printers have a far higher plastic content than a desktop computer. Our sorting process enables us to separate different materials, ensuring that each component is processed in the most efficient and sustainable manner possible. Is this a growth business for you?

Yes, e-waste recycling and recovery is a growth industry for us. As more companies become aware of the importance of responsible e-waste management, we have seen an increase in demand for our services. We are continually investing in our processes and technology to ensure we can offer the most efficient and innovative ITAD & resource recovery solutions. In these economically challenging times, do you find much fluctuation in the amount of components your company is able to export?

Increasing interest in ZLD driven by costs and environment

Membrane can only work to bring the product up to a certain concentration. To achieve complete separation, evaporation / crystallization processes are needed for completing the process. As explained before, evaporation (due to the latent heat) is highly energy consuming. Therefore, it is wise to choose an evaporation process that involves ways of energy optimization, the most popular being:

• Multistage evaporation: using the latent heat of the evaporated water as energy source in a next evaporation stage reduces the overall consumption of the boiler to the evaporation plant.

• Thermal Vapor Recompression (TVR): evaporated steam is mixed with boiler steam. The reuse of the evaporate steam reduces the energy demand.

• Mechanical Vapor Recompression (MVR): An MVR compressor (driven by an electrical motor) can be used to compress the evaporated steam, thus increasing its pressure, and use this steam as the energy input for the process. MVR compression is very efficient in terms of energy consumption.

Due to the factors outlined above, (multistage) vapour compression plants remain the main method employed for ZLD processing globally, with evaporation typically recovering around 95 per cent of wastewater as distillate. Any remaining concentrate is then further treated physically or

chemically to produce solid residues (such as crystals) and water. Evaporators used in ZLD systems are often run at lower pressures in order to reduce the boiling point of the liquid being treated.

The HRS ZLD solution

Depending on the product to be concentrated, HRS can select from a series of technologies for designing the most optimal ZLD process. Energy optimization methods (multistage, TVR, MVR) can be combined with several types of heat transfer technologies (plate evaporators, corrugated tube evaporators, scraped surface evaporators). Whatever the technology applied, the overall process can be separated into three steps:

1. Evaporation / concentration: The product is concentrated to just below its maximum concentration (saturation). The evaporation plant is usually a multistage evaporator setup.

2. Cooling: if the maximum solubility curve is steep (large concentration at high temperature, low concentration at low temperature), the product obtained in step 1 is cooled, provoking immediate precipitation of dissolved solids.

3. Crystallisation: Crystallisation / sedimentation of the solids produced in step 2 occurs in specially designed crystallisation tanks. A supernatant layer of concentrated solution remains after this stage

Despite the economic climate we have seen steady growth in the demand for e-waste recycling and the export of processed materials. We have also been able to maintain strong relationships with our suppliers overseas. It’s important to note that e-waste is a global issue, and the need for responsible disposal and recovery of materials remains a priority regardless of economic conditions.

and is returned to step 1 for reprocessing. For products without a steep solubility curve, it is necessary to concentrate inside the evaporator to above the maximum solubility. This means that the step 1 process is equipped with a final evaporator stage (finisher) that is specially designed to work with suspended solids. The fluid with suspended solids is then transferred directly to the crystallisation tanks in step 3.

The brine cooler and evaporator finisher work with solids in suspension and often this means dealing with fouling products. A typical HRS evaporator / finisher will use Unicus scraped surface evaporators that are self-cleaning and maintain optimal evaporation rates.

Typically, our R series scraped surface coolers are used for cooling the saturated brines that are send to the crystallization tanks. The result is an efficient process which can work continuously without requiring scheduled downtime.

Whatever kind of evaporator is employed, heat exchangers have a crucial role to play in ZLD systems in reducing running costs by utilising heat from process water and other existing sources, and also recapturing heat at the end of the process and reusing it to boost the energy efficiency of the overall ZLD system.