NZ Manufacturer October 2021 by Media Hawkes Bay Limited

October 2021

www.nzmanufacturer.co.nz WOMEN IN 9 ENGINEERING Insa Errey.

INTERVIEW 11 THE Scott Matthews, Chief Executive, Easy Build Ltd.

Listen to uniquely Kiwi stories contributing to New Zealand’s future

www.akiwioriginal.com

COMMENT 12Problem solving the next frontier.

Aspiring Materials raises $1m from Icehouse Ventures for carbon capture tech Climate-tech startup Aspiring Materials has raised $1 million to further expand its carbon capture technology for reducing industrial carbon emissions.

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The Christchurch-based company’s pre-seed funding round was led by Icehouse Ventures with support from Outset Ventures.

Spend $100’s not $1000’s

Aspiring Materials extracts mineral products from globally abundant olivine-rich silicate rocks, using one of these minerals, magnesium hydroxide, to produce a powdery material that can remove and solidify carbon dioxide at the source of emission, such as a factory’s exhaust system. The captured carbon forms a safe carbonate substance which can be repurposed for a variety of uses from masonry construction blocks to cement additives. Further, the company’s innovative mineral extraction method is a closed loop process with several commercially viable options available for the two other minerals produced at the same time as the magnesium hydroxide. The silica can be used to replace around a third of the Portland cement required for the production of concrete, which is currently responsible for around 10% of the world’s carbon emissions. And a third extracted mineral, iron oxide, can be onsold as a high purity raw material for iron production. While the concept of using olivine rocks to extract magnesium for carbon sequestration has been explored for at least two decades, Aspiring co-founder and civil engineer Dr. Allan Scott says nobody’s been able to figure out how to make a carbon-free and waste-free way of supplying it.

Easy to learn Free on-line training Allan Scott, Co-Founder.

“Our method is capable of significantly reducing CO2 emissions that is not only environmentally-friendly, but is also scalable and profitable,” says Scott. “We’ve not found any other method out there right now that comes close. “Other experts and scientists who’ve previously thought that carbon sequestration on a global scale was a pipe dream have reached out to us saying that we are onto something. It’s exciting to be able to move onto the next phase so we can realise our vision of building a low carbon future.” Scott, an associate professor of civil engineering at the University of Canterbury (UC) co-founded Aspiring Materials two years ago with Dr. Christopher Oze, a US-based geology professor. The pair began

continued on Page 6

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CONTENTS Contents

DEPARTMENTS 1 LEAD LEAD

ADVISORS

Aspiring raises $1m for carbon Get yourMaterials carbon diet on track. capture technology.

EDITORIAL 54 BUSINESS When EMEXNEWS 2021 comes to town. Varonis – 2021 Manufacturing Data Risk BUSINESS NEWS 6 Report.

Manufacturing in the age of sustainability. How to reduce your exposure to risk through Is NZ’s Covid response world class? your people. UKK’s CPTPP a win for exporters.

Kirk Hope

TECHNOLOGY 7 MANUFACTURING MANUFACTURING TECHNOLOGY 8 Qual IT partners with Millpond.

NZ Code can make manufacturing more RS Components launches RS PRO Facilities competitive. Maintenance Solutions. Dewalt Design Assist breaking new ground.

9 WOMEN ANALYSISIN ENGINEERING 10 Insa Errey.

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 Walsh

8 9

Ian is Managing Director of Intent Group, 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.

Time for change.

Anatomy of a data-driven supply chain. INTERVIEW 11 THE EMEXMatthews, 2021 Chief Executive, 14 Scott FloorBuild Plan Ltd. and Exhibitors. -15 Easy 12 COMMENT ANALYSIS 16 Problem solving next frontier. Achieving carbonthe neutrality: One company’s lessons learnt.

13 THE CIRCULAR ECONOMY SMART value MANUFACTURING of materials and manufacturing in 17 The the circular economy. Australia launches lunar exploration mission. 14

11 9

CuttingPRODUCTS edge tool for underwater recovery. NEW

Matrix 320 reader empowers traceability for More performance, intuitive operation, more automation and logistics. variety.

QUALITYmilling CONTROL for vibration-free 21 Optimised

NDC sensors control manufacturing at the machining. fromt line.

MANUFACTURING 17 SMART NEW PRODUCTS 22 Program your robot faster.

Structural bearings deliver extreme low-level Yubico first YubiKeys with biometric. frictionlaunches performance. Cost-effective and lubrication – free mounting How distributed manufacturing is reducing of solar panels. operational risk. AC Servo System provides highest-level safety. Digital Boost reaches 40,000 small business sign-ups, launches mobile app DEVELOPMENTS

25 Mint Innovation raises $20m to build gold 22 DEVELOPMENTS biorefineries.

Leeann Watson

Is the Chief Executive of the Canterbury Employers’ Chamber of Commerce (the Chamber).and is a strong voice for Canterbury business.

Lewis Woodward

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.

19 Brett O’Riley

19 21 25

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.

New appointments at injection TMX. HRS highlights steam for food sterilisation. New Zealand Space Agency joins international space coordination Is automotive readygroup. for hydrogen?

WORD REARLAST VIEW 23 28 THE

Climate Commission calls forclimate decisive AI can beChange a powerful tool to combat action. change.

28 23 3

Good news for a start-up

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

MANAGING EDITOR

Through the challenging times in which we live, it is good to learn of

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

companies breaking through, being innovative and finding success.

CONTRIBUTORS Holly Green, Rebecca Reed, Alistair Gordon, Ian Walsh Matt Hale, Dr. Jim Goddin Mathew Hunter

One such company, appearing in this issue, is Aspiring Materials, a climate-tech start-up, that has raised

ADVERTISING

$1m to further expand its carbon capture technology

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

(Page 1). The

DESIGN & PRODUCTION

company

extracts

mineral

products

from

olivine-rich silicate rocks, using one of the materials,

Kim Alves, KA Design T: + 64 6 870 8133 E: kim.alves@xtra.co.nz

magnesium hydroxide, to produce a powdery material that can remove and solidify carbon dioxide at the

WEB MASTER

source of emission, such as a factory’s exhaust system.

Julian Goodbehere E: julian@isystems.co.nz

Elsewhere in October issue you can read about Insa

PUBLISHING SERVICES

Errey (Page 10) a female engineer with a passion

On-Line Publisher Media Hawke’s Bay Ltd

for making positive lasting change, who has worked with Engineers Without Borders Australia to support

DIGITAL SUBSCRIPTIONS

remote communities to review feasible energy options

E: publisher@xtra.co.nz Free of Charge.

and supporting water, sanitation and hygiene projects. Ian Walsh (Page 13) looks at problem solving and

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

how much time companies invest in it. He suggests companies start to identify recurrent problems and start a structured problem-solving intervention. On Friday, government is to release the plan for business in

Vol.12 No. 9 OCTOBER 2021

Auckland going forward. Fridays 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.

NZ Manufacturer October 2021 /

are good days for government doing things like this because if you are dissatisfied there is a weekend – or long weekend – for ‘things to quieten down’.

www.nzmanufacturer.co.nz

Doug Green

Success Through Innovation

Editorial

Business news Hanga-Aro-Rau Workforce Development Council appoints Chief Executive The Hanga-Aro-Rau Workforce Development Council (WDC) has appointed Phil Alexander-Crawford (Ngāti Hine, Ngāti Rēhia, Ngāpuhi) as Chief Executive. The appointment is a significant milestone in the establishment of the Workforce Development Council, which will give manufacturing, engineering and logistics industries greater leadership in the vocational education system. Phil is a highly experienced leader of transformation, who has worked with and for iwi and hapū. Phil is currently Director of Te Pae Tawhiti – Māori Equity Partnership at Te Pūkenga.

He has held senior leadership positions in the vocational education sector, including Chief Executive of Te Matarau Education Trust, General Manager Education for the Ngātiwai Trust Board and as Director of Development for Tai Tokerau Wananga (NorthTec). Industries represented by Hanga-Aro-Rau include manufacturing and processing, extractives and drilling, transport (including heavy and commercial), postal, warehousing and related engineering.

Varonis - 2021 Manufacturing Data Risk Report Varonis, a pioneer in data security and analytics, has released its 2021 Manufacturing Data Risk Report, which examines the state of data security within industrial manufacturers and engineering firms.

data which specifically puts manufacturers at risk – this data is overexposed and under protected, and to limit the damage attackers can do, companies must improve their cyber security practices.

• 4 in 10 organisations have 1,000+ sensitive files open to every employee.

The report found cybersecurity maturity in the manufacturing sector lags behind other industries such as finance, with nearly half of all companies still underprepared for a disruptive attack. It is the sensitive and often highly valuable nature of their

Key findings from the report include:

• More than half of companies have 500+ accounts with passwords that never expire.

Commercial & industrial growth

• Every employee can access, on average, 6 million files on their first day on the job. For large companies, that number doubles.

• 44% of companies have more than 1,000 active “ghost user” accounts enabled.

Employment growth

Economic output

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

getba

getba.org.nz

Greater East Tamaki Business Association Inc.

www.nzmanufacturer.co.nz

NZ Manufacturer October 2021

Business News How to reduce your exposure to risk through your people Your employees touch every aspect of your business; from day-to-day operations, engaging with customers, utilising technology, creating your processes and policies, to making decisions and taking action (or inaction) that affects your business daily.

responded to appropriately. People naturally become aware of threats to the things that are important to them, often instinctively. Their desire to protect what is important can also

Your people are literally the heart of your business.

The importance of engaged employees for risk management

Employees tend to be drawn to organisations where they believe there is an alignment in values and a sense they are heard and can contribute to the business. It gives employees a deeper reason to show up every day and take pride in their work.

Disengagement is a significant risk to organisations, though many executives’ associate disengagement with productivity and don’t always consider the risk exposure.

and colleagues. This desire to protect can provide

When employees are disengaged, they are at best satisfied with the bare minimum level of productivity and focus. Which is why statistics shared from Gallup’s recent State of the Global Workplace: 2021 Report, that 80% of workers are not engaged or are actively disengaged, is so concerning.

The benefits of a person-centred approach to risk

When it comes to disengaged employees in the context of risk, there are three concerns:

with, through and by your people, that is how you

Whereas employees who feel trapped in their organisation’s rigid structure of rules, reporting and penalties, can find themselves becoming slaves to the numbers. Creating a workplace where people are afraid to come forward, and where risks can be buried, only to surface in negative outcomes.

Don’t over pitch culture Many organisations promote (pitch) their culture as a point of difference to the market, prospective employees and current employees. Their aim is to portray a favourable image, for example promoting trust, empowerment, inclusiveness. The issue is when reality conflicts with what is being promoted, the work environment is not as promised. This may do harm to the employee and expose the organisation to a disengaged or disgruntled worker.

1. Lack of attention leads to errors, and ‘unintentional’ insider threats which is the most common type making up two-thirds of incidents. 2. A lack of situational awareness, employees don’t even see there is a risk. 3. A low ‘care factor’ if they do identify a threat or vulnerability, they see it as “someone else’s problem.”

A disengaged workforce ultimately leads to lower productivity and could even make for a hostile work environment – likely the opposite of what was pitched. Despite your best efforts, you can inadvertently create the very environment you are trying to avoid.

This is why a focus on disengagement is important to your risk management. It takes an engaged workforce to provide risk resilience, because when it comes to the execution of your risk management plan, and day-to-day risk management, this is ultimately the responsibility of your people.

If your advertised culture is something that you are aspiring to rather than one that already exists, then you need to be up front about this. Especially with prospective candidates, they will appreciate the candour and might even decide that they want to be part of a team that brings that culture together.

If your people are not engaged, they might see a potential threat and think it is someone else’s problem. But if they are engaged, they are far more likely to come to you and raise their concern that something in not quite right.

continued from Page 1

These conversations can sound out areas of potential harm and are among the most effective ways to reduce organisational risk, if captured and

apply to your organisation. Engaged employees want to protect the well-being of their organisation the opportunity for employees to become human risk sensors – proactively sensing risk.

extend well beyond risk mitigation. It will positively benefit your reputation and revenue and improve your workplace culture. By changing your approach to risk, focusing on risk are going to truly reduce your organisational risk exposure and drive transformational change. Lisa Sisson, author of ‘Risk Starts And Ends

With

People:

Demystifying risk for executives and leaders’, is

sought-after

speaker,

mentor,

consultant and author who

helps

executives

and leaders who have become

distracted

and with

overwhelmed ‘managing

demystifying their

and

organisation.

risk’,

tackling To

learn

risk more,

within visit

www.unearth.com.au

Aspiring Materials raises $1m from Icehouse Ventures for carbon capture tech

developing the method while working together at the University of Canterbury nearly a decade ago and Oze, a New Zealand permanent resident, is planning to rejoin Scott early next year.

allow them to keep going: “We’re grateful to the team at Icehouse Ventures and Outset Ventures for backing us with the funds and support we need to scale up our science to the next phase.

supply of olivine, which exists in abundance at the Earth’s surface on every continent, making it easy to transport the magnesium hydroxide powder to the source of emissions.

The funds raised will allow the growing Aspiring team to sequester larger volumes in a pre-pilot development phase within the new commercial facilities they plan to secure by February 2022.

Icehouse Ventures Partner Barnaby Marshall says: “Founders forging new science and engineering frontiers like Allan and Christopher are urgently needed to conquer the existential threat of climate change. Aspiring’s method represents a major advance in the ability to reduce global carbon emissions while also being scalable, sustainable, and profitable.

For example, capturing all the earth’s carbon emissions for 2021 would require 16% of the olivine deposit located in Red Hills, near Nelson, New Zealand. And an olivine deposit in Oman could be used to sequester all man-made carbon emissions for the next 1000 years.

The funds have also enabled the company to fast-track the appointment of inaugural CEO Mark Chadderton, a returning New Zealander who brings more than twenty years experience leading teams within global gas and energy companies. And a lab engineer joined the company this month. Scott says their carbon capture technology is already attracting overseas interest and the funding will

NZ Manufacturer October 2021 /

Massive scale The Aspiring Materials team say it’s possible to sequester an entire year of manmade CO2 emissions using a small percentage of the world’s ubiquitous

www.nzmanufacturer.co.nz

A recent UnivDatos Market Insights July 2021 report projects the Global Carbon Capture and Sequestration Market is expected to grow at a CAGR of 12.97% from 2021-2027 to reach USD 9.99 billion by 2027.

Manufacturing Technology Qual IT partners with Millpond greater certainty for projects Qual IT is partnering with Millpond to provide specialised project management and training expertise for organisations undertaking digital transformation, enabling greater clarity and certainty for their customer’s IT projects. Having seen Millpond’s track record of excellent delivery in the market, and having a similar people-centric organisational culture, Qual IT felt that the time was right to take a cornerstone shareholding in the company.

“We are continuously looking for ways to improve our service, and being able to offer our clients a safe pair of hands to oversee the delivery of their IT projects was a logical next step,” says Shane Hewson, co-founder and director of New Zealand information technology and quality assurance company Qual IT. Qual IT has carved a niche in the IT market, providing independent, integrated Quality Assurance services for over 17 years to organisations across all kinds of industries and across a variety of project types.

Mark Young, General Manager of Southern operations for Qual IT (Left), James Dobson, CEO of Millpond (Right).

Schaeffler expands OPTIME availability The latest update of OPTIME integrates Schaeffler’s condition monitoring systems (CMS) SmartCheck and ProLink. OPTIME therefore covers condition monitoring for a very wide range of machines and often even entire plants. Analysis enables maintenance teams to predict machine problems and act appropriately. As a result, customers reduce downtime and increase the profitability of their machinery. Avoid downtimes, increase profitability Particularly for companies operating in system-intensive process industries, avoiding unplanned downtimes means greater profitability. Via the smartphone or desktop app, customers with OPTIME have a constant eye on the status of their plant, even with hundreds of machines, as the

messages are user-friendly and prioritised according to criticality. As a result, in-house maintenance personnel or even service companies can plan maintenance measures, personnel utilisation, and the procurement of replacement parts in a timely and cost-efficient manner. They have the flexibility to decide whether they want to draw on other services and if so, which ones. The modular service concept offers online, remote or on-site services. Condition monitoring can be easy Users of digital services in the industrial environment also expect the information provided to be easily understood and the hardware and software to be uncomplicated to get around.

Condition monitoring systems by Schaeffler can be used without needing extra qualifications because with the help of the Schaeffler know-how, the system configuration and data analysis are largely automated. This integrated knowledge is integral not only to the highly scalable OPTIME solution with wireless single-channel sensors, but also to the two systems for machines with dynamic speed and load conditions and involving environments with temperatures in excess of 85 degrees Celsius – the single-channel CMS SmartCheck and the multi-channel CMS ProLink. With condition monitoring solutions, operators and maintenance personnel have an expert eye tracking the condition of practically every machine in the plant via the app.

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NZ Manufacturer October 2021

Manufacturing Technology Why technical specialists feel their careers are “stuck” - and how to fix it -Alistair Gordon, CEO Expertunity

Talented technical specialists keep your organisation functioning. Data scientists and SEO specialists, product engineers, developers and market analysts - whatever field they’re in, technical experts are critical. They’re also hard to hire, expensive and hard to retain. Worse, they have an underserved reputation for being bad with business and soft skills - with negotiation, stakeholder engagement, commercial acumen and knowledge transfer. What if I said to you that the problem isn’t nature, it’s nurture? And if I then said that most organisations frame their idea of a “high-potential employee” in a manner that excludes experts? Who are, when you think about it, the people you probably most rely on to change the way your organisation works, or to transform the way it approaches difficult problems? Organisations know what to do when they see a high-potential people leader – they roll out the red carpet. Emerging people leaders get coaching to polish business skills. They have well-developed career ladders and an appraisal process. People leaders enjoy all the encouragement of traditional leadership development. They’re seen as high potential because they can lead a team, and maybe even become CEO one day. Experts, meanwhile, don’t want to manage a team or be CEO. So they aren’t offered the same “high potential training” to polish their business and people skills. (Or they’re sent on the same training as people leaders, which isn’t that relevant to the challenges they face.) The problem then compounds. Without development, it’s assumed experts were “born that way” – that they were never capable of developing

soft skills in the first place. And as a result, they don’t get promotion or movement. They stay in the same roles for a long time – far beyond the time where the role is rewarding or motivating.They’re stuck. They’re probably not happy, and eventually they leave. To get them unstuck, rethink your idea of potential.

Redefine potential Ask a CIO, or your head of data science, or the head of policy how they define “high potential”. They’ll say that in a technical team, it’s not only about people leadership. Instead, they want experts to use domain knowledge to create competitive advantage, or to solve the problems that threaten your business. They’ll also agree that talented experts do need to master a broad range of enterprise skills - not just soft skills, but coaching to understand risk and reward, the creation and maintenance of business relationships, and your organisation’s commercials.

Five tips to get experts un-stuck There’s five ways experts can achieve greater job satisfaction - while also adding value to your marketing and organisational strategy. 1. Redefine “high-performing” to reflect the value added to your business, not just people leadership potential. Experts create competitive advantage, but only if you support and encourage their presence. 2. Frame enterprise skills as part of an expert’s day to day role. People leaders are told from day

one that commercial acumen and soft skills are critical to their long-term career. Tell experts the same. 3. Create an expert capability framework. Do your experts understand which non-technical skills you want them to acquire? It helps to define what mastery looks like. 4. Consider where you need to shift focus to “expertship” rather than “leadership”. Expertship develops the skills needed to lead ideas, projects and innovation, where Leadership coaches the skills needed to lead teams. Experts welcome ideas to become better experts. 5. Ask leaders of technical teams to identify “stuck” experts, who have potential to add greater value than you may have realised. Most employers look the same to experts. They’re not that aware of expert challenges, not that interested in expert ideas. Hiring is simplified and retention increased when experts understand that you encourage their work and ideas. You’re also improving expert happiness and creativity and effectiveness.

RS Components launches RS PRO Facilities Maintenance Solutions RS Components (RS), a trading brand of Electrocomponents plc, a global omni-channel provider of product and service solutions, has launched the RS PRO Facilities Maintenance solutions portfolio, which comprises quality-tested products for a host of industries and working environments. Aimed at a broad selection of customers in Australia and New Zealand, the range supports maintenance requirements within the process manufacturing, equipment manufacturing, utilities and energy, engineering services, mining aggregates and construction, wholesale and distribution, transport and defence sectors, and design and development laboratories.

All products in the RS PRO Facilities Maintenance range have high in-stock availability and have been through rigorous testing processes to ensure reliability to meet design and compliance specifications.

The expanded range introduces over 1,000 products to offer a comprehensive choice of quality products including site safety and lighting solutions, tool kits, janitorial & cleaning, test & measurement, workwear & personal protective equipment (PPE) and more.

“The RS PRO range increases the breadth and depth of choice for customers seeking facilities maintenance products that meet design and compliance specifications, at a competitive price,” said Ian Macgregor, RS

NZ Manufacturer October 2021 /

They are covered by the RS PRO Seal of Approval and come with a three-year warranty.

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PRO Product Manager, for Australia & New Zealand (ANZ). “We offer a huge variety of products for different applications to keep facilities and buildings operating efficiently and safely and help keep businesses running smoothly.”

Women in Engineering Insa Errety

Insa Errey is a female engineer originally from Sydney who now calls Auckland home. She currently operates as an independent consultant under Curios Sustainability. How long have you been an engineer? Almost 10 years. I was a late bloomer into engineering.

operational disruption, impacts of market forces and future stranded assets with the changing energy market.

What field of engineering do you specialise in?

Here I see engineers having the important role of leaders within this space, driving innovation and change. We need to embrace this challenge as a positive opportunity.

I specialise in Industrial sustainability. My background is in Chemical biomolecular engineering, with my past experiences being in beverage manufacturing. What projects are you most proud of? It is always rewarding to complete large-scale implementations such as fuel switching projects and wastewater recycling projects. But I think my proudest project is more subtle. In my previous company I mobilised employee awareness toward the issues of sustainability and energy efficiency. My campaign drove awareness through cultural change and started a larger shift toward collaboration on energy efficiency. This has seen year on year energy efficiency improvements driving down operational costs, increasing competitive advantage and most of all reducing emissions from their major manufacturing sites across Australia and NZ. Is there scope for creativity, creative thinking? Absolutely. Creativity is the foundation on innovation. I actually went to a performing arts high school, now a long time ago, and I think that is what dew me to engineering was the ability to still be creative and think outside the box but also make significant impact toward system pressures facing us today. What challenges do engineers face in today’s business world? I think that the main challenge facing engineers is that which we are all facing, climate change, and how this is impacting all areas of how we do business. Businesses and, in particular, manufacturing, are facing and experiencing risks associated with

Do you work well in a team? Yes, working in a team is essential in engineering. In this time of the virus, are there projects being worked on? Yes just because we are in lockdowns does not mean we stop. Manufacturing is an essential service and needs to continue to supply consumers. My role continues to support manufacturing operations and focus the challenges facing decarbonisation. What gives you satisfaction?/ What do you enjoy about engineering? What gives me the most satisfaction with engineering is the ability to make positive lasting change. I have spent most of my career focusing on improving sustainability challenges facing manufacturing. However, I have also been passionate about humanitarian engineering, here I have worked with Engineers Without Boarder Australia to support remote communities across Australasia to review feasible energy options and supporting water, sanitation and hygiene projects. More locally I have worked with the Red Cross in disaster management and recovery primarily with Australian bushfires. What is it like to be a women engineer in manufacturing? Well yes women are a minority within engineering and even more so in manufacturing engineering. It is positive to see over the last few years the push for diversity and increase in female numbers within

manufacturing. However, there is still some work to be done to breakdown the unconscious bias mindset. I also see an opportunity to promote engineering to girls and get them interested early on;here I am currently an ambassador for Engineering NZ’s “Wonder project” which is igniting STEM in the next generation. Favourite book, last book read? What is my favourite book is a hard question. I do really enjoy reading and audiobooks with my favourite genre of non-fiction, reading about amazing people who have overcome adversity. I just finished “The Dressmakers of Yarrandarrah Prison” by Meredith Jaffe. Favourite quote? Probably from the Dalai Lama “If you think it is too small to make a difference, try sleeping with a mosquito”. I think this is a great quote within the context of energy efficiency. The biggest influence in your life? I would have to say my daughter. I am a mum of a wonderfully curious 3-year-old daughter who asks the most inspiring questions every day. As an engineer I do think it is so important we stop and question why things are as they are. Here my daughter inspires me to stop and ask the obvious questions or even question why we do thing the way we do. It makes you think, is there a better way? or why do we do it at all? At the moment her favourite is why do we need to get dressed? Can we not be like the Bananas B1 & B2 and wear pyjamas all day?

MBIE backs Yellow Chapter for seismic assessments Engineering New Zealand welcomes the Ministry of Business, Innovation and Employment’s release of the findings of the C5 evidence project. The Seismic Assessment of Existing Buildings (2017), or ‘Red Book’, is a mandatory set of technical guidelines for seismic assessments. One section, C5, deals with the assessment of concrete buildings. In 2018, C5 was revised to include the latest knowledge following the 2016 Kaikōura Earthquake. Engineers can now use this revision, known as the ‘Yellow Chapter’, for all assessments – except when determining whether a building is earthquake-prone, whereby the Red Book must be used. A %NBS (New Building Standard) rating indicates how well a building protects life when compared with a hypothetical similar new building on that same site and which complies with the minimum requirements of the Building Code. An earthquake-prone building has a rating of 34% NBS or less and has been deemed ‘earthquakeprone’ by the relevant local authority.

The C5 evidence project involved an independent assessment of 22 buildings to compare %NBS ratings using both the Red Book and Yellow Chapter. Prepared by Engineering New Zealand, the project was developed to help inform MBIE’s decisions around the regulatory status of the Yellow Chapter. The project found that there was little difference in %NBS ratings, regardless of whether the building was assessed using the Red Book or Yellow Chapter. However, Red Book and Yellow Chapter assessments identified different vulnerabilities within buildings. This means decisions about retrofits are likely to differ, depending on which assessment method is used. The study also found that building owners had not widely used the Red Book for assessments since its 2017 release. As well as having a wider scope of application, feedback from engineers who assess buildings and who were involved in the project was that Yellow C5 is technically superior and more straightforward to

use than the corresponding Red Book section. Chief Executive of Engineering New Zealand Dr Richard Templer says, “Engineers should use the revised Yellow Chapter version of the Red Book when carrying out assessments, with one exception – and that’s when you are assessing specifically whether a building is earthquake-prone under the legislation. “By using the Yellow Chapter, engineers can help owners decide appropriate retrofit solutions for their building using the latest knowledge.” The potential impact on the building system will be assessed by MBIE to inform the future regulatory status of the Yellow Chapter.

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NZ Manufacturer October 2021

HEADING

Democratisng carbon fibre

An Auckland company has come up with a way of making the miracle material available to all.

If you think about Auckland and carbon fibre technology, scenes of the America’s Cup and the industries that surround it spring to mind. Ventilation tubes in dusty Australian coal mines are probably not your first mental image. Yet this less than glamorous gear represents the start of a promising new trade, thanks to the ingenuity of Graeme Rivers, founder of North Shore-based Rivers Carbon Technologies, and a Callaghan Innovation Project Grant. All sorts have come out of Rivers Carbon’s Albany workshop – from the foils for elite America’s Cup yachts to replica chassis for E-Type Jaguars. But while money may be no object in these high-end industries, the wonders of carbon fibre are generally outside the budget of ordinary businesses. Until now. Rivers Carbon has come up with a lower cost way of making carbon fibre products for everyday sectors such as construction and mining. After months of researching cores, cloth types, resins, hardeners and trihydrate mixes, Graeme Rivers developed a ‘cold cure’ method of setting carbon fibre, rather than pressurising and cooking it in an autoclave.

Rivers Carbon settled on ventilation tubing for underground mining as its first application for the new carbon fibre. Currently the fibreglass tubes used in the mines are heavy and have a tendency to crack and break. Both factors create health and safety issues. In contrast, Rivers’ Premium High Carbon Fibre tubes are light, durable, and can be easily lifted above the shoulder making them far easier to install. The company has exported ventilation tubing to Australia. Staff at BHP Billiton Illawarra Coal’s West Cliff mine in New South Wales say they’ve had no injuries to people or breakages since they started using carbon fibre tubing, and the company is now looking at other applications for the material. “We have a lot of manual handling, a lot of heavy implements, so really we’re looking to find the next level use of carbon fibre,” Health and Safety Manager Peter Rolfe says.

Rivers Carbon makes wheel hub covers for the motors on giant mining trucks and man doors for mine shaft safety. It is investigating using the new carbon fibre in everything from prosthetic feet to dinghies to construction beams. “There’s no limit to where we can go. If something requires strength and it moves, so that weight is an issue, then we can play in that space,” General Manager Stephen Beaumont says.

Automation the next step Graeme Rivers set up Rivers Carbon in 2004 and did a wide range of innovative small run production such as parts for race cars. The company attracted the attention of investment firm Lewis Holdings in 2010. “Graeme is quite brilliant in some of the problems that he’s solved through the use of carbon fibre,” Director Dave Tibby says. The Project Grant from Callaghan Innovation allowed the business to expand its focus and develop a manufacturing process for a cost effective alternative fibre. The Project Grant was a great way for a company of Rivers Carbon’s size to access R&D support.

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Rivers Carbon is already making wheel hub covers for giant mining trucks

The Interview Scott Matthews, Chief Executive, Easy Build Ltd -by Rebecca Reed Why ought someone buy a modular house? Most of us dream of home ownership, in fact most people would argue that it’s a human right. We have all been raised in an environment in NZ where you commonly design your own home, and every home is different. The building industry advertise this all the time, but then customers wonder why the house is often poorly insulated, expensive and requires lots of heating. This is very different to many parts of the world where people by a house off plan and it is one of perhaps 30 in the same location that looks similar. I often make the analogy that if you want a good, reliable and fairly priced car, you would buy a Toyota Corolla, however if you want something different you would drive a custom build or a Ferrari. Looking at a modular home vs. a custom designed home, the pricing difference is similar, but you’ll get better bang for your buck with a modular home in terms of build time, thermal efficiency, environmental friendliness, and other benefits, when compared to a standard construction house of the same price. Modular homes are normally quick to build, well insulated and built, minimise waste and are normally priced the same as a similar sized home, but superior quality. Where did the concept come from for your company? The concept is relatively old, with the original inventor using this method some 30 years ago. However, the designs were brought up to date and the business was launched in its own right 5 years ago. We have a simple but enduring purpose. We want to provide Kiwis with warm, robust, and affordable housing because we believe everyone should enjoy living in their own EasyBuild home.

12 weeks, but are closed in and weathertight within two weeks on-site.

Like Adrian we support local whenever possible, and we believe in providing housing solutions to Kiwis.

Describe the manufacturing process

How many staff in your company?

Essentially the skeleton of the house is produced as component pieces in a factory, so every piece required for the shell of the house is cut marked drilled and prepared for quick assembly on site.

We currently have 15 staff based in our factory in Upper Hutt, but this is constantly increasing to keep up with demand. In addition, we have 10 teams across the country who sell and build our homes in their regions.

All external walls are constructed as super insulated panels, containing insulation suitable for any NZ climate, conduits for power, a waterproof shell and finally the windows, rebates and window architraves are fitted before the house is sent to site in a shipping container. Describe the work you are doing for Koru Kainga housing development? We feel very privileged as a business to be working with Koru Kāinga and our own values align with the objectives of this development; to bring affordable, quality housing to local families and first home buyers.

We always try and hire locally and I’m proud that we have created jobs and opportunities in the Hutt Valley. How are you currently finding the business climate? The current environment is challenging but rewarding. Our business is growing, and we are currently negotiating contracts with housing providers and other developers similar to Adrian, whilst also developing relationships with Government. Finding good staff can be challenging and of course we want to support and keep them.

We have worked with Koru Homes NZ founder Adrian Chooi to design 51 three-bedroom homes in Wainuiomata, Lower Hutt and provided a team of experts or a “dream team” to support the planning and resource consent application.

Is supply chain affecting your company at present?

Developments of this nature don’t just happen, and we have really enjoyed supporting this development. We are proud to be part of New Zealand’s first private development dedicated to getting first home buyers on the property ladder.

Materials are rising in cost on a regular basis and supplies have often been hard to secure.

Why do you think you were chosen owner Adrian as the preferred company to build these homes? I think there are a couple of reasons why Adrian has chosen EasyBuild to partner with on this project and hopefully future ventures. We provide a robust, warm, affordable housing solutions, we are experts in what we do, and we share common goals and values.

The current supply chain and also the pricing changes have been a challenge for most builders in NZ, if not a global issue.

Given our time in business we have some deep and established relationships with suppliers and merchants that are supplying us and all supporting us to the best of their abilities but even so it can be tough, and we spend lots of time on the phone calling in favours and chasing materials.

We want to provide Kiwis with warm, robust, and affordable housing.

What is your point of difference? We’re a local business building affordable, quality, robust, and warm homes. We build quickly and efficiently whilst reducing waste and trying to source materials locally wherever possible. We also create opportunities to train and support those returning to work and looking to engage in the workforce. Available nationwide, we now have 10 licensee locations building houses in their local communities across the North Island from Northland to Wellington and are looking to expand into the South Island. What is the construction time from start to finish? Excluding the time to create the pack in the factory, our homes on average are built and fully finished on-site in

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FEATURES November 2021 Issue INDUSTRY 4.0 COMPANY PROFILE THE CIRCULAR ECONOMY

Comment Problem solving the next frontier -Ian Walsh, Managing Director, Intent Group

Over the last few years, I have run several courses and seminars for business leaders, wanting to improve their business performance and productivity. One of the questions I typically ask is how much time a week they invest in problem solving? The answers vary, but many suggest they do a fair amount of problem solving. I then ask how many of them dedicate a set amount of time each week to structured problem solving as opposed to reactive, during on the event, problem solving. After some muttering and reflection, for most of the group, the answer is none. Less than 10% invest structured time with their teams to solve problems!

CYBER SECURITY

It was Einstein who defined insanity as doing the same thing over and over and expecting a different result. Surely you can’t expect your business to improve if you don’t invest any time in solving problems to root cause?

THE CIRCULAR ECONOMY

Improvement itself is defined as solving the right (more impactful) problems at a faster rate than the ones that are occurring. If all you are doing is reacting to what occurs then you are treading water and in today’s competitive landscape, I believe going backwards. The question I have is why do we do this? Or why don’t we invest in structured problem solving? Here are the top 5 great myths:

MACHINE TOOLS

1. It takes too long, and we don’t have time. But we have time to react to the failure and lose production while we fix it.

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2. We are too busy. This is because we are reacting to all the problems that we haven’t fixed. 3. We don’t need to do this as we have engineers who solve the problems, thus placing all responsibility on one group for this activity. This is ‘I operate, you fix’ mentality and does not help teamwork, or long-term problem resolution.

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4. We just need to get going. This leads to rubber band, duct tape, cable tie and cardboard engineering type solutions. These are at best countermeasures and lead to repeat failure. 5. We all know what the problem is so let’s just do what we did last time? If you did it last time and it failed, why would you do it again? This is leading to recurrent failure and ever decreasing circles of despair!

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So, what do world class companies do? Here are 5 key things they do.

Doug Green,

1. They invest in training their leaders in problem-solving skills. This is done under the guidance of a mentor. They are given specific problems to work on and coached to develop their problem-solving skills. Like any skill it requires practice and training.

P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz

2. They mandate structured problem solving. So, when a trigger is hit (a certain amount of downtime for instance) then a structured problem solve is required.

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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.

3. They categorise problems, so that they know which resources should be applied to each problem. Some problems are best done by operators, some by engineers and some by teams, for example. 4. They check that problems are solved to root cause and stay solved. The concept of a 100-year fix, so that the problem doesn’t come back and as a result you create capacity and bank the improved productivity. 5. They use specific problem-solving approaches in the right way, for example, 3Q, 5Whys, 5W1H, Fishbones, Cause and Effect Trees and RCA analysis. They hit the right nail with the right hammer.

Opinion

As I See It

As you build capability and processes around problem-solving the good news is the results just get better and better.

Manufacturing Profiles

Business News

People also get involved as it is human nature to like to improve things, reduce waste and solve problems.

Letters to the Editor

Appointments

Politics of Manufacturing

Around New Zealand

So, if you are not doing this already I highly commend you start identifying some of those recurrent problems and start a structured problem-solving intervention.

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Equipment for Sale

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If you need help with how to go about this drop me a line as happy to help, and this is a critical first step in building a world class company. All the best on your journey.

As you build capability and processes around problem-solving, the good news is the results just get better and better.

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The Circular Economy The value of materials and manufacturing in a circular economy Part 1 of 2 of thinkstep-anz’s circular economy series By Dr. Jim Goddin

Circular products are built to last. The materials that make them up stay in use for as long as possible. When they can no longer be used in their original form, they contribute to other products. A circular economy is based on three principles: designing out waste, keeping products and materials in use, and regenerating natural systems. Circular economy thinking is gaining traction in New Zealand and Australia but focuses predominantly on avoiding or minimising waste through recycling. In New Zealand, waste — especially single-use packaging and plastic waste — has enjoyed the spotlight as a high-priority environmental issue for quite some time. In the latest Better Futures report by Colmar Brunton, two of the top ten concerns for New Zealanders were not enough waste being recycled and, overpackaging, non-recyclable packaging and the amount of waste going to landfill. Yet, waste remains a stubborn issue to tackle. Waste avoidance through recycling is a prominent component of the circular economy and is, from a practical perspective, where most products will need to end up. Recycling is, however, the outermost ‘loop’ in the circular economy model, with materials typically representing a tiny portion of the economic value of products. Recovering the more substantial value added to materials through manufacturing is a more significant portion of the prize at stake.

The inner loops of the circular economy model Dig a little deeper into the circular economy model and you get to the inner ‘loops’ where the systems-level change happens. Strategies in the inner loops of the circular economy include

product life extension, enhanced product utilisation (through leasing models for example), reuse, repair and remanufacturing. The inner loops address the root causes of waste: overproduction and overconsumption. A key economic advantage of the inner loops is that they maintain and recover the manufacturing value that is otherwise lost when products are recycled. We need to see a greater level of ambition in New Zealand — and the policies, standards, and funding to nurture that ambition. The Sustainable Business Network’s Going Full Circle report emphasises the business risk of not preparing for a circular future. Extended Producer Responsibility schemes look set to become the norm in regions like the European Union and the UK, where taxes linked to recycled content targets already exist. Further policies requiring circularity for imported products are rumoured to be in development. Initiatives like these will start to have trade implications for New Zealand by impacting the products and materials we import and those we produce for export.

but they only scratch the surface of what a circular economy has to offer. The World Economic Forum estimates the value of the circular economy at US$4.5Tn. It’s largely this that’s attracted businesses and governments, alongside the opportunity for job creation. However, only a tiny portion of this economic opportunity relates to material value recovered through recycling and avoiding waste. As a stark example of this, the material value of an iPhone 6 is estimated to be a mere US$1.03. Everything between that material value and the retail price represents the value added through manufacturing, intellectual property, branding, advertising, and services – i.e. value lost when the product is recycled. Shifting our focus towards the inner loops of the circular economy enables us to retain the significant value added to materials through manufacturing. In our next article, we will explore what it will require to gain the full benefits of a circular economy — reconsidering how we design products, supply chains and business models.

A circular product looks beyond recycling Avoiding or minimising waste is a given in a circular economy. To that end, actions like recycling and recovering materials are a great starting point,

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The future potential of process control systems By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers Thanks to developments such as Industry 4.0, digitisation, and the cloud, together with improvements in process control and communication technology, it is easier than ever for equipment manufacturers to offer remote assistance and monitoring. HRS offers remote telemetry and control options for all applicable products and systems, using class-leading technology from Siemens and Allen-Bradley Products. The company is keen to exploit the potential of process controls to improve levels of operational knowledge, process management and operational efficiency. Process controls can incorporate a range of functions, such as visualisation and Human Machine Interface (HMI) solutions, as well as programming tools and advanced software applications. A combination of programmable logic controllers (PLCs) and graphic terminals provide easy to use, reliable controls.

A suite of bespoke software monitors and controls key parameters. This data can easily be transferred to remote systems – either those belonging to the client or HRS itself, using either hardwired (ethernet) or secure wireless (4G/5G) communication technology. Remote operation and monitoring provide a number of benefits, including the ability for clients to view and control equipment from a central point, something which is particularly beneficial for complex installations, or those which are spread across numerous buildings or sites. It also allows HRS staff to assist with operations such as commissioning, upgrading or running-in, and to provide ongoing technical support should this be required. Looking to the future, digital process control technology is likely to become even more beneficial to processing industries. Control software can be constantly kept up to date, helping to keep systems operating at peak efficiency, but it is perhaps in the area of simulation that the greatest benefits could eventually be realised.

Engineers and commentators increasingly refer to the concept of a ‘digital twin’ – a virtual version of a physical system or piece of equipment which can be used to simulate any change to operation, from differences in product specification to adjusting physical settings such as valve diameter or tube length. When coupled with artificial intelligence (AI), such virtual systems can determine the optimum hygiene regimes, best energy efficiency and even the most productive time of day to run certain operations. While HRS technology is not at this level yet, there is no doubt that as an industry we are getting closer. If such a future is to be realised, then information technology (IT) and operational engineering functions will need to become even closer, a trend which we are already seeing in many businesses. Industry 4.0 is a term that is often discussed, but not always fully appreciated. However, the last year has begun to show us what the near future will look like for process control.

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New Products Mobile sanitary conveyor bag dump system A new sanitary mobile Tilt-Down Flexible Screw Conveyor with Integral Bag Dump Station and Compactor allows the transfer of material manually dumped from handheld bags into elevated process equipment, and the disposal of empty bags, dust-free. Mounted on a mobile frame with locking castors and a fold-down step, the Bag Dump Station is secured to the floor hopper with quick-release clamps, and features a gasketted bag disposal chute through the side wall of the hopper hood, allowing the operator to pass empty bags directly into the bag compactor.

bulk solids ranging from large pellets to sub-micron powders, including products that pack, cake, seize, smear, fluidise, or crumble, with no separation of blended products. The flexible screw is the only moving part contacting material, and is driven by an electric motor beyond the point at which material is discharged, preventing material contact with seals. The Bag Dump Station, support boom and conveyor assembly can be tilted down to manoeuvre through standard doorways and aisles, and around corners for use anywhere in the plant.

The entire unit can be rolled to a cleaning station where a lower clean-out cap on the conveyor tube can be removed to flush the smooth interior surfaces with steam, water or cleaning solutions, or to fully remove the flexible screw for cleaning and inspection. The system is available in carbon steel with durable industrial coating, with stainless steel material contact surfaces, or in all-stainless steel (shown) finished to industrial, food, dairy or pharmaceutical standards.

Dust generated from both dumping and compaction is drawn onto the system’s two cartridge filters. An automatic reverse-pulse filter cleaning system releases short blasts of compressed air inside the filters at timed intervals. This causes any dust built up on the outer surfaces to fall into the hopper, conserving useable product. Filters are readily accessed by removing the interior baffle, and replaced using quick-disconnect fittings. The compactor employs a pneumatic air cylinder to compress 50 to 80 empty bags into a removable bin lined with a plastic waste bag for dust-free tie-off and disposal. The main door, and a flapper door within the bag infeed chute, are equipped with safety interlocks that prevent operation of the compactor unless both doors are closed. The hopper discharges into an enclosed, 4.6 m flexible screw conveyor that handles a broad range of materials including free- and non-free-flowing

More performance, intuitive operation, more variety In mid-September, Treotham released 19 new models of the Wenglor C5PC series of 1D/2D code scanners, once again expanding its portfolio with more powerful and easy-to-operate code scanners.

The simple installation via Plug & Play in particular, as well as the intuitive, browser-based WebLink user interface or the uniform interface concept across all scanners, open up a large number of new application solutions for users.

The WebLink user interface pre-installed in each scanner guides users to install and set up the scanners, even without any programming knowledge. The decoding of codes can be started directly after the IP address has been entered. The scanners can be easily integrated into systems thanks to the available interfaces such as digital IOs, RS-232, Ethernet TCP/ IP, PROFINET and EtherNet/IPTM. “The two biggest advantages of the new series are the easy initial start-up and networking for users”, explains Mikael Paltoft, Managing Director, Treotham Automation.

The Right (Hardware) Solution for Every Application From now on, the C5PC series provided will be available in variants with static focus or auto-focus, with resolutions of 0.3 megapixels, 1.2 megapixels or 5 megapixels and with optics in SD, HD or LR. There are seven different focal distances between 50 and 1,200 mm. With these hardware combinations, 1D and 2D codes can be read and decoded reliably, even if they have been printed, needle punched or lasered directly onto the object (also called DPM, Direct Part Marking).

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Quality Standards, Daisy Chain and Tamper Protection Round Off the Portfolio All common standards for determining code quality are met with the scanners: ISO/IEC TR 29158 and EN 15415, EN 15416 and EN 16022. With CodeScan 360, up to eight scanners can be connected via daisy chain, providing a 360° visual field. This means that several scanners can be arranged in a circle around an object and connected together, for example. The code on the object is safely decoded by one of the scanners in the system, regardless of its position. The user not only receives secure all-round detection, but also the configuration and results are managed as it were a single scanner. The scanners can also be password-protected for protection against manipulation. Different user roles and levels are available here in WebLink. The new Multishot Configuration Database is also located in WebLink. Here, users can select different configurations stored in the integrated database, after which the scanner automatically performs quick multiple scans at different positions as well as at different heights and brightness levels. The scanner processes these and evaluates them simultaneously.

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Our comprehensive range matches energy chains and cables to the movement on your machine. For vertical, horizontal or rotary motion, as standard or as special solutions, with smart technology for predictive maintenance. From individual components with no minimum order quantity to harnesed, readyto-intstall systems. All motion plastics® can be configured and calculated online. igus.co.nz/the-chain

igus® products exclusively available from Treotham New Zealand Ltd www.treotham.co.nz

0800 847 200

info@treotham.co.nz

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New Products tna solutions launches robag 3e Global food processing and packaging solutions specialist, tna solutions, has unveiled the latest iteration of its flagship vertical form fill and seal (VFFS) packaging system, the tna robag 3e. Featuring a new CXE integrated display controller, smart diagnostic tools and intuitive time-saving components, the system is capable of delivering up to 250 bags per minute (bpm) with wastage as low as 0.1%, alongside enhanced serviceability.

Expanded connectivity and simpler servicing The simplicity of the new tna robag 3e VFFS packaging solution makes it easy to operate, service

and maintain. Featuring EtherCAT real-time protocol and an integrated display controller system, this latest tna robag reduces cabling infrastructure by 20%, enabling easier servicing and lower total installed costs. The new system shares common core components with tna roflo distribution conveyors and the tna intelli-flav seasoning system reducing the need for additional spare parts stocking, and features integrated LED lighting in the packaging jaw area to make maintenance safer and easier to perform. Equipped with smart diagnostics and remote connectivity, the tna robag 3e also offers real-time communication.

High performance and quality standards, are capable of producing a wide variety of products at speeds of up to 250 bpm. Featuring reliable new stainless-steel reinforced doors and tunnel guards, along with an integrated film cutting and dispensing component, the solution delivers maximum efficiency and enhanced energy savings throughout its lifetime,

New igus material for the food industry How do exactly ten grams of gummy bears end up in a small bag? With dosing systems equipped with highly sensitive mechanisms. Such mechanisms fill thousands of bags in no time. Slides and belts then move the sweets to a box.

The new material is electrostatically dissipative, ensuring that the bags do not stick to each other and employees do not receive electric shocks. In very dusty environments such as flour processing, sparks can also lead to dust explosions.

At these high speeds, all the packaging mechanisms, and especially their bearings, are subjected to wear. Plain bearings made of the new iglidur AX500 high-performance polymer from Treotham help make bearing points maintenance-free and durable.

These sparks can take the form of small arcs that occur when moving machine parts do not have an electrically dissipative design.

Safe, wear-resistant bearings, even in high temperatures iglidur AX500 is also specifically suited to the high-temperature range, allowing it to be used in applications such as ovens and bottle cleaning. Its good chemical resistance means that aggressive cleaning agents will not harm the bearing. Nor is there any problem if iglidur AX500 contacts food, since the tribologically optimised polymer, with its embedded solid lubricants, requires no additional lubrication. The material also complies with Regulation (EU) No. 10/2011.

The igus iglidur AX500 is a new, wear-resistant material for the food industry that is electrically dissipative and can be used at high temperatures.

iglidur AX500 plain bearings are not only maintenance-free, unlike stainless steel bearings, but also cost and weigh less than the latter.

On the test rig: wear testing iglidur AX500 achieves much better wear results than the long-running food material iglidur A500. The wear of the iglidur A500 and iglidur AX500 was tested in a rotation test on stainless steel shafts in the 3,800 square metre in-house laboratory at igus in Cologne. The new material achieved a coefficient of wear that was up to three times as good as those of the old one.

Special dimensions from injection moulding can be supplied in a few days Treotham currently offers the new igus material in standard dimensions (6-20mm diameters), with or without a flange. For special dimensions that are needed quickly, the FastLine service is also available to users. Expanding in-house toolmaking allows igus to manufacture and deliver Treotham’s iglidur polymer plain bearings in special dimensions at low part prices within a few days.

Optimised milling for vibration-free machining Sandvik Coromant has launched a new high-feed milling tool, the CoroMill MH20, primarily designed for milling cavities, or pockets, in ISO S, M and P materials. Ensuring secure and vibration-free machining, especially at long overhangs, the CoroMill MH20 delivers best-in-class edge security for a variety of industries and is particularly suited for machining aerospace components. The CoroMill MH20 complements existing products in the CoroMill range, and fills a strategic gap in the high feed indexable milling product line. Designed to deliver reliability with minimal vibration, the CoroMill MH20 has been adapted for applications where components are notoriously difficult to machine, such as in the oil and gas, mold and die and aerospace sectors. The tool’s ability to machine at long overhangs makes it especially beneficial to the aerospace sector.

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This method is an important requirement when machining deep, narrow pockets to produce the components that form an aircraft’s frame, such as its supporting beams found within the sub segment aerospace frame. These beams are often machined from forged titanium and when paired with the requirement for long overhangs, this creates a difficult machining environment with a high risk of vibration. In contrast to the conventional four-edge concept, the CoroMill MH20 is designed with a two-edge insert. This is especially beneficial as it means the weakest section of the insert is far away from the main cutting zone, delivering greater reliability and protection against wear. It also means that machining against a corner or wall will not impact the next edge or leading corner, ensuring an equal performance per edge. Another area of innovation is the CoroMill MH20’s

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insert cutting edge geometry. While the sloped edge design delivers a gradual and light-cutting action that requires less power consumption to enable the use of smaller machines, the optimised edge line of main cutting edge and insert corner radius delivers further process security and enables reliable, unmanned machining.

ADVISORS Mike Shatford

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

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.

Iain Hosie

Iain Hosie, NanoLayr, Technical Director and Founder Iain is the co-Founder and Technical Director of Revolution Fibres. Iain has been deeply involved in nanofibre production and the development of many unique nanofibre products in the past ten years. Iain co-founded Revolution Fibres in 2009 and led the business since 2012, taking it from a small start-up to a recognszed leader in nanofibre production. Iain has recently moved to the Technical Director role – with a focus on keeping Revolution Fibres at the forefront of textiles innovation.

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Heat, mold, repeat: The benefits of thermoplastics Thermoplastics are polymers that become highly flexible when heated, and hard when cooled. Their structure consists of monomer chains with weak bonds between them that can break upon heating. Thermoplastics can be heated and cooled several times without losing much of their chemical or mechanical properties. When heated, they can be molded into virtually any shape. For example, a thermoplastic composite could be pultruded into a flat structure, and then bent afterwards to create a curved shape. Thermoplastics can also be shaped through injection molding. In this manufacturing process, plastic pellets are loaded into a barrel where they are melted and injected at pressure into a mold cavity, which fills and solidifies to create the final product. Injection molding can be used for more than just a standalone part, as it opens the possibility of over molding. During this process, additional components are molded around an existing part to add to the overall structure. It’s essentially adding one layer over another. Thermoplastics can be over molded onto a different material, such as a metal, to create a top layer with advantageous aesthetic and performance characteristics.

together to create a strong bond that removes the need for gluing.

Molding the market Thermoplastics are advancing the composite market, with a report by MarketsandMarkets predicting the thermoplastic composites market size to increase at a compound annual growth rate (CAGR) of 7.5 per cent to reach USD 31.8 billion by 2025. The report outlines the ability of thermoplastics to be molded and remolded as a key reason for their popularity growth, along with their recyclability.

such as the sharp peg that helps the fence enter the ground and the holders for the electric wire, are over molded onto a thermoplastic rod to create a durable bond. While thermoplastics prove a valuable material for containing and protecting products of all shapes and sizes, their benefits span far beyond the packaging industry. The ability of thermoplastics to be melted and remolded into practically any 3D shape unlocks a plethora of design possibilities, making them influential in a wide range of industries.

Thermoplastics can be easily recycled at the end of their use cycle as their polymer chain does not degrade significantly when melted down, so the material can be reshaped into a new product without diminishing its performance. Thermoplastics have the potential to create advanced products for a variety of applications.

This could involve, for example, creating a softer handle for a more comfortable grip on a tool, such as a hammer.

For example, as part of Exel’s olive picking system, thermoplastic thread connectors are over molded onto the picking rods so that they can easily be fitted to the handle.

It’s also possible to over mold a thermoplastic on top of another thermoplastic part, which melts them

Exel is also using the material in electric fences for animal enclosures, where thermoplastic parts,

Digital Boost reaches 40,000 small business sign-ups, launches mobile app Over 40,000 small businesses are now participating in the Digital Boost skills training initiative, and to make this on-the-go digital education more easily accessible a new Digital Boost Live app has been launched. The Mind Lab built the free Digital Boost Live app for iPhone and Android in partnership with The Ministry of Business, Innovation and Employment (MBIE) on the back of a new Better for Business report, which evaluated the impact that Digital Boost has had on the small businesses participating in the initiative.

“We know the content is resonating. And now we want to make that content accessible to people who work more from their mobile devices.

Clearhead mental health podcast, provide a simple, hands-free way for business owners to absorb key information from experts.

“Digital Boost Live is designed to work for busy small business operators who need up-to-date digital information in the palm of their hand.”

“Push notifications allow users to keep up-to-date with events, while the single sign-on saves time,” she says.

MBIE’s Digital Boost Director Malcolm Luey says the latest report showed that 20% more small businesses surveyed have a website since Digital Boost began in January this year.

The Mind Lab CEO Frances Valintine says her team is acutely aware of the pressures small business operators are currently facing with COVID-19 alert level fluctuations. In response, access to support via mental health support services, such as Clearhead, are now available to all Digital Boost users.

“Digital Boost users now have the flexibility to switch between the Digital Boost website and the app depending on their unique and evolving needs.”

“More than ever, small businesses need to adapt to digital demands and our research confirms they know this too, with 83 percent of businesses surveyed indicating the importance of becoming more digital in order for their business to survive,” says Valintine, who is also the founder of the company.

Key Features The Digital Boost Live app is an extension of digitalboost.co.nz, with added features such as a real-time view of learning progress, podcasts, push notifications, and a single sign-on. Valintine says exclusive content, such as the

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The Digital Boost Live app continues to provide access to: • Over 500 short three-to-five minute learning videos, including how to use digital marketing to increase sales, real world case studies and Q&A sessions with experts. • Podcasts with business owners. • Hundreds of downloadable learning summaries. • Case studies featuring Kiwi small business owners. • Live Q&A sessions with experts and past recordings. Digital Boost Live is available for free now on the App Store and Google Play.

Program your robot faster with Robotmaster’s latest update Hypertherm has an update to its Robotmaster offline robot programming software. The new version 7.5 update focuses on accelerating and simplifying the programming process and includes new features for a variety of robotic applications.

Key highlights include: New material removal simulation capabilities so users can visually see what the material removal process will look like. This can help users forecast whether a collision between the robotic arm and stock material could occur in real life.

Improvements to the overall user experience (UX) and user interface (UI) for easier and faster programming. Users will experience an improved tab system menu design, a cleaner interface, and many other improvements for an overall 50 percent reduction in programming time. Streamlined programming using two new modes: Operation-focused and Orientation helper. Operation-focused consolidates the tools and workflows needed for an error-free program onto one window while Orientation helper, with its combination of axis configuration and optimised automatic path planning, provides live feedback on the feasibility of a planned operation. This makes it ideal for task experts

with no robotics experience. Enhanced CAM functionality to manage and store operation parameters in an optimised manner resulting in a smoother programming experience. Formalized and enhanced support for macros to manage and validate robot behaviour outside of the trajectory scope. A new feature called Macro manager ensures an error- and collision-free path between operations and the executed external macro. New simplified processor framework allows users to make updates with minimal training and no coding experience.

Yubico launches first YubiKeys with biometric Yubico, the leading provider of hardware authentication security keys, now has available the YubiKey Bio Series, the first series that supports fingerprint recognition for secure passwordless and second-factor logins. Built for biometric authentication on desktops, the YubiKey Bio Series supports modern FIDO2/ WebAuthn and U2F protocols, in both USB-A and USB-C form factors. In keeping with Yubico’s innovation and design philosophy, the YubiKey Bio does not require any batteries, drivers, or associated software. The new security keys integrate with the native biometric enrolment and management features supported in the latest platforms and operating systems. Once a YubiKey Bio is set up, users will experience secure second factor and passwordless logins for desktop-based FIDO-supported services and applications. The series reimagines biometric authentication on a security key. Its three chip architecture allows the biometric fingerprint material to be stored in

a separate secure element which delivers enhanced protection from physical attacks. The YubiKey Bio acts as a single, trusted hardware-backed root of trust which allows the user to authenticate with the same key across multiple desktop devices, operating systems, and applications. The YubiKey Bio enables biometric login on desktop with all applications and services that support FIDO protocols and works out-of-the-box with Citrix Workspace, Duo, GitHub, IBM Security Verify, Microsoft Azure Active Directory and Microsoft 365, Okta and Ping Identity. With the growing adoption of modern authentication, Yubico continues to work closely with its partner ecosystem to encourage support of biometric authentication as detailed in the WebAuthn and FIDO2 specs.

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How distributed manufacturing is reducing operational risk By Mathew Hunter, innovation product marketing manager, Konica Minolta

Distributed localised production has emerged as a counterpoint to globalisation as it places the production of goods closer to consumers or at the point of use.

productivity, sustainability, inclusivity, and quality of work; and to grow aspects of manufacturing where New Zealand has an existing or emerging competitive advantage.

To grow aspects of manufacturing

Using additive manufacturing means manufacturers can produce goods onsite, which delivers a host of financial, efficiency, and environmental advantages.

where New Zealand has an existing or

Although globalisation can offer businesses many benefits, the trend towards distributed manufacturing is increasing.

When the global pandemic swept through the world in early 2020, New Zealand manufacturers with supply lines based in other countries were significantly affected.

Particularly in recent times, this acceleration is due to factors such as: rising fuel prices, which has significantly increased long-haul shipping cost; concerns over climate change and its negative environmental effects; and the lack of control over stock levels, timing and import restrictions when relying on overseas supply lines. Distributed manufacturing uses additive manufacturing to place production sites across dispersed locations, which are interconnected and coordinated through technology. Sites can download designs and 3D-print them on the spot. Because this model relies on local manufacturing, producers have a higher level of flexibility and agility, providing faster turnaround times, quicker delivery of goods, and customised products. This can help manufacturers compete more effectively, particularly in a disrupted environment, as it reduces operational risks. By implementing a distributed manufacturing model, manufacturers can overcome many challenges currently impacting global trade, including constant trade wars and tariffs as well as pandemic-related border closures. Setting up local manufacturing operations also helps support innovation for individual manufacturers and helps the country as a whole gain more resource sovereignty. The New Zealand government has recently launched an approach to industry policy to help grow more innovative industries across the nation. Manufacturing is a key industry for New Zealand to grow and become a more productive, sustainable, and inclusive economy. The Advanced Manufacturing Industry Transformation Plan aims to: help lift the sector’s

emerging competitive advantage

Not only was it difficult and more expensive to get product shipments to New Zealand, many manufacturing lines ceased production as countries went into lockdowns.

Additive manufacturing also provides manufacturers the opportunity to improve original parts and create stronger, more effective parts. An example of this is switching a cast iron part for a lighter, stronger, and more durable carbon fibre equivalent.

This made it difficult for manufacturers to have visibility into products and delivery timing, and made it near impossible to plan ahead.

It’s time to rethink global supply chains

The impact of the global pandemic, coupled with the long-term goal of creating a thriving, innovative manufacturing industry in New Zealand, has incentivised manufacturers to rethink global supply chains and review operating models.

The significant disruption caused by the pandemic highlighted just how fragile global supply chains are. With the rising costs and limited shipping capacity, this is a pivotal time for manufacturers to rethink operations.

Moving production lines onto home soil provides many benefits. Importantly, it reduces operational risks involved in overseas lines and can ensure business continues even when faced with uncertain times ahead.

For manufacturers that supply perishable goods, such as meat processors, it’s imperative that operations are continuously flowing, with minimal downtime if breakages do happen.

The role of additive manufacturing Distributed manufacturing is facilitated by 3D printing, otherwise known as additive manufacturing, which provides on-demand, digitised manufacturing. 3D printing technology has evolved to provide manufacturers with an array of material options for designs, which include stainless steel, copper, nylon, carbon fibre, and fibreglass, among others. Some of the benefits additive manufacturing provides manufacturers include: - increased control of production - shorter lead times - more viable short-run projects as there is no minimum order requirement - prototypes can be developed quickly - flexibility and versatility to provide customised solutions - ability to create replacement parts on-site. Additive manufacturing can provide significant productivity improvements for production lines. When parts break or get worn down, they can be replaced quickly and without fuss using a 3D printer. This can reduce the downtime and costs associated with waiting on the new parts to arrive. Manufacturers can simply create the part needed within the facility and get the line back up and running within hours, rather than waiting days or weeks.

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This is also particularly helpful when specialised parts are needed or if the part is no longer manufactured by the original maker.

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During the last 18 months, manufacturers likely experienced long delays for parts and higher costs, and the downtime would have cost them profits, particularly those that had to dispose of perishable goods during that time. This ability to reduce operational risks such as downtime makes establishing distributed manufacturing processes imperative to business’s future growth and success. Additive manufacturing provides manufacturers the tools to create broken parts quickly, reduce downtime and the costs associated with replacement parts. It can also reduce the risk of lost profits from having to dispose of goods or delays in the finished products. Additive manufacturing also provides manufacturers with the advantage of being able to customise solutions with the versatility of 3D printing. Because distributed manufacturing moves supply chains locally, manufacturers can gain many benefits around improved productivity, supply chain efficiency, visibility, and adaptability as well as more accuracy when planning product completion, delivery, and future workloads. Manufacturing is a vital component of the New Zealand economy and will remain important to its growth in the future. Through innovative technology, bolstering onshore production lines, and leveraging technology for market competitiveness, New Zealand manufacturers can reinforce supply chains and ensure they are ready for future industry evolution and global disruptions.

The future potential of process control systems By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

Thanks to developments such as Industry 4.0, digitisation, and the cloud, together with improvements in process control and communication technology, it is easier than ever for equipment manufacturers to offer remote assistance and monitoring. The restrictions on travel and face-to-face working imposed the Coronavirus pandemic highlighted the benefits of remote commissioning to companies, many of whom are now looking to extract the most benefit from this technology. HRS offers remote telemetry and control options for all applicable products and systems, using class-leading technology from Siemens and Allen-Bradley Products. We are keen to exploit the potential of process controls to improve levels of operational knowledge, process management and operational efficiency. Process controls can incorporate a range of functions, such as visualization and Human Machine Interface (HMI) solutions, as well as programming tools and advanced software applications. We utilise a combination of programmable logic controllers (PLCs) and graphic terminals to provide easy to use, reliable controls. HRS also utilises a suite of bespoke software to monitor and control key parameters. This data can easily be transferred to remote systems – either those belonging to the client or HRS itself, using either hardwired (ethernet) or secure wireless (4G/5G) communication technology. Remote operation and monitoring provide a number of benefits, including the ability for clients to view and control equipment from a central

point, something which is particularly beneficial for complex installations, or those which are spread across numerous buildings or sites. It also allows HRS staff to assist with operations such as commissioning, upgrading or running-in, and to provide ongoing technical support should this be required. Looking to the future, digital process control technology is likely to become even more beneficial to processing industries. Control software can be constantly kept up to date, helping to keep systems operating at peak efficiency, but it is perhaps in the area of simulation that the greatest benefits could eventually be realised.

While our technology is not at this level yet, there is no doubt that as an industry we are getting closer. If such a future is to be realised, then information technology (IT) and operational engineering functions will need to become even closer, a trend which we are already seeing in many businesses. Industry 4.0 is a term that is often discussed, but not always fully appreciated. However, the last year has begun to show us what the near future will look like for process control.

As well as remote monitoring, the HMI controls allow full control of HRS systems via a dedicated interface.

The technologies driving opportunities in automation Swisslog Australia & New Zealand Managing Director Francis Meier discusses these trends and the future of automation.

Fast-moving industries like retail, food and beverage, warehousing, and logistics have been driving the boom and rapid advancement of e-commerce and the digital marketplace. Intralogistics, AI, Digitalisation and IoT are already thrusting industry forward in ways we never would have thought possible in years gone by. “Just as the merging of digital, AI and remote monitoring are hallmarks of Industry 4.0 in industrial markets, these giant steps in automation will be commercial markets’ pathway to the future. Leaders in their field are already moving into these fields, and the benefits are beginning to filter through to new levels of industry,” said Mr Meier.

“As these future-focused technologies advance further, automation-driven industries need to ask how they can not only utilize these advances, but actively shape the new technology to deliver specific business advantages, and achieve long-term growth,” he said.

Turning big data into big opportunities One of the key themes is big data, and how forward-thinking companies can better utilise this information to drive growth and company advancement. “Big data refers to large and complex data sets being collected and stored continuously. Collection is one part of the equation – how we use it is the more challenging, and exciting part,” says Mr Meier. “With the right tools, such as intelligent software, it is possible to transform big data into ‘smart data’. This is where you can optimise

processes, provide clarity on past, present and future operation figures, and be proactive rather than reactive to change.”

Companies to benefit from automation growth The continued growth in automated solutions and intelligent use of data will significantly improve warehouse performance, and allow companies to flexibly adapt to change, says Mr Meier. “The Covid-19 pandemic has shown how quickly the world sometimes need to change, so flexibility is crucial. Flexible, robotic-driven automation solutions are already giving companies the responsiveness and adaptability to change, and we expect this to continue to improve further in years to come,” he said. Other trends Mr Meier believes will play a big role in the future include: • Virtual reality and augmented reality • Artificial Intelligence and machine learning • Urbanisation – which will drive warehouses and distribution centres closer to cities

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Developments SaferMe’s contact tracing helps Sistema put worker safety first Sistema Plastics employs over seven hundred people at its Auckland, New Zealand facility and since the onset of the Covid -19 pandemic has implemented several precautions to ensure health and safety in the workplace, including staggering shifts, compartmentalising sections of the facility and increasing cleaning and sanitation.

logging and notification system.”

spread.

Muirhead said SaferMe would help the company mitigate Covid-19 as keeping workers safe and informed is the first line of defense to limit the threat of exposure and the potential for the virus to

“New variants show why this technology is important. Any solution that helps ensure continuity and creates a workplace that workers feel safe coming to is critical,” said Muirhead.

As New Zealand continues to mitigate the pandemic, Sistema has partnered with SaferMe to implement their contact logging technology solution to more accurately pinpoint worker interactions so appropriate prevention measures, including testing and self-isolation, can be activated quickly if a positive Covid-19 case is detected. The SaferMe technology helps Sistema Plastics protect the privacy of its employees as no location information collected, or personal information is stored with SaferMe. Sistema Plastics Chief Executive Officer, Drew Muirhead explained, “The safety of our people is our number one priority as we continue to ensure we can get essential products to consumers. “ SaferMe helps us keep our workers safe and our facility operational through the rapid contact Picture taken before Covid arrived.

New appointments at TMX TMX, Asia-Pacific business transformation consultancy, has consolidated its position as independent automation advisors in New Zealand by announcing two significant appointments to its supply chain division.

property and construction project management.

of industry experience and expertise in delivering

The appointments also highlight TMX’s focus on growing their automation offering as more businesses in New Zealand take up the chance to automate aspects of their supply chain.

global projects in fresh produce grading/packaging,

TMX has appointed Mark Rummins, former Logistics Network Manager at Fonterra, as Associate Director - Supply Chain and Francis Umali, as Senior Project Manager - Automation.

TMX is currently working on automation projects with New Zealand Post, GPC and Coolpak in addition to several other major clients.

These appointments build TMX’s supply chain advisory offering in New Zealand and support the firm’s full end-to-end integrated consulting services in supply chain, automation, freight and logistics,

warehouse storage solutions, machine safety, and semiconductor manufacturing.

Mark brings over 15 years of experience in New Zealand’s supply chain and logistics sector to TMX. Prior to his career at Fonterra, Mark was Director of Operations at DHL. An automation expert, Francis has over 15 years

New Zealand Space Agency joins international space coordination group The New Zealand Space Agency will become the 27th member of the International Space Exploration Coordination Group (ISECG), the Ministry of Business, Innovation and Employment (MBIE) has announced. The ISECG is a non-binding, technical coordination forum and includes all of the world’s major space agencies with each agency represented by its technical space exploration experts. Membership provides the opportunity for member space agencies to share their space exploration objectives and interests with the goal of strengthening their individual space programmes and the collective international space exploration effort. MBIE

Deputy

Secretary

Labour,

Science

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and

Enterprise and Head of the New Zealand Space Agency, Paul Stocks says: “We are very pleased to join the ISECG in this new era of space exploration. ISECG membership will enable New Zealand to build international partnerships for participation in globally coordinated space exploration efforts. “It will also provide opportunities for New Zealand’s space sector to participate in and benefit from these partnerships. “We will leverage our membership to better connect our researchers to leading international institutions and collaboration opportunities. “There is on-going space exploration research at universities and within the commercial space sector in New Zealand – for example, Rocket Lab’s planned

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scientific mission to Venus and the University of Canterbury’s research into materials that can be used to build habitats on Mars as well as its contributions to joint international spacecraft missions to investigate interstellar objects,” says Mr Stocks. Dr Christian Lange, current chair of the ISECG and Director, Space Exploration Planning, Coordination and Advanced Concepts at the Canadian Space Agency says: “We are pleased to welcome our new member from New Zealand. ISECG has continued to grow substantially over the last years. Space agencies consider the work of ISECG important to globally advance space exploration while supporting their own national priorities. We look forward to work with our new colleagues from New Zealand.”

The Last Word AI can be a powerful tool to combat climate change With record heat waves globally and extreme flooding impacting Europe and China, now is a pivotal moment to interrogate the interplay of technology and the environment, including the role of artificial intelligence (AI). What would it take to make AI ‘greener’? On the one hand, we first need to collectively recognise that there are tangible costs to the creation and use of AI systems – and, in fact, they can be quite large. GPT-3, a recent powerful language model by OpenAI, is estimated to have consumed enough energy in training to leave a carbon footprint equivalent to driving a car from Earth to the moon and back. There are beneficial impacts that AI can have on our relationship to the environment as well. A comprehensive study in 2020 assessed the potential impact of AI on the United Nations’ 17 Sustainable Development Goals, encompassing societal, economic and environmental outcomes. The researchers found that AI could positively enable 93% of the environmental targets, including the creation of smart and low-carbon cities; Internet-of-Things devices and appliances that can modulate their consumption of electricity; better integration of renewable energy through smart grids; the identification of desertification trends via satellite imagery; and combating marine pollution.

that resulted in the burning of around 714,000 acres. For a country steeped in natural wonder, with a population and economy that depends heavily on thriving forests, any type of wildfire is a devastating tragedy. Entel Ocean, the digital unit of Entel, sought to identify fires earlier using IoT sensors. These sensors act as a digital “nose” placed on trees, capable of detecting particles in the air.

AI use cases in industry can serve to help the environment and reduce carbon emissions.

The data produced by these sensors enabled Entel Ocean to use AI for automatically predicting when a forest fire would start. “We have been detecting a forest fire 12 minutes before traditional methods – this is a big deal when it comes to preventing fires,” says Lenor Ferrebuz Bastidas, enterprise digital solutions spokesperson for Entel Ocean. “Considering fire can spread in a matter of seconds, every minute helps.”

For example, OYAK Cimento, a Turkish based cement manufacturing group is using AI to significantly reduce their carbon footprint.

Trade-offs

Cement and telecom

According to Berkan Fidan, Performance & Process Director at OYAK Cimento: “Enterprise AI-assisted process control helps to increase operational efficiency, which means higher production with lower unit energy consumption. “If we consider a single moderate capacity level cement plant with 1 million tons of cement production, just a 1% of additional clinker reduction – with AI-assisted process and quality control – produces a reduction of around 7,000 tons of CO2 per year. This equals CO2 absorption of 320,000 trees in a year.” According to the think tank Chatham House, cement accounts for approximately 8% of CO2 emissions. Thus, there is a clear environmental need to improve efficiency in cement manufacturing and one tool to do so is AI. Another example of AI having a positive environmental impact concerns Entel, the largest Chilean telecommunications company, and sensor data to identify forest fires.

Through these applications, AI can be a powerful tool to combat climate change. But its role also as a contributor cannot be overlooked. To that end, the first step is to promote the practice of more holistic and multidimensional model evaluation. To date, the major focus of research and innovation has been on improving accuracy or creating new algorithm methods. These aims often consume larger and larger amounts of data, building ever more complex models. The most telling example is in deep learning, where computational resources went up 300,0000 times between 2012-2018. Yet, the relationship between model accuracy and complexity is logarithmic. For exponential increases in model size and training requirements, there are linear improvements to performance. In the hunt for accuracy, less priority is given to developing methods with improved time-to-train or resource efficiency.

It takes a collaborative effort to successfully fight forest fires that have been raging in many parts of the world, including Greece and Northern California.

Moving forward, we need to recognize the trade-off between model accuracy and efficiency and the model’s carbon footprint, regarding both during training and when making inferences.

Chile is frequently impacted by severe climate change and catastrophic weather conditions, which previously led to the worst wildfire in Chile’s history in 2017

The carbon footprint of a model can be complicated to determine and compare across modelling approaches and data centre infrastructures. A reasonable place to start may be by assessing the number of floating-point operations – that is, a discrete count of how many simple mathematical operations (for example, multiplication, division, addition, subtraction, and variable assignment) – that need to be performed to train a model. This factor and others can impact energy consumption along with the architecture of the model and the training resources, such as hardware like GPU or CPUs. Additionally, the physical considerations of the storage and cooling of the servers comes into play. As a final complication, it also matters where the energy is sourced from. Energy primarily from renewable resources compared to natural gas or coal will have a reduced carbon footprint. Let’s ask: “How much more can we do with less?” Taking into account energy-conserving constraints may drive us towards new and creative innovations in AI. By pivoting to this mindset instead of bigger is always better and by pursuing AI use cases in the environmental space, AI can remain at the cutting edge, becoming a sustainable technology of the future and a major asset in the protection of our global climate.

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Analysis

ANALYSIS

Put money in your pocket – don’t throw it away! Simon Ganley, managing director, Ganley Engineering

It is amazing the number of manufacturers who give away money. It must be exciting to be a shareholder in such companies that do so well they can throw profits away. Let me explain. If the company processes food, powders, industrial and horticultural products in a drier, fryer, oven or some other processing equipment, the process needs to be controlled or what gets produced can be scrap, downgrade or otherwise given away. We have attached an unadulterated X by Y plot of milk powder. It could just as easily be wood fibre, confectionery, pharmaceuticals, cereals or a multitude of other products. But lets run with milk Chart1 powder as an example. Title: 3.5

The blue spots represent the testing laboratory reference results from the fluid bed drier. The red spots are simply a comparison with an offline analyser. The fluid bed drier produces 10 tonne an hour and each blue spot shows a reference test each 8 hours. This means that each spot covers 80 tonnes. The current selling price of milk powder is $3182 a tonne. So each spot represents $254,560.00 of product value. Now the specifications for milk powder shows a standard upper level of +/- 4.0% moisture. Because this fluid bed drier has no active controls on it, the operators are flying blind and going for safety by over-drying. None of the powder makes it to within 1.0% of being right and the average amount of product being given away is 1.5%. Let’s take 1.5% of the value of an 8 hour run.

Gauge values

2.5

2 Initial gauge/ reference value s Recalibrated samples

That makes up to $3,818 of given away money. That is over $80,000 a week and means a return on investment in days rather than weeks.

1.5

0.5

But things get worse. What was the energy cost to unnecessarily

0 0

0.5

1.5 2 Reference values

2.5

3.5

over-dry for the year? Or the cost to run staff who could be better employed and leave the control of the drier to proven technology? Now please appreciate that world-wide over the past 30 years we have had thousands of NDC Technologies sensors ( www.ndc.com) controlling all manner of products to the top of the specification. Each of them was only purchased after very thorough due diligence and specifically tailored for an application. The payback is usually very fast and self-funded from extra production and cost savings. So if you are an owner or shareholder of a company that uses a drier, fryer, oven or other processing equipment, maybe this is a good time to peel off your current test results. If what you show is less than top specification, this could be a good opportunity to talk with Ganley Engineering ( www.ganleyengineering.co.nz) so we can talk about how we can clean up what you make with a self-funded and very proven solution. And put money in your pocket instead of throwing it away. You don’t get much for free these days. But something that quickly pays for itself and gives you a profit that is as good as it gets.

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Take Control of Your Dairy Powder Quality Backed by 50 years of industry experience, our intelligent and connected in-process solutions fit right into the fluid bed dryer to optimize your product quality. ► Measure moisture, protein and fat/oil content ► Produce more consistent product within specification ► Automatically control the drying process

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