NZ Manufacturer September 2014

September 2014

www.nzmanufacturer.co.nz

BUSINESS NEWS Policies to improve manufacturing and exporting.

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9-22

THE FUTURE OF MANUFACTURING A new mindset in production design.

Robots benefit plastics technology company High labour costs and geographic remoteness have meant to be competitive in global markets, New Zealand (NZ) manufacturers have needed to apply new, innovative technologies to their production processes to deliver products to market faster, cheaper and with the highest level of quality.

Safe and easy-to-program: There are many important factors to consider when investing in new technology including the safety of your staff.

To solve part of that problem, Talbot Technologies deployed two of Universal Robots’ UR10 industrial robot arms to perform in-mould modelling, transfer moulding and co-moulding tasks on the company’s Christchurch production line. Since the installation of the first UR10 in 2013, Talbot Technologies has already reported increases in productivity, reliability, quality and cost savings.

versatility to deliver the type of results we need. After extensive discussions with Design Energy, we agreed that the style of robot offered by Universal Robots would best suit our requirements,” Wilson commented.

“We had looked at other robots, however the strong ROI combined with its reliability and versatility made the UR10 a more desirable value proposition for us overall.

“The safety of our employees is paramount. The collaborative nature of the UR10 means our employees and robots can work on the production line together and share the workload of tasks – without the threat of injury,” said Wilson.

Best-in-class technology and support: Talbot Technologies is an integrated technical plastics manufacturer and solution provider that works as a design, development and production partner across a wide range of industries, for companies across the globe.

“Also another important factor in our decision was knowing we had the support of Design Energy who has all the capability of systemising the robot to our particular application,” said Wilson.

In contrast to traditional industrial robots in the market, Universal Robots’ small and lightweight robotic arms are able to work safely alongside staff (subject to a risk assessment). The UR10 robots comply with the ISO standard

for Collaborative Robots never exceeding a force of more than 150 newtons. The robots are also equipped with a state-of-the-art “stop-force” safety feature which automatically stops the robot from operating when it is subject to substantial resistance.

Another major factor to consider when investing in a new technology solution is its level of complexity.

According to Wilson, “One of the most appealing aspects of Universal Robots’ new generation of industrial robots is they no longer require specialist knowledge to operate. Our technicians can quickly and easily learn how to

continued on Page 23

Talbot Technologies, like so many NZ companies, has been trialling various technologies aimed at providing high quality output at a lower cost.

Having been introduced to Universal Robots’ technology by Design Energy, the company’s NZ distributor, Talbot Technologies began exploring various application options.

According to Steve Wilson, Executive D i r e c t o r of Talbot Technologies, the business Steve Wilson r e q u i r e d a flexible, ease-to-program five axis robot for a particular type of application.

“We conduct complex in-mould labelling which has quite a few components and a fixed rail robot simply doesn’t have the capacity or the

Investment Opportunity

Hasmate Ltd, a privately owned company, cloud-based, is going to another level of excellence.

Established and proven business provider to SME’s since 1993.

Risk Management – health and safety compliance.

Internationally compatible.

Our ideal investor will have a focus on health and safety and improvement in the workplace.

Gordon Anderson, Hasmate Ltd. • E: Gordon@hasmate.co.nz • www.hasmate.co.nz • P: 06 842 2499

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NZ Manufacturer September 2014

ORGANISED BY

Work spares us from three evils: boredom, vice, and need.

– Voltaire

This is the trade show for New Zealand’s food, beverage, processing and packaging technology industries. Experience the latest technical advances first hand, talk to the experts, and connect with the products, services, and machinery you need to meet the demands of tomorrows market place.

DIARISE THESE DATES 23-25 SEPTEMBER 2014 PRE-REGISTER FOR FREE ATTENDANCE USING PROMO CODE: NZMANUFACT

www.foodtechpacktech.co.nz

WIN

One lucky Foodtech Packtech visitor will walk away with a fabulous

www.nzmanufacturer.co.nz

Ford Territory TS RWD Diesel RRP From $59,990

NZ Manufacturer September 2014

3

CONTENTS DEPARTMENTS NEWS 5 BUSINESS Policies to improve manufacturing and

ADVISORS Larry Wiechern

Is the Manager of the Maintenance and Reliability Centre, Manukau Institute of Technology.

exporting.

TECHNOLOGY 6 MANUFACTURING Keeping track of manufacturing operations.

New PowerINSPECT inspection software launched.

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TECHNOLOGY 8 MANUFACTURING Aerospace inspection gear takes off.

First on-machine switch simplifies network design.

PACKTECH 2014 9-22 FOODTECH PREVIEW Packaging House delivers more products.

New launch by ES Plastics at Foodtech.

Complete process solutions covered.

ESL Technology delivering packaged beverages with superior freshness.

Agribusiness skills gained in new ways.

APC Technology celebrates 30 years.

A sustainable solution for food and farm waste.

Drying Solutions on Stand 2100.

Catherine Beard

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How the next evolution of the Internet is changing everything.

Brian Willoughby

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28-29 WORKSHOP TOOLS

A first for Australasia.

Affordable pure sine inverter range.

Customised surface inspection.

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.

Professor John Raine

Is Head of the School of Engineering and Pro Vice Chancellor – Innovation andEnterprise at the Auckland University of Technology.

Bruce Goldsworthy

31 REAR VIEW

Neglect: Knowing an issue and not addressing it.

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

Is president of the NZ Manufacturers and Exporters Association and managing director of Contex Engineers and Plinius Audio.

FUTURE OF MANUFACTURING 24 THE A new mindset

26-27 THE FUTURE OF MANUFACTURING

Craig Carlyle

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

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An advocate for NZ manufacturing for 40 years, he was Chief Executive of the Auckland Manufacturers Association for seven years He has been Manager of EMA’s Advocacy and Manufacturing Services, and lately manager for Export New Zealand in the north.

See us on Stand 2001.

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NZ Manufacturer September 2014

EDITORIAL

Food industries PUBLISHER

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

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

CONTRIBUTORS

Holly Green, Nick Inskip, John Walley, Peter Dickin Sandra Lukey.

ADVERTISING

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

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

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Dan Browne E: dan@membrana.co.nz

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

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ON A ROLL On a clear, dark night on Manufacturing Street, three companies were working late processing some last minute export orders. They knew they needed to complete the orders this week so they could concentrate on the upcoming elections being held this weekend.

Anyway, we won’t go there…

Instead I’ll focus on Foodtech Packtech and suggest how this major trade show assists New Zealand food manufacturers and processors contribute to the economy.

MEDIA HAWKES BAY LTD

When we talk – and talk up – our manufacturing efforts every month, food manufacturing – and forestry – plays a huge role.

Vol.5 No. 8 September 2014

New Zealand’s reputation as a manufacturer of quality food products is renowned around the world as our geographic location provides a secure and environmentally friendly haven to get on and do the job.

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

Affiliates

ASIA

MANUFACTURING NEWS the

FactoryFloor www.nzmanufacturer.co.nz

From a manufacturing prospective, Foodtech Packtech and EMEX ‘do it’ for manufacturers. The chance to display the latest technologies and services to assist industry development is a huge commitment from the organisers XPO Exhibitions and exhibitors alike. But it pays off. New Zealand, rich in land, rich in ability leads the world and with a bit of nous and the right equipment there are opportunities there waiting to be ‘gathered’.

The organic apple from the tree goes to Watties for processing, the Marlborough wine is enjoyed with a meal in London and quality venison is on the menu in Tokyo. We do well and the right equipment for processing in challenging market conditions gets us there.

Entrepreneurs in business today focus on hi-tech – maybe Apps – hospitality – the bed and breakfast in the country for the tourists - or research the best aspects of rural manufacturing to be a part of. This includes horticulture, agriculture and the wine industry.

Manufacturers’ Trading Post

THE

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

Invariably the nation is changing.

There is huge interest in moving out of the big cities to the regions to follow the dream. Food industries are where a lot of the dreams are focussed. And Foodtech Packtech puts them on display.

Doug Green

NZ Manufacturer September 2014

I have not failed. I’ve just found 10,000 ways that won’t work.

— Thomas A. Edison

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BUSINESS NEWS

Policies to improve manufacturing and exporting -John Walley, NZMEA With it being election time, there has been a lot of policy discussion, however it is worth considering the policies that manufacturers and exporters might want to see put in place to support and improve the sector. We will also discuss why supporting and promoting the success of this sector is so important, not just for those operating or working in the sector, but for the future prosperity of our economy and our people.

Looking at fiscal policy, Capital Gains Tax (CGT) could be introduced to rebalance investment incentives and move further towards a no exceptions, low and broad tax system.

Currently investment in housing and property assets carry significant tax advantages, pulling investment away from productive enterprises and contributing to ever higher house prices and potentially, financial instability.

Another vital area is government procurement – it makes sense to have an explicit buy New Zealand preference that recognises all the benefits of buying locally, with rules which make it possible for smaller New Zealand firms to tender for government contracts.

This way, by making the most of our government spending, local activity and capability development would be supported and developed over time.

Many economies around the world are moving towards a two target system of monetary policies in response to the GFC. New Zealand has made some progress with the introduction of loan to value ratios and other tools primarily

Commercial & industrial growth

for financial stability that have some impact on inflation. But our current one target (inflation), one lever (OCR) system has consequences that damage the external sector through the single minded focus on inflation. The Reserve Bank Act could be changed, to target the external balance and exchange rate in conjunction with inflation.

A competitive and stable exchange rate over time would make a huge difference to exporters, allowing them to compete on the world stage without margins being eroded.

There are also more direct policies to help the sector, such as accelerated depreciation, which would allow businesses to more quickly depreciate assets like plant and equipment. This incentivises and makes investment in new equipment easier, and would better reflect modern machine tool characteristics.

For incentivising Research and Development (R&D), currently we have a grant system, run through Callaghan innovation but New Zealand lags far behind the OECD when it comes to

R&D spending. We believe a R&D tax credit is a much more effective way of promoting and broadly encouraging R&D and innovation, without having to pick winners.

Finally, vocational and tertiary education policies that are aligned with the needs of manufacturers and exporters have been a bit of a football lately. Skills and capability development takes time and effort from industry and the training system, and how policy and practice operate in this area is vital for the development of the economy.

Why is this important to all New Zealanders?

The policies above would have a direct positive effect on our manufacturing and exporting sectors, improving their ability to compete on the world stage, innovate and invest in their future.

This is important for everyone, not just those in the sector; the success of manufacturing and exporting feeds through to the rest of the economy, supporting jobs, promoting investment and bringing much needed activity

Employment growth

helping us shift towards a higher value economy.

Every job in manufacturing creates two to five more jobs in the wider economy, many of which are highly skilled and innovative jobs that are needed to keep people here. Each dollar of export turnover generates $1.74 elsewhere in the economy. The sector also contributes much to the increasing complexity of our economy – focusing on becoming more complex, rather than slipping towards simplicity supports our future capability to add value, and continually build on this to make ever more complex and niche goods.

If we want a higher value, more diverse and complex economy with better job opportunities, then supporting the manufacturing and exporting sectors is necessary - the range of policies described can move us towards these outcomes, we just need to decide to put them in place.

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.org.nz

getba

www.nzmanufacturer.co.nz

Greater East Tamaki Business Association Inc.

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NZ Manufacturer September 2014

MANUFACTURING TECHNOLOGY Keeping track of manufacturing operations AIDC (Automatic Identification and Data Capture) solutions and advances in technology enable manufacturers to see what’s happening with all their operational events - assets, transactions and people - in real-time.

When this visibility is aligned to single network connectivity, it creates an integrated production environment with data excellence at its heart.

Not only can you see where everything is, and what it’s doing, but you can also see everything relative to everything else. Business decisions are made in full awareness, leading to greater efficiencies and more ability to fulfil customer needs precisely while meeting your own business goals.

These technologies include: Barcodes Radio Frequency Identification (RFID) Environmental sensors Real-Time Locating Systems (RTLS) Global Positioning System (GPS)

Barcodes Used mainly as a means of tracking stock in retail stores, barcodes have been used in increasingly diverse settings for a wider range of functions.

In manufacturing, barcode applications have spread throughout the enterprise to include warehousing, customer service functions, time, attendance, and package delivery, as well as the assembly line operation itself, helping to improve data management and accessibility, and reduce costs.

The benefits of barcodes Improved data accuracy is the single most common motivation for putting a barcode system in place. Companies with integrated bar-coding systems that enable users to scan barcodes rather than type numbers commonly achieve 99% data accuracy.

For companies in which data errors are a mere nuisance, the difference between 85% and 99% may not seem that extreme. But for manufacturing enterprises looking to optimise efficiency, the goal are 100% accuracy. Barcoding is one of the most cost-effective tools that these

organisations have to ensure data credibility and reduce the impact of human error.

Efficiency benefits Besides providing near-perfect accuracy, barcoding also enables users to work faster, without sacrificing accuracy. When factoring in the time it takes to correct simple data entry errors, it is easy to see the improved efficiency that comes with barcoding.

In addition, by providing computer systems the capability to ‘see’ exactly what is happening, barcodes enable instant conversion from physical actions into digital transactions. This conversion of former manual tasks to electronic processes occurs in real-time, increasing efficiency and allowing management to make decisions based on current data and personnel to be employed in other, more productive areas.

Consistency Barcoding, particularly in fast-paced industrial environments, enables consistent and predictable operations for enhanced product quality by Combining data management functions and preventing bottlenecks at data entry stations. Auto- ID systems usually operate at a defined pace, either self-determined by the printer’s maximum speed or triggered by the action of another device.

For instance, in an assembly line, operations that were previously slowed by congestion at the point of data entry can now progress smoothly through a system of automated print-and-apply labelling machines and fixed scanners. In addition, employing standardised barcode symbologies and compliance labelling ensures that barcode information is captured and relayed in a way that is universally understood and accepted.

Improved inventory and asset management In manufacturing, the barcode contains internal information such as production line number, of completion, materials used, serial numbers and miscellaneous quality control information. By scanning the label in the shipping department, the company can identify the exact inventory.

RFID Manufacturing operations are increasingly adopting RFID tags. These www.nzmanufacturer.co.nz

carry an RFID transponder, commonly called a ‘smart label’ to complement the barcode and text on the labels. Unlike barcodes, RFID technology requires no line-of-sight between the object and the reader. This solution enables the identification and recording of entire pallet loads in less time than it takes to scan a barcode shipping label.

component of all manufacturing, distribution, and retail operations, thus presenting a form of currency in many business relationships. Companies that can document the product lifecycle and tracing history to the item build strong customer loyalty.

Besides improving accuracy, RFID and barcode data collection is faster than manual collection, which improves labour productivity. Replacing paper forms with much smaller barcode labels and embedded RFID tags produces media savings that frequently reach six figures annually, even for companies with moderate levels of production tracking and shipping activity.

Real Time Locating Systems (RTLS) deliver precise visibility of critical assets - supply chain, manufacturing, and human, in real-time. For enterprises with geographically dispersed sites, this means having end-to-end visibility and traceability of all containers, pallets, and packages. For manufacturers, it enables intelligent management and flow of all critical assets, whether in the facility or in the yard.

As customers demand build-to-order and just-in-time deliveries from their suppliers - replacing the traditional build-to-stock model - traceability and data collection at the item level is critical. A relatively small investment in an RFID tracking system will ensure scheduling and materials applications will deliver benefits, leveraging the investment in those more expensive planning applications. In real-time, as well as the precise date and time that any product leaves the warehouse.

Simplifying materials management and streamlining production line applications In terms of stock management, after an item’s inventory routing instructions are encoded and labelled at the receiving dock, on arrival at the warehouse, users can use a mobile device to scan the RFID to record its arrival. The host materials control or warehouse management system (WMS) then directs the worker to the appropriate putaway location based on the item’s size, shelf-life, and predicted consumption schedule.

Most businesses apply RFID and barcode shipping labels when finished goods leave their facility. The most efficient producers have learned that pushing their identification and tracking systems as far back into the production process as possible provides tremendous labour and material savings.

RFID and barcode systems provide a high return-on- investment by reducing data entry and processing time, improving quality, and boosting the real-time performance of enterprise software applications.

Information

today

is

a

valued

RTLS

RTLS solutions can incorporate a mix of barcode, RFID, GPS and sensory technologies that mark, track and show the status of assets in real-time.

Where passive technologies such as barcodes simply locate an item, the active RFID element of these solutions delivers both live location and actual status.

Simplify asset management Controlling hundreds or thousands of assets performance objectives. is a daunting challenge. RTLS allows operations to find assets in seconds, as opposed to taking hours using a manual process. Beyond the ability to locate a sub-assembly or final product on demand, operations can use the tracking data to optimize processes, workflow cycle time, and dwell time.

RTLS enables users to view the precise location of assets and eliminate time-consuming manual searches and audits. Location data integrates into existing enterprise resource planning systems, allowing enterprises to realize more value from their IT infrastructure.

Also, real-time enterprise visibility minimises the need for equipment relocation.

Instead of moving equipment to central locations, assets can be stored closer to the point of use, which increases speed of production.

The optimal RTLS platform integrates hardware and software with existing BI and ERP solutions to help enterprises align their strategies cross-functionally.

When coupled with passive RFID and barcode systems, RTLS enables you to track, locate, and manage critical assets across the value chain.

NZ Manufacturer September 2014

There are no mistakes, only opportunities.

— Tina Fey (from her book, Bossypants)

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MANUFACTURING TECHNOLOGY

New PowerINSPECT inspection software launched The latest release of Delcam’s PowerINSPECT inspection software has a new interface with new icons that make the software more intuitive and even easier to use.

Other enhancements in the new version include the ability to create compound items, and so speed up and simplify repetitive measurements, enhancements to the measurement dialogs and a further increase in the range of geometric features that can be inspected.

toolbars, which allow frequently-used commands to be grouped together in one convenient place, and so improve speed and ease of use. It is possible to export and import toolbars, so users can easily transfer their set-up to a different PC or share their toolbars with other operators.

The new interface was developed to further improve the ease of use that has been central to PowerINSPECT becoming the world’s leading hardware-independent inspection software. Over the last few releases, the software has seen a significant increase in the range of measurements that it can make.

During inspection, 2D features (circles, slots, rectangles and the like) are always projected to a reference plane.

For example, when inspecting a circle representing the top of a cylinder, the user will want to measure the properties of the circle and its height.

PowerINSPECT can now create a compound item that combines the plane and the feature together into a single compound feature, and assumes that the 2D feature is to be reported, while the plane is not. This leads to a shorter sequence tree that is easier to navigate and a report that shows only the properties of the 2D features by default.

The software can now be used to take all types of simple measurements and to inspect a growing variety of geometric features, as well as offering more tools for analysing complex 3D surfaces. In addition to making it easier to negotiate the greater range of options, the new interface features freshly-designed icons, which give a cleaner look and feel to the software.

In addition, PowerINSPECT now has the ability for users to create custom

This option is especially valuable for any iterative building operation, where an assembly needs to be measured, adjusted and re-measured

until the results are acceptable. Using compound features makes it much quicker and easier to go back and forth between measurements.

In particular, if the plane needs to be re-measured to determine the height of the circle, rather than the xy position, it can be re-measured immediately. This new functionality was primarily designed for the building and calibration of fixtures but it is useful in any scenario where the user has to re-measure and adjust features within an assembly.

Enhancements to the measurement dialogs in PowerINSPECT allow a wider range of information to be shown in addition to the measured values. The user can now also choose to display nominal, deviation and error values, helping to highlight immediately whether each measured feature is in tolerance. This provides the operator with more complete information, allowing even faster decisions about the status of the part and whether to continue with, or to end, the measurement routine.

The range of geometric features that can be measured with PowerINSPECT continues to be increased with a new option to create a probed ellipse. A new constructed geometric feature allows the user to create the circle at the intersection of two tori. This can then be used to locate the transition point in ‘S’ bends in tubing and ductwork applications. In addition, enhancements have been made to the measurement of a constructed ellipse.

Improved calibration records can now be recorded in the probe database.

This allows better traceability of the data and provides more assistance for the user to manage their calibrations.

Finally, PowerINSPECT now includes improved support for the Renishaw PH20 probe. This probe is becoming more popular as the five-axis motion of the PH20 does not require calibration of every stylus angle and allows measurement points to be taken by moving only the head rather than the complete CMM structure, so maintaining accuracy at higher measuring speeds.

PowerINSPECT has a new interface for faster, easier inspection.

www.nzmanufacturer.co.nz

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NZ Manufacturer September 2014

MANUFACTURING TECHNOLOGY

Your time is limited, so don’t waste it living someone else’s life.

— Steve Jobs

The changing face of health and safety in NZ On the 1st of April 2015 NZ health and safety law will change with the implementation of the Australian based Worksafe NZ Act. This is an unprecedented departure in New Zealand law that has been quickly enacted on by the National government as a result of the Pike River tragedy to help achieve their goal to reduce the unacceptable workplace fatality rate by 25% by 20/20.

to three million dollars and up to five years in jail, this is to be taken seriously.

For many, they will think that its business as usual, but with penalties up

Another important aspect of these changes will be and ability to quickly

This responsibility for health and safety in the business will now rest with the business owner’s, directors and officers of the business, The Buck Will Stop At The Top.

provide evidence of compliance when called upon by visiting inspectors, this is where the “Hasmate” excels.

businesses to manage many aspects of their compliance management responsibilities.

Hasmate is a Cloud based compliance management program has been developed by NZ health and safety professionals for NZ business as a risk management tool It is now being used by a wide range of NZ

Gordon Anderson 06 8422499 Gordon@Hasmate.co.nz Napier

Aerospace inspection gear takes off The AeroCheck Eddy Current Flaw Detector is fully capable of all the typical eddy current inspection applications on an aircraft including paint thickness, sub-surface and surface crack detection.

The AeroCheck is ideal for inspecting areas such as: Wheel brakes; Wheels; Landing gear; Fasteners; Engine mounts; Fuselage; Wing surface and hinges; Bulkheads; Door access points; Engine blades; Engine discs and much more. Fitted with the industry standard 12-Way Lemo connector and co-axial Lemo 00 connectors the AeroCheck can be used with absolute, bridge and reflection probes without the need for adaptors. The AeroCheck includes rotary capability as standard and can be used with the

ETher Mercury, Hocking 33A100, and Rohmann MR3 Drive. With a crisp daylight readable LCD colour screen, weighing just 1.2kg and housed in a tough case, the AeroCheck is ideal for working in any environment and can be used for up to ten hours with a pencil probe and seven hours with the rotary drive and probe attached.

The intuitive menu options can be configured to the user’s personal preferences and with the built-in “flip” function the AeroCheck works equally well for left or right-handed operators.

First on-machine switch simplifies network design Rockwell Automation has announced the launch of the Allen-Bradley ArmorStratix 5700, its first on-machine switch. Built with ruggedised IP67 protection, the Layer 2 managed industrial Ethernet switch can be mounted directly onto a machine or application, reducing the overall size and cost of a control cabinet, and shrinking the machine footprint

would otherwise remain isolated from business-level systems. Using the Cisco IOS network infrastructure software, this switch manages the transfer of production data to enterprise-level databases and information systems for improved decision making.

In many applications, cabinet space for system-level networks is limited or nonexistent. The ArmorStratix 5700 switch expands the Allen-Bradley On-Machine offering from Rockwell Automation – an industrially hardened portfolio of products that requires no cabinetry – and leverages pre-configured, quick-connect systems and simplified wiring layouts to reduce installation, troubleshooting and maintenance activities.”

Senior analyst with ARC Advisory Group comments: “Machine-mounted Ethernet switches with M12 connectors and IP67 ratings are very popular among machine builders. The new ArmorStratix 5700 switch is a joint Rockwell Automation-Cisco developed product that includes these features along with Cisco IOS. This robust, machine-mounted switch is a new development that should go a long way toward resolving the information technology/operational technology struggles in manufacturing plants today.”

The ArmorStratix 5700 managed switch advances connected enterprise goals by delivering integration of machine-level data that, due to cost or location,

This industrial switch simplifies the design and development of machine-level networks through configuration and monitoring tools.

www.nzmanufacturer.co.nz

These tools help enable easy setup and diagnostics from within the Rockwell Automation Integrated Architecture system – bridging the gap between IT and the automation engineer.

The ArmorStratix 5700 Layer 2 switch offers high availability, Quality of Service (QoS), and automated monitoring to help simplify network optimization and convergence. The switch comes standard with 8, 16 and 24 fixed-port configurations, and each base model comes with M12 Ethernet connectors, SD flash card, dual-power inputs and a panel-mounted design. An expanded ArmorStratix 5700 switch offering includes 10 and 18 fixed-port configurations, with 2 gigabit ports,

hardware-based IEEE 1588, hardware alarms, and up to eight Power over Ethernet (PoE) ports.

NZ’S LARGEST EVENT FOR Work spares us from three evils: boredom, FOOD & BEVERAGE MANUFACTURERS vice, and need.

NZ Manufacturer September 2014

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This is the trade show for New Zealand’s food, beverage, processing and packaging technology industries. Experience the latest technological advances first hand. Talk to the experts. Connect with the products, services, and machinery you need to meet the demands of tomorrows market place.

220+

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Latest Innovation and Technology

Industry led Seminars

ADDING VALUE TO NEW ZEALAND’S FOOD CHAIN

23-25 SEPTEMBER 2014, ASB SHOWGROUNDS, AUCKLAND

University of Queensland MPI MBIE/University of Auckland Lincoln University University of Auckland Massey University University of Auckland FF Instrumentation University of Auckland

Dr Gordon L. Robertson Dr. Ian Ferguson Prof. Jim Metson Prof. Charles Brennan Prof. Brent R. Young Mr. Tom Robertson Dr. Dongxiao Sun-Waterhouse Bob Olayo Dr Ilva Dana Rupenthal

MBIE/Coriolis Comvita Limited NZIFST NZ Food Innovation Network Massey University Plant & Food Research AUT University The Icehouse Scion Pride in Print NZ Food Innovation Network

Mr. Andrew McCallum and Mr. Tim Morris Dr. Ralf Schlothauer Dr. David Everett Angus Brown Prof. Richard Archer John S. Mitchell Prof. Owen Young Ms. Liz Wotherspoon Lou Sherman Sue Archibald John Morgan

Australian Institute of Packaging

Richard Manatan, Sarah Yanez, Matt Bogust and Peter Snopko Prof. Richard Archer Dr. Gareth Marlow Prof. Richard Archer Graham Fletcher Matthew Bird Dr. Anne Perera A/Prof. Nazimah Hamid Tony Mutukumira Saskia van der Geest

Massey University University of Auckland Massey University Plant & Food Research APC Technology Food & Nutrition Consultant AUT University Massey University New Product Development Specialist

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NZ Manufacturer September 2014

FOODTECH PACKTECH Packaging House delivers more products Packaging House is a major distributor of foodservice packaging, cleaning, hygiene and industrial consumables in New Zealand.

In fact, they deliver more products to more industries through more branches than anyone else.

Whether they’re supplying takeaway cups for cafes, stretch film for warehouses, or latex gloves for surgeries, Packaging House take care of the everyday essentials needed to keep business running smoothly and efficiently.

And it’s something they’ve been doing for over 40 years.

Their wide-ranging expertise also extends to the food processing industry. Packaging House can deliver a healthy menu of options to ensure food production is safe and risk-free this includes the ability to supply you with expertise to make HACCP part of your business.

SERVING UP FOOD PROCESSING EXPERTISE In addition to HACCP compliant hygiene consumables, to compliment and complete your Risk Management Programme, Packaging House now

have new ranges available: a full range of food processor brushware, metal detectable tools and hygiene consumables, a personal safety range and a complete stretch film, tape and strap machinery, and consumables range.

There is also a choice of finance options available, from outright purchase, to lease, lease to own and amortisation.

THE RIGHT SOLUTIONS No one knows a business like the person who runs it, that’s why a specialist from Packaging House takes the time to get to know your business and discover what it needs to operate day to day. Armed with this knowledge, they can get to work and deliver solutions to help your business run like a well-oiled machine.

COLLECTIVE BUYING POWER You need to buy at the best possible price, and thanks to Packaging House’s collective buying power, they can deliver better prices across the widest range of products. Combine this with the lower administration

costs of dealing with one supplier, and your procurement costs will come down quickly.

Better still, Packaging House can supply you with just one invoice - so your valuable time won’t be taken up dealing with multiple orders from a range of suppliers.

PROCUREMENT MADE EASY Everyday ordering has become a breeze, thanks to Packaging House’s website. It’s there 24 hours a day, seven days a week, allowing you the freedom to place orders or access information whenever you need to. And as you’d expect, it’s loaded with features designed to make procurement simple and efficient, such as compliance to preferred product lines, and detailed tracking and reporting.

Once your orders have been placed, efficiency is a priority. You just can’t afford to leave customers waiting, that’s why Packaging House offers the choice of pick-up or fast delivery from any of its warehouses across the country. This means your business is less likely to be slowed down by a

lack of supplies.

All this delivers you with more time to focus on your core business.

LOCAL KNOWLEDGE GLOBAL EFFICIENCY Packaging House understands the importance of keeping informed about global trends and developments. That’s why they’re always on the look out for new products to make life easier for customers.

The Packaging House global sourcing office in Shanghai has developed a strong network of global suppliers across all their product categories.

They can also ensure the quality and performance of all globally sourced products, so customers can have confidence in all aspects of the supply chain.

FINDING OUT MORE IS EASY Call Packaging House on 0800 722 567 or email marketing@packaginghouse. co.nz and find out how they can deliver more for you, including time, value, service and expertise.

New launch by ES Plastics at Foodtech Packtech ES Plastics, appearing on Stand 2001 at Foodtech Paktech, were told by the market that In addition to their cube style Fortress Jerry cans, they wanted a “premium” style of Jerry Can for agricultural and horticultural based products that would make their product stand out when placed alongside their competitors’ products when sold in a retail environment.

From this requirement comes the Swing Handle family of Jerry Cans.

There was also the need to make these jerry cans compatible with plastic recycling programmes such as Agrecovery and Plasback where the containers need to be triple rinsed.

The Swing Handle Jerry Cans, being launched at Foodtech Packtech, all

www.nzmanufacturer.co.nz

feature the same fitting, as well as base dimensions. It is only the height that varies offering 10 and 20 Litre capacities (Dangerous Goods approved) with a 15 Litre option pending.

All are equipped with an injection moulded “loop” style handle that is secured to the Jerry Can by way of a pivot pin which allow the handle to move backwards and forwards to give the user greater control over the rate of pour as well as better access to hard to reach places over the more common “in-line” handles which are fixed.

Complementing the swing handle is a rubberised grip that makes carrying, and pouring this Jerry Can the most ergonomically available.

At the front of the Jerry Cans is a

70mm Tamper Evident Cap, which is the widest diameter permissible under Dangerous Goods testing rules. This wide diameter enables liquid contents of various viscosities to be emptied quickly, which is very handy if pouring above shoulder height!

At the rear is the standard 38mm Tamper Evident Cap that acts as a breather cap to provide a smoother pour if needed, and this cap can also be vented to stop the Jerry Cans from expanding when used with industrial products that give off vapour, i.e. chlorine based chemicals.

The Swing Handle Jerry Cans also feature a 3/4” BSP Drainage bung at the base so that a tap can be fitted after being pierced, allowing the

Jerry Cans to be placed on a shelf for decanting and still be in the vertical position so that product labels can be easily identified and remain legible.

In between the 38mm cap and the Drainage Bung runs a Visi-Strip of Natural material allowing the user to see at a glance the balance of contents of the Jerry Can without needing to open the caps and peer inside and guess.

All in all, the new Swing Handle range of Jerry Cans is the new generation of containers for all markets where you want to be offering your customers the best package!

NZ Manufacturer September 2014

11

Work spares us from three evils: boredom, vice, and need.

YOU SUPPLY THE FOOD, WE’LL ENSURE HACCP IS ON THE MENU.

– Voltaire

At Packaging House, we can help you ensure your food production is safe and risk-free. That’s because our team can supply you with the expertise needed to make HACCP part of your business.

We’re also experts in sourcing and delivering everyday business essentials – something we’ve been doing for over 40 years. We can supply you with stretch film and strap, workplace cleaning products, safety, kitchen and cafeteria products, and more. And with nationwide warehouses, you won’t be slowed down by lack of supplies.

All this gives you more time to focus on your core business.

Better still, our One Source model makes procurement simpler and can significantly reduce your costs through reduced Your Company vendors, consolidated Colour Coded Zones for HACCP invoicing and collective buying power.

Request your FREE onsite appraisal from a Packaging House specialist by visiting www.packaginghouse.co.nz/food_processor

Your Company Colour Coded Zones for HACCP

DELIVERING MORE expertise Visit us at Foodtech Packtech, Hall 3, Stand 3131, ASB Showgrounds Auckland, September 23-25, 2014.

12

NZ Manufacturer September 2014

Complete process solutions covered Aurora Process Solutions is a recognised leader in the process equipment industry. Our experience, technical knowledge, product ranges, system solutions and back-up service capabilities unlock process potential through Australasia and beyond.

With expertise and turnkey equipment ranges covering Bulk Materials Handling, Industrial Packaging, Fluid Process and Quality Assurance, Aurora continues to provide our clients with market leading solutions.

Bulk Materials Handling - Industrial and Bulk Bag filling, closing and unloading systems - Palletising - Floveyor aero-mechanical conveying - Bulk materials handling, blending, batching, transfer conveying

and more. We continue to establish strong strategic global partnerships to increase our range of process solutions, along with constant R & D and system development.

- Parts and Servicing - Pigging Systems - Hygienic Valves Quality Assurance - Magnetic Separators - Metal Detectors - Checkweighing - Metal detectable products Satisfied clients, using solutions that add value to their product is a key focus of Aurora’s as they work to ensure projects are delivered satisfactorily from concept to completion.

“Throughout the process we found Aurora to be very professional and excellent to work with” comments John Leathart - Fonterra.

Aurora has partnered with processors in many different industries, including - Automation servicing, custom design the Dairy, Food, Beverage, Brewery, Wine, Grain & Seed, Fertiliser, and specification Growers, HVAC, Stock & Animal Feed, Fluid Process Wastewater, Laundry, Quarry & Mining, Romheld_PackTech:Layout 1 Oil 13/7/12 2:53 PM Page 1 & Gas, Pulp & Paper, Industrial - Heat Exchangers

Paul Gunningham of Apollo Projects has worked with Aurora on multiple projects across a range of industries.

“Aurora is excellent, I can’t speak highly enough of them. They know what they’re talking about, they are polite and friendly, prompt and reliable and they always deliver what they say they will.” Says Paul.

At Aurora we stand close behind our product and all our industry leading brands are backed by expert advice, installation and scheduled servicing that is second to none. ““I can’t fault them. They’re very personable, very quick and easy to communicate with.

Every dealing with Aurora is positive” said Paul Wake of McCain Foods after a recent project with Aurora. “They really are the experts in the field,” Andrew Clayton of Champion Flour confirms.

Romheld Automation brings their automotive industry experience to the packaging and materials handling industries of Australia & New Zealand. We understand high volumes with short cycle times, reliability and repeatability.

We represent a number of European and American manufacturers who specialise in manufacturing high quality innovative handling equipment, predominantly for use on robots and gantries.

UNIGRIPPER intelligent vacuum grippers will handle most products as they are self sealing wherever there is a gap between the products being handled. This flexibility allows a single Unigripper to handle product, slip sheets AND PALLETS without any changeover. Unigrippers currently in production in Australlia and NZ are handling cartons, tubs, cans, bags, bricks, timber, and more SAS bag grippers use pneumatically actuated toughened stainless fingers and are fully adjustable to differing bag widths and thicknesses. Available in 25kg and 50kg capacities, they maintain the bags shape and flatness to optimise stability during stacking. Pallet and slip sheet handling options are available.

SCHUNK servo-electric grippers are available with one or two servo motors utilising ball screws to move the fingers in either synchronous or asynchronous motions. This system allows unlimited variations in pick and place positions, including off centre with accurate position monitoring at all times.

Come and see all these grippers at stand 3107 at Foodtech Packtech 2012.

Ph: +61 2 9721 1799 Email: sales@romheld.com.au Web: www.romheld.com.au

See us on Stand 3121 www.nzmanufacturer.co.nz

No matter what stage of your process you’re at right now, make Aurora your process equipment partner.

Visit our stand #3078 at the Foodtech Packtech Exhibition, ASB Showgrounds, Auckland from 23rd – 25th of September 2014. Aurora will have on display a range of our Process Equipment solutions.

NZ Manufacturer September 2014

13

Work spares us from three evils: boredom, vice, and need.

– Voltaire

PROCESSING POTENTIAL UNLOCKED TAKE THE OPPORTUNITY TO CONNECT WITH THE AURORA EXPERTS – VIEW OUR PRODUCTS, SERVICES AND SOLUTIONS AT FOODTECH PACKTECH. PARTNER WITH US TO UNLOCK YOUR PROCESS POTENTIAL AND MEET THE DEMANDS OF TOMORROWS PROCESS INDUSTRY.

UNLOCK EFFICIENCY

UNLOCK PERFORMANCE

UNLOCK OPPORTUNITIES

COME SEE US AT STAND 3078

23-25 September 2014 at the ASB Showgrounds, Auckland

0800 55 77 33 | sales@aurora-nz.com | www.aurora-nz.com www.nzmanufacturer.co.nz

14

NZ Manufacturer September 2014

ESL - technology delivering packaged beverages with superior freshness With a lot of talk in the beverage industry about non-heat pasteurisation, we are pleased to announce that there is another effective method available that is more economic, more efficient, more beneficial and more compact than other alternatives on the market.

With increasing desires to process and consume beverages/food with all the

nutritional components still intact, we have some improved and realistic solutions relevant to products such as fruit juices, protein drinks, isotonic drinks, milk, bottled water and RTD’s.

We offer proven, non-invasive alternatives to heat-based pasteurisation, preserving the organoleptic integrity of the raw

materials and the finished product.

This is certainly one of the significant growth areas of innovation in the beverage industry.

For more information about this technology, please contact Paul Baggio at info@fbpropak.com or phone +61 3 9924-4050.

ATTENTION

All Health And Safety Officers Slippery floors are a serious safety hazard and one of the greatest causes of workplace accidents. Colourgrip® eliminates this overnight and brings them up to Code. Our incredibly robust resin and aggregate system boasts nearly 20 years’ experience, saving lives on roading networks around the World.

With Colourgrip® now available to NZ industry, if you need to stop your fork hoists from skidding, create highly visible and grippy staff walkways, line marking that won’t wear off, and have a Best Value mind-set then you need to talk to us.

Phone 09 274 42 84 Mobile 022056 7799 www.colourgripsurfacing.co.nz enquiries@colourgrip.co.nz Visit us on Stand 2015

www.nzmanufacturer.co.nz

Auckland 23-25 September

ESL

NZ Manufacturer September 2014

15

Work spares us from three evils: boredom, vice, and need.

– Voltaire

without heat pasteurisation

With a lot of talk in the beverage industry about non-heat pasteurisation, we are pleased to announce that there is another effective method available that is more economic, more efficient, more beneficial and more compact than other alternatives on the market. With increasing desires to process and consume beverages/food with all the nutritional components still intact, we have some improved and realistic solutions relevant to products such as fruit juices, protein drinks, isotonic drinks, milk, bottled water and RTD’s. We offer proven, non-invasive alternatives to heat-based pasteurisation, preserving the organoleptic integrity of the raw materials and the finished product. This is certainly one of the significant growth areas of innovation in the beverage industry.

For more info please contact Paul Baggio at info@fbpropak.com.au or call +61 3 9924-4050. You’ll also see more of our food/beverage technology range on Stand 2049 at Foodtech Packtech in Auckland from 23-25 September 2014.

www.nzmanufacturer.co.nz

See us on Stand 2049

16

NZ Manufacturer September 2014

Work spares us from three evils: boredom, vice, and need.

– Voltaire

FLOORPLAN

www.nzmanufacturer.co.nz

NZ Manufacturer September 2014

17

Agribusiness skills gained in new ways Agribusiness decision makers, on the farm and in horticulture, have identified they want better business development opportunities for themselves and their team – and the Diploma in Agribusiness Management is meeting this demand.

The qualification delivered by Aoraki Polytechnic, in partnership with Primary ITO, uses new learning technologies to help students add meaningful capability to their agribusiness. The first intake of students is two months into their learning, which has been very different to the traditional class-room based learning that is the norm.

Mike Parr is one of Aoraki’s dedicated agribusiness tutors, working in Timaru, Ashburton and Oamaru. He has spent the first six weeks of the Diploma helping students gather evidence for the ‘ACCK’ process (‘Assessment of Current Competency and Knowledge’). Aoraki Polytechnic is the first organisation to use ACCK in agribusiness.

This innovative method identifies that many people may already be skilled in

many areas of their business, and this enables students to learn what they need to learn, rather than starting from scratch. Each student compiles a portfolio of evidence, which they can then choose to put forward for assessment.

ACCK is a process of identifying previous experience, knowledge and transferrable skills sets and gaining recognition. It is an excellent way to fill-in gaps in skill-sets.

“The purpose behind the ACCK process is to highlight to the student ‘Yes, I have covered this,’ or ‘There’s a whole lot of stuff that I don’t know’. It’s a navel-gazing exercise to look quite hard at themselves, at what they have learned, and what they need to learn,” says Mike.

To kick-start their agribusiness learning, students attended a one-day workshop which showcased the software programme they’ll use throughout the Diploma. The online learning platform called ‘Moodle’ allows the student to learn at their own pace, at a time that is convenient for them and with full access to all the resources they need to

complete the study, including videos and regular communications.

Online learning allows students to spend as much time in their business as possible while, importantly, not losing motivation to study, since their tutor can keep an eye on their progress. This is well supported by in-class workshops and one-on-one learning which is tailored to individual needs.

“One of the students had been doing some class study previously – she found it frustrating that she had to go through all of the class material, even though she was competent in 70% of it. With the Agribusiness Diploma, she can attribute her previous learning to the qualification. She also only needs to attend a physical meeting with me every three weeks; the rest of it can be email or phone contact. We set goals for the skill areas she is lacking in. She loves the format and can go at her own pace,” Mike explains.

Another innovative tactic is that the Diploma allows students to learn from the industry experts in workshops.

Cara Gregan, a local farmer, presented

at the students’ first workshop which focussed on Human R e s o u r c e Management.

In charge of HR at Gregan Farms Cara Gregan in Hunter, South Canterbury, Cara was a natural choice to promote discussion about HR issues as she has successfully implemented several changes in their agribusiness.

“Dairy farmers sometimes have bad reputations for looking after staff. We look at our staff’s drivers, and these aren’t always money. One of our staff had a baby recently – we’ve given him a 1.5 hour lunchbreak every day so he and his partner can spend time with their newborn.”

Registrations are taking place for the next intake at Aoraki Polytechnic . As well as human resources, students learn about business management, financial management and sustainability.

when

reliability is everything!

0508 FORKIT (367 548) info@centrafork.co.nz www.centrafork.co.nz

Stand # 3129

www.nzmanufacturer.co.nz

18

NZ Manufacturer September 2014

APC Technology celebrates 30 years APC Technology, a South Australian designer and manufacturer of harsh environment solutions, is celebrating 30 years of business.

Incorporated in 1984, APC Technology was a pioneer in the design and manufacture of COTS based rugged hardware.

During the first 25 years a majority of contracts were predominately defence based and within Australia.

Today, APC Technology continues to work in the Defence Industry but has also diversified into oil & gas, mining, energy, food & pharmaceutical and other industrial manufacture. The organisation has developed a strong partnership and distribution network which now covers Asia, Europe and N&S America.

This diversification has seen APC Technology grows from strength to strength in multiple markets across the globe.

Highlights over the last 12 months include multiple defence contract

wins, the award of a major contract within the rail industry, which has subsequently doubled in size, and the continued growth of other key customers.

The formation of APC Research, a wholly owned subsidiary dedicated to R&D, will ensure APC stays at the forefront of technology. Additionally, the announcement that Singapore Technologies Kinetics (STK) has chosen to work closely with APC Technology on the upcoming Land 400 project, further highlights how far the company has come.

Peter Hodson, Chairman of the APC Technology board commented, “APC Technology started out with a corporate mission to make tough computers for tough conditions. Our recent financial results are proof that we have kept this goal integral to our

business model over the last 30 years whilst evolving to keep pace with the changing demands of the market place.”

“APC Technology started out with a corporate mission to make tough computers for tough conditions.”

Reflecting on APC Technology’s successes, Scott Begbie, Managing

Director commented, “APC Technology has always been about working with the customer to provide innovative solutions.

“Our clients value the depth and breadth of our skills and loo k to us to augment their own in-house engineering capabilities.

It is testament to the efforts and ingenuity of the staff at APC Technology that we have more than doubled our turnover in five years, with a minimal increase in personnel.

“We have set in place a strategy to continue this trend over the next five years and I fully believe we will be successful in our endeavours.”

APC Technology is planning to celebrate their 30 years in business with a number of activities over the coming financial year.

Computing Solutions for Tough Conditions Celebrating 30 years designing & manufacturing state of the art computer/control technology packages for defence & industrial businesses.

Solutions designed specifically for farming and food processing industries Engineered to survive shock, vibration, extreme temperatures & environments Customisation options to meet the clients needs including I/Os, user interface & mounting

Built to Last

See us on

Stand 3142

www.nzmanufacturer.co.nz

Waterproof

Sunlight Readable

www.apctechnology.com.au Tel: +61 (0)8 8363 0400

Fully Sealed

Introducing

Work spares us from three evils: boredom, vice, and need.

– Voltaire

NZ Manufacturer September 2014

19

A point of difference in today’s busy FMCG market.

Developed by AsureQuality, inSight™ provides shoppers with independently verified information about the products they are about to buy.

After a successful application process, producers can place the inSight™ logo and a QR code on their product packaging.

When shoppers scan the QR code at the point of sale they can access information about the product, including: • • • • •

Environmental sustainability Social and ethical concerns Nutritional information Safety and quality Origin

Call us now on 0508 00 11 22 to find out how inSight™ can add value to your business. www.aqinsight.com

www.nzmanufacturer.co.nz A new innovation taking product assurances into the 21st Century

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NZ Manufacturer September 2014

A sustainable solution for food and farm waste New Zealand company Biocosmo Technologies has developed a sustainable solution for organic food waste which they believe will help to eliminate the need for landfills.

Its food waste recycling system utilises new, patented technology to provide an end-to-end solution, processing waste in a matter of days and avoiding the problems caused by the toxic gases and sludge that are created when food matter decomposes.

The machine can process a variety of food wastes including household, hospitality, abattoir, paunch grass, poultry and fish processing, animal hair and waste water solids. The waste can take as little as three days to process and produces an innovative biological fertiliser solution for horticulture, agriculture and the home gardener.

The technology means that there is no need to dispose of these organic wastes in a landfill, with huge environmental benefits and economic benefits.

Landfill fees and associated transport costs can be reduced, councils can better meet environmental compliance

SEE US ON STAND 3005 www.nzmanufacturer.co.nz

targets and keep the costs of the disposal of organic matter down – ultimately helping to reduce rates.

have considered to get the process

Biocosmo Director Nick Morison, says it has taken six years to develop the concept. “There are many factors we

recycling company in Auckland, to

exactly right. The system is now being used very successfully by a rubbish dispose of household and hospitality food waste.”

Waikato Regional Council was an early adopter of the technology, using it to process the carp that is trapped in rivers and lakes in the region. The fish take three days to process and the fertiliser output is used for the council’s riparian planting programme.

NZ Manufacturer September 2014

The company has fielded enquiries about the waste system from Australia, China, South Africa and India. “It’s exciting for us to get the technology to a stage where we can sell machines around the world.

We can custom-make the machines depending on the nature and quantity of a company’s waste stream. We can produce portable systems that are the size of a shipping container or much larger industrial scale plants suited to specific needs,” says Morison.

The system’s operational costs are exceptionally low compared to other in-vessel processing systems as there is no need for an external heat supply.

The smaller machines consume power at a rate of $2.00 per hour (@25 cents/ Kw/hr).

The system provides an ideal solution for single source producers such as fish farms, abattoirs, chicken farms, etc. to dispose of their organic matter. For example, the waste from a chicken farm includes feathers, eggs, chicken mortalities and waste which can all be processed by the machine. Single source inputs process more quickly than multiple sources of food.

“We believe that this technology is part of the answer to the problem of burgeoning landfills as it’s the only 100 percent no-waste solution that we are aware of on the market. The biological fertiliser also potentially has a significant contribution to make to soil health and plant growth.”

How it works The Biocosmo process uses naturally occurring and non-pathogenic bacteria to carry out a natural decomposition process in uniquely accelerated conditions.

Trillions of bacteria operate to completely render the food waste down in a matter of days. By comparison the process would take months or years if waste was buried in the ground.

temperature and produce large quantities of heat. Their exothermic metabolism destroys any pathogens that many be present, effectively pasteurising the throughput.

The system uses multiple, sealed reactors, ensuring complete retention of all nutrients that are present in the original waste materials.

The smaller shipping container-sized processing plants are easily transported and are able to be readily relocated.

These systems can process up to five tonne of waste per day.

The end product is a dry, stable biological fertiliser that is ready for use. The fertiliser is a matrix of organic matter that utilises nothing but good

21

bacteria and is free from harmful chemicals that could be passed into the food chain. Biocosmo fertiliser is high in organic material and provides nutrients and capacity to retain important moisture in the soil.

Fertiliser made from foods high in protein contains nitrogen and other beneficial elements in a form that makes them readily available to plants.

It supports soil friendly micro-organisms which are essential for natural growth and improves resistance to pests and disease. Biocosmo biological fertiliser also acts as a soil conditioner by actively breaking the down the soil’s chemical dependency so the soil can heal itself.

The bacteria naturally breaks down food wastes, using extracellular enzymes. Many different enzymes are produced by the bacteria, enabling the effective decomposition of a wide range of food groups.

The bacteria operate at high

Cleaning on an industrial scale.

The bigger the task the higher the performance.

Dirt accrues in the widest variety of forms in various branches of industry. Often the roughest operating conditions call for robust and durable machines. And innovative solutions that combine environmental protection and economic viability. Kärcher system solutions specially for industry: vacuum cleaners, high-pressure cleaners and scrubbing machines with cleaning agents for the food industry. Systems that solve problems.

Kärcher eco!efficiency – achieve more for less. www.kärcher.co.nz

0800 KARCHER www.nzmanufacturer.co.nz

22

NZ Manufacturer September 2014

Drying Solutions Limited on Stand 2100 The REXMOI® Heat Pump Dehumidifier Dryer was originally developed to dry nuts at lower temperatures. Since then we have found various other products that need drying.

Over the years we have developed the technology that enables drying to take place at temperatures anywhere between 10oC to 70oC (most efficiently between 20oC to 40oC). The units are electronically controlled allowing a wide range of applications.

used where there is a need to control humidity and/or temperature in manufacturing areas.

With this method of drying nothing is removed except water. The dryers are fully enclosed so the

drying is not affected by external weather conditions, atmosphere, or contaminants. The trays are all food grade stainless steel.

Any product that has excess moisture can be dried.

For more information contact: Robert Barnes, Drying Solutions Limited Phone 027 493 9693 A/hrs 07 544 2980 Email admin@dryingsolutions.co.nz Website www.dryingsolutions.co.nz

With this air drying method in an enclosed insulated chamber, the heat is not lost and is recovered with only the moisture removed. This means that the energy use is much lower and is not affected by external conditions. For around 2Kw input you get 6Kw heat and you can remove 6 to 7 litres per hour or around 180 litres of water per 24 hours (depending on the product and conditions).

The current units are portable and are available for test drying. The analysis and information obtained from testing assist in designing units to specific specifications. The same principles are

The REXMOI® Heat Pump Dehumidifier Dryer was originally developed to dry nuts at lower temperatures.

• Drying takes place at temperatures between 10oC to 70oC (most efficiently between 20oC to 40oC).

• The units are electronically controlled allowing a wide range of applications.

• With this air drying method in an enclosed insulated chamber, the heat is not lost and is recovered with only the moisture removed.

• The dryers are fully enclosed so the drying is not affected by external weather conditions, atmosphere, or contaminants.

• The trays are all food grade stainless steel.

• Any product that has excess moisture can be dried.

See us on Stand 2100 PO Box 205, Tauranga 3140 www.dryingsolutions.co.nz Email admin@dryingsolutions.co.nz Phone 027 493 9693 A/Hrs 07 544 2980 www.nzmanufacturer.co.nz

Your Perfect Climate

NZ Manufacturer September 2014

23

DEVELOPMENTS continued from Page 1 program and operate the robots, saving the business a great deal of time in the implementation phase and in re-purposing the robots to carry out different tasks.”

The UR10 can be completely reconfigured and deployed for any number of tasks in a matter of hours.

The programming is very intuitive, combining a graphical user interface with a teach function which enables the operator to simply grab the robot arm and show it how a movement should be performed. The user-friendly interface then allows staff to drag and drop the routines to do their programming - this functionality is very similar to an iPad. UR10s in action: In the past, Talbot Technologies relied heavily on manual handling of products and in some cases utilised rail robotic technology.

However due to the company’s rapid growth, Wilson needed to streamline the production process to help drive efficiencies in workflow.

“The UR10’s have enabled us to combine functions that occurred off-machine and on-machine and others which happen either prior or post production – helping us to better streamline the process flow,” Wilson said.

When asked what appealed to him the most about the Universal Robots UR10, Wilson was quick to acknowledge the technology’s compactness, ease-of-programming, as well as value for money and the short payback period on return.

“At the moment the main cost reduction is gained through an improvement in quality. We always get exactly the output we want product wise without repeatability through error which has provided a solid return on our investment.

“We expect to see a full return on

investment within 12 months from implementation which for us provides significant cost saving benefits which can be used elsewhere to expand our rapidly growing business. We are planning on adding additional functions to what the robots currently do which will make other downstream processes obsolete and provide further return as we go forward.”

Final thoughts: Wilson said that Talbot Technologies was expanding exponentially and the workers displaced on the manual labelling

an integrated technical plastics manufacturer and solution provider that works as a design, development and production partner across a wide range of industries, for companies across the globe.

Talbot Technologies not only combines plastic Thermoforming and Injection Moulding technologies in one world class facility, but also offers a comprehensive in-house tool room facility. In addition to the design and fabrication of new tools, the in-house tool room facility allows for timely

“One of the most appealing aspects of Universal Robots’ new generation of industrial robots is they no longer require specialist knowledge to operate.” process had been redeployed in other areas of the operation which offered further productivity benefits.

He said overall the biggest single reason for recommending Universal Robots is the size of the unit. “They provide all the flexibility we require to perform complex tasks, moving between in-mould labelling, transfer moulding and co-moulding efficiently and effectively”.

About Talbot Technologies Talbot Technologies is located in Christchurch, New Zealand and is the outcome of the merging of world class technical injection moulder Talbot Plastics (Established 1972), with innovative leader in technical thermoforming Airform International (Established 1995). The result is

servicing of existing production tools, as well as fast turnaround of tool modifications during design and development project phases.

Talbot Technologies strongly supports the principles of lean manufacturing and assists customers to add value at the point of source manufacture to minimize product handling. This includes a range of assembly solutions including: ultrasonic welding, robotic gluing, application of post moulding decorative finishes, component assembly and electronics assembly.

Talbot Technologies is a true plastics technology development partner with a team who thrive on the challenge of new projects. The Team at Talbot Technologies work with customers during the early development stages

of a project to refine the part design and design for manufacture, providing technical advice on polymer selection, tooling design and manufacture, right through to ensuring quality products are consistently produced to a high standard and meeting customer specifications.

About Design Energy Design Energy is a New Zealand business which specialises in the development and commissioning of equipment solutions which solve problems, deliver productivity gains and enhance its customers’ business.

Founded in 2007, Design Energy handles everything from process engineering consultation to machine design, through to the supply and service of full turn-key systems. Design Energy partnered with Universal Robots to deliver quality robotic and automation solutions to some of the country’s leading producers and manufacturers.

About Universal Robots Universal Robots (UR) is a global developer and manufacturer of flexible and user friendly industrial robots. Headquartered in Odense, Denmark, the company has a global network of about 200 sales partners in 50 countries serving an ever growing list of customers across multiple sector including automotive, electronics, manufacturing, consumer goods, food & beverage and processing.

About the Robots UR’s robots are modularly designed, hand assembled and can function without the cumbersome safety fencing that most robots require. They are equipped with a state-of-the-art “stop-force” safety feature. The built-in software generates a protective stop if the robot hit something – hugely minimising the occurrence of serious workplace accidents.

The hassle free apprenticeship service Apprentice Training New Zealand recruits, employs and manages apprentices to train in your business.

0800 526 1800 www.atnz.org.nz www.nzmanufacturer.co.nz

24

NZ Manufacturer September 2014

THE FUTURE OF MANUFACTURING

If you are going through hell, keep going.

— Winston Churchill

A new mindset in production design The terms 3D printing and ‘additive manufacturing’ refer to processes that automatically build objects layer by layer from computer data.

The technology is already well-used in many sectors including transportation, health care, military and education.

Uses include building concept models, functional prototypes, factory tooling (such as moulds and robot-arm ends), and even finished goods (such as aircraft internal components).

The aerospace and medical industries in particular have developed advanced applications for 3D printing. 3D printing is sometimes referred to as ‘rapid prototyping’ but this term does not encompass all current uses for the technology. Materials used in 3D printing include resins, plastics and, in some cases, metal.

The soluble support material holds up overhanging portions while the model is being built, and allows for complex models‚ even nested structures and multipart assemblies with moving parts‚ to be 3D printed. When the print job is complete, the support material washes away and the model is ready to be used or, if desired is finished with paint or another process.

The earliest method, stereolithography, has been around since the late 1980s, but adoption was limited because of the toxic chemicals it required and the fragility of its models. Other technologies have evolved since then, including fused deposition modelling (FDM). FDM, introduced in the early 1990s, lays down super-thin layers of production-grade thermoplastic, yielding comparatively durable models.

Since 3D printing’s inception, system reliability and model quality have increased, resulting in diverse applications. At the same time, prices have gone down to the point where some systems are affordable even for small businesses.

In a 2011 report, Wohlers Associates predicted that worldwide annual sales of additive manufacturing systems will reach 15,000 functions as office equipment inside a department or even as units by 2015‚ more than double the 2010 rate. Lower-priced individual cubicle. By comparison, large rapid prototyping professional systems will drive most of this growth.

Some 3D printers are small enough and clean enough to 3D-printed models are shown with soluble support material (brown) intact, and after removal. systems are affordable even for small businesses. www.nzmanufacturer.co.nz

In FDM technology, printer software on the user’s Windows dedicated staff of experts. The very cheapest class of 3D printers comprises home-use devices now on the market for network or workstation accepts computer-aided design (CAD) data in an STL format.

The software works like a paper printer’s hobbyists. While fascinating for enthusiasts, these machines differ from small professional systems in that the resulting driver, sending data to the 3D printer as a job and telling the print head where to lay down material.

Filaments of plastic modelling material and soluble support material are heated to a semi-liquid state, forced through an extrusion tip and precisely deposited in extremely fine layers.

(FDM layer thickness ranges from 0.005 inch [.127 mm] to 0.013 inch [.330 mm], depending on the system.) The print head moves in X-Y coordinates, and the modelling base moves down the Z axis as the model and its support material are built from the bottom up.

Trends toward affordability and ease of use are bringing professional 3D printing technology in-house for many designers and engineers. The growing expectation that a CAD drawing can become a real three-dimensional object in a matter of hours is altering how companies see the design process.

It can be faster, more effective and less costly.

Graco Inc. makes paint spraying and texturing equipment for professional use. Its engineers used a 3D printer to experiment with various paint gun and nozzle combinations to create the perfect spray pattern and volume. The resulting new spray-texture gun was based on functional prototypes 3D printed in ABS plastic. Graco estimates that 3D printing helped reduce development time by as much as 75 percent.

The journey from brilliant idea to successful product is fraught with hurdles. Analysis of new product development by Greg Stevens and James Burley in their oft-cited study “3,000 Raw Ideas = 1 Commercial Success” found that in addition to 3,000 raw ideas, a single successful innovation also requires 125 small projects, four major developments and 1.7 products launches.3 3D printing capabilities can speed the process by which companies determine whether concepts are worthy of development resources.

While outsourcing 3D printing might result in models equal in quality to those 3D printed in-house, the Graco example illustrates the benefits of investing in your own machine. A highly iterative process can only happen in a feasible time frame when engineers can see quick feedback on design changes.

In-house 3D printing eliminates shipping delays and reduces administrative slowdowns that can accompany sourcing prototypes from external services.

Faster turnaround is the only way to enable iterative discovery without lengthening the design process.3D printing users in aerospace, automotive, industrial design and education have reported improvements of 43 to 96 percent in prototyping speed when switching from traditional methods to 3D printing.

Traditional prototyping methods include injection moulding, CNC machining, metal machining and 2D laser cutting. In some cases, lead time required by a machine shop had been a major factor in slowing prototype creation.

As the trend toward affordable 3D printing continues to result in more

decentralised machines, for example in departments or individual cubicles, opportunities to speed the design cycle are multiplying.

An optimised design process with more prototype iterations can help minimise risk of product failure. Because 3D printers can produce models with fine feature details and the strength to withstand rigorous testing; designers can be more confident in their work.

Additionally, data integrity and security is paramount. The acquisition cost of a professional 3D printing system can in-house remove any worry that might stem from sending intellectual property offsite.

Making needed changes as early as possible saves money and time. 3D-printed models can give designers and engineers a thorough understanding of potential products earlier in the design process than other methods, minimising the risk that problems will go unnoticed until it’s too late.

3D printing provides a highly cost-efficient means of producing numerous design iterations and gaining immediate feedback throughout the critical beginning stages of the development process. The ability to refine form, fit and function quickly can significantly improve production costs and time to market. This can create a distinct competitive advantage for those companies who include 3D printing as an integral part of their design process.

Lower costs will continue to expand the 3D printing market, especially in small to medium-sized businesses and schools. The speed, consistency, accuracy and low cost of these printers will help companies reduce time-to-market and maintain a competitive edge.

2014 NZ Manufacturer September 2014

Work spares us from three evils: boredom, vice, and need.

– Voltaire

25

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NZ Manufacturer September 2014

THE FUTURE OF MANUFACTURING

The Internet of Things: How the Next Evolution of the Internet The Internet of Things (IoT), sometimes referred to as the Internet of Objects, will change everything—including ourselves. This may seem like a bold statement, but consider the impact the Internet already has had on education, communication, business, science, government, and humanity. Clearly, the Internet is one of the most important and powerful creations in all of human history.

its potential to change everything we know to be true today.

IoT Today As with many new concepts, IoT’s roots can be traced back to the Massachusetts Institute of Technology (MIT), from work at the Auto-ID Centre. Founded in 1999, this group was working in the

Before we can begin to see the importance of IoT, it is first necessary to understand the differences between the Internet and the World Wide Web.

Now consider that IoT represents the next evolution of the Internet, taking a huge leap in its ability to gather, analyze, and distribute data that we can turn into information, knowledge, and, ultimately, wisdom. In this context, IoT becomes immensely important.

Already, IoT projects are under way that promise to close the gap between poor and rich, improve distribution of the world’s resources to those who need them most, and help us understand our planet so we can be more proactive and less reactive. Even so, several barriers exist that threaten to slow IoT development, including the transition to IPv6, having a common set of standards, and developing energy sources for millions—even billions—of minute sensors.

However, as businesses, governments, standards bodies, and academia work together to solve these challenges, IoT will continue to progress. The goal of this paper, therefore, is to educate you in plain and simple terms so you can be well versed in IoT and understand

field of networked radio frequency identification (RFID) and emerging sensing technologies. The labs consisted of seven research universities located across four continents. These institutions were chosen by the Auto-ID Centre to design the architecture for IoT. IoT is simply the point in time when more “things or objects” were connected to the Internet than people.

In 2003, there were approximately 6.3 billion people living on the planet and 500 million devices connected to the Internet.

By dividing the number of connected devices by the world population, we find that there was less than one (0.08)

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device for every person. Based on Cisco IBSG’s definition, IoT didn’t yet exist in 2003 because the number of connected things was relatively small given that ubiquitous devices such as smart phones were just being introduced.

For example, Steve Jobs, Apple’s CEO, didn’t unveil the iPhone until January 9, 2007 at the Macworld conference.

Explosive growth of smart phones and tablet PCs brought the number of devices connected to the Internet to 12.5 billion in 2010, while the world’s human population increased to 6.8 billion, making the number of connected devices per person more than 1 (1.84 to be exact) for the first time in history.

Methodology In January 2009, a team of researchers in China studied Internet routing data in six-month intervals, from December 2001 to December 2006. Similar to the properties of Moore’s Law, their findings showed that the Internet doubles in size every 5.32 years.

It is estimated IoT was “born” sometime between 2008 and 2009. Today, IoT is well under way, as initiatives such as Cisco’s Planetary Skin, smart grid, and intelligent vehicles continue to progress.

It is predicted there will be 25 billion devices connected to the Internet by 2015 and 50 billion by 2020. It is important to note that these estimates do not take into account rapid advances in Internet or device technology; the numbers presented are based on what is known to be true today.

Additionally, the number of connected devices per person may seem low. This is because the calculation is based on the entire world population, much of which is not yet connected to the Internet.

By reducing the population sample to people actually connected to the

Internet, the number of connected devices per person rises dramatically. For example, we know that approximately 2 billion people use the Internet today.

Using this figure, the number of connected devices per person jumps to 6.25 in 2010, instead of 1.84.

Of course, we know nothing remains static, especially when it comes to the Internet. Initiatives and advances, such as Cisco’s Planetary Skin, HP’s central nervous system for the earth (CeNSE), and smart dust, have the potential to add millions—even billions—of sensors to the Internet. As cows, water pipes, people, and even shoes, trees, and animals become connected to IoT, the world has the potential to become a better place.

Currently, IoT is made up of a loose collection of disparate, purpose-built networks. Today’s cars, for example, have multiple networks to control engine function, safety features, communications systems, and so on.

Commercial and residential buildings also have various control systems for heating, venting, and air conditioning (HVAC); telephone service; security; and lighting. As IoT evolves, these networks, and many others, will be connected with added security, analytics, and management capabilities (see Figure 2).

This will allow IoT to become even more powerful in what it can help people achieve.

Interestingly, this situation mirrors what the technology industry experienced in the early days of networking. In the late 1980s and early 1990s, Cisco, for example, established itself by bringing disparate networks together with multi-protocol routing, eventually leading to IP as the common networking standard. With IoT, history is repeating itself, albeit on a much grander scale.

Why Is IoT Important?

Before we can begin to see the importance of IoT, it is first necessary to understand the differences between the Internet and the World Wide Web (or web)—terms that are often used interchangeably. The Internet is the physical layer or network made up of switches, routers, and other equipment.

Its primary function is to transport information from one point to another quickly, reliably, and securely. The web, on the other hand, is an application

NZ Manufacturer September 2014

27

The difference between winning and losing is most often not quitting.

— Walt Disney

t Is Changing Everything layer that operates on top of the Internet. Its primary role is to provide an interface that makes the information flowing across the Internet usable.

IoT: First Evolution of the Internet The Internet has been on a steady path of development and improvement, but arguably hasn’t changed much.

It essentially does the same thing that it was designed to do during the ARPANET era. For example, in the early days, there were several communication protocols, including AppleTalk, Token Ring, and IP. Today, the Internet is largely standardised on IP. In this context, IoT becomes immensely important because it is the first real evolution of the Internet—a leap that will lead to revolutionary applications that have the potential to dramatically improve the way people live, learn, work, and entertain themselves.

Already, IoT has made the Internet sensory (temperature, pressure, vibration, light, moisture, stress), allowing us to become more proactive and less reactive.

In addition, the Internet is expanding into places that until now have been unreachable. Patients are ingesting Internet devices into their own bodies to help doctors diagnose and determine the causes of certain diseases.

Extremely small sensors can be placed on plants, animals, and geologic features, and connected to the Internet.

We Evolve Because We Communicate Humans evolve because they communicate. Once fire was discovered and shared, for example, it didn’t need to be rediscovered, only communicated.

A more modern-day example is the discovery of the helix structure of DNA, molecules that carry genetic information from one generation to another. After the article was published in a scientific paper by James Watson and Francis Crick in April 1953, the disciplines of medicine and genetics were able to build on this information to take giant leaps forward.

This principle of sharing information and building on discoveries can best be understood by examining how humans process data (see Figure 3). From bottom to top, the pyramid layers

include data, information, knowledge, and wisdom.

Data is the raw material that is processed into information.

Individual data by itself is not very useful, but volumes of it can identify trends and patterns. This and other sources of information come together to form knowledge. In the simplest sense, knowledge is information of which someone is aware.

Wisdom is then born from knowledge plus experience.

Even cows will have sensors.

While knowledge changes over time, wisdom is timeless, and it all begins with sensing, and machine-to-machine the acquisition of data. communication. In fact, the possibilities It is also important to note there is a direct correlation between the input (data) and output (wisdom). The more data that is created, the more knowledge and wisdom people can obtain. IoT dramatically increases the amount of data available for us to process. This, coupled with the Internet’s ability to communicate this data, will enable people to advance even further.

IoT: Critical for Human Progression As the planet’s population continues to increase, it becomes even more important for people to become stewards of the earth and its resources.

In addition, people desire to live healthy, fulfilling, and comfortable lives for themselves, their families, and those they care about. By combining the ability of the next evolution of the Internet (IoT) to sense, collect, transmit, analyse, and distribute data on a massive scale with the way people process information, humanity will have the knowledge and wisdom it needs not only to survive, but to thrive in the coming months, years, decades, and centuries.

IoT Applications: What Cows, Water Pipes, and People Have in Common When we crossed the threshold of connecting more objects than people to the Internet, a huge window of opportunity opened for the creation of applications in the areas of automation,

be self-sustaining. Imagine changing batteries in billions of devices deployed

are almost endless. The following examples highlight some of the ways IoT is changing people’s lives for the better.

across the planet and even into space.

Holy Cow!

such as vibrations, light, and airflow.

In the world of IoT, even cows will be connected. A special report in The Economist titled “Augmented Business” described how cows will be monitored.

Sparked, a Dutch start-up company, implants sensors in the ears of cattle.

This allows farmers to monitor cows’ health and track their movements, ensuring a healthier, more plentiful supply of meat for people to consume.

On average, each cow generates about 200 megabytes of information a year.

Obviously, this isn’t possible. What’s needed is a way for sensors to generate electricity from environmental elements In a significant breakthrough, scientists announced

a

commercially

viable

nanogenerator—a flexible chip that uses body movements such as the pinch of a finger to generate electricity—at the 241st National Meeting & Exposition of the American Chemical Society in March 2011.

“This development [the nanogenerator] represents

a

milestone

toward

producing portable electronics that can be powered by body movements

Challenges and Barriers to IoT

without the use of batteries or electrical

Several barriers, however, have the potential to slow the development of IoT. The three largest are the deployment of IPv6, power for sensors, and agreement on standards.

potential is only limited by one’s imagi-

Deployment of IPv6. The world ran out of IPv4 addresses in February 2010.

While no real impact has been seen by the general public, this situation has the potential to slow IoT’s progress since the potentially billions of new sensors will require unique IP addresses. In addition, IPv6 makes the management of networks easier due to auto configuration capabilities and offers improved security features.

Sensor energy. For IoT to reach its full potential, sensors will need to

outlets. Our nanogenerators are poised to change lives in the future. Their nation.”Zhong Lin Wang, Lead Scientist, Georgia Institute of Technology.

Standards. While much progress has been made in the area of standards, more is needed, especially in the areas of security, privacy, architecture, and communications. IEEE is just one of the organisations working to solve these challenges by ensuring that IPv6 packets can be routed across different network types.

It is important to note that while barriers and challenges exist, they are not insurmountable. Given the benefits of IoT, these issues will get worked out.

It is only a matter of time. www.nzmanufacturer.co.nz

28

NZ Manufacturer September 2014

WORKSHOP TOOLS

If you can’t fly then run, if you can’t run then walk, if you can’t walk then crawl, but whatever you do you have to keep moving forward.

Battery analysers simplify the testing of backup systems Batteries are the mainstay of backup power systems and require regular testing to ensure their reliability.

The new Fluke® 500 Series Battery Analysers simplify the workflow of testing stationary batteries and battery banks through an intuitive user interface that provides quick, guided test setups ensuring technicians are capturing the correct data while visual and audio feedback cues reduce the risk of errors.

The Fluke 500 Series is ideal for testing mission critical battery back-up applications in data centres, hospitals, airports, utilities, oil and gas and railways.

The rugged, compact 500 Series Battery Analysers perform all key

measurements including battery resistance, dc and ac voltage, dc and ac current (Fluke BT521 model only), ripple voltage, frequency, and battery temperature (BT521 only). 500 Series Battery Analysers have been specifically designed for measurements on stationary batteries including GEL, AGM (absorbed glass MAT), lithium-ion, as well as wet-cell lead-acid batteries.

The 500 Series intelligent test probes streamline the testing process by displaying measurement results on their integrated LCD displays eliminating the need for technicians to stop and look at the mainframe.

Technicians can capture voltage readings and temperature logging automatically or via the integrated save button, simplifying and speeding up the test process. The probes feature infrared temperature measurement (BT521 only), tri-colour LED for pass/fail/warning indications, and audio feedback.

The analysers include a convenient magnetic hanging strap with shoulder strap and an innovative carrying harness reduce fatigue while measuring long battery strings. They also include simple, yet powerful reporting and analysis tools that manage large volumes of data to produce analysis graphics and data tables on a PC or create quick email format reports with .csv files.

— Martin Luther King, Jr.

A first for Australasia Zenith Tecnica Ltd is pleased to announce the commissioning of Australasia’s first commercial Electron Beam Melting Machine.

Based in Albany, Auckland Zenith Tecnica has been established as a manufacturing bureau for rapid prototyping and small run production of metallic parts.

The machine, an Arcam Q10, is capable of printing completely solid engineering components directly from CAD files. Zenith selected EBM additive manufacturing technology because of its metallurgical superiority, speed, scalability and yield. The initial Q10 machine has a build volume of 200 mm x 200 mm x 200 mm and power of 3 kW. The company will commission a larger Q20 machine in September.

This machine will have a build volume of Ø 350 x 390 mm and a power of up to 10 kW. Both machines will manufacture in Ti6Al4V ELI (Extra Low Interstitials). The company is presently in negotiations for an A2X high temperature machine to manufacture in Inconel and other nickel base alloys.

The General Manager, Martyn Newby, says that additive manufacturing (AM) with EBM frees the engineer to quickly build a working component for real use, not just as a plastic “mock-up”.

He also says that this is the first time complex three dimensional “cored shapes” have

been offered in titanium, a metal with outstanding structural properties and corrosion resistance.

In addition threads, keyways, slots can be built into the component with minimal and sometimes no machining; true “Near Net Shape” production.

The EBM process is perfect for making foam and mesh components in part or in whole to improve structural efficiency. Apart from its speed and cleanliness electron beam technology permits the complete control of the thermal history of the product, ensuring all components are delivered stress relieved with the optimum microstructure.

In addition Q10 and 20 are the only AM machines that image each layer for 3D analysis. The customer will receive a tomographic model that is actually better than an X-Ray radiograph. Zenith has mechanical engineers that can produce an AM manufactured component from a physical component, sketch, photo or solid-model.

The company is also supported by Arcam and a Network of EBM and other AM companies in Europe and the US. For more information, visit www.zenithtecnica.com.

Affordable pure sine inverter range A new, affordable range of pure sine wave inverters allow users to capitalise on pure sine wave technology without the commonly associated high cost.

hair dryers and microwave ovens to be run from a 12-volt battery, bringing the modern comforts of home to a vehicle, caravan/camper or boat.

Projecta developed Pro-Wave as a mid-level alternative to its flagship Intelli-Wave series of pure sine wave inverters, for applications that surpass the capabilities of much cheaper, modified sine wave inverters.

The market is moving towards pure sine wave inverter technology because of the higher performance and reliability.

Campers, off-road enthusiasts and boat owners use an inverter to allow items such as laptop computers, TVs, fridges,

Modified sine wave inverters use a cheaper, less advanced technology and the end result is a power wave that isn’t as clean or uninterrupted as that of AC mains.

Highly sensitive electrical appliances, such as computers, AM radios, televisions and medical equipment can experience static and interruption to operation when using a modified sine wave inverter. Pure sine wave inverters overcome this with more advanced and more expensive technology, perfectly replicating the AC mains sine wave and

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ensuring clean power and seamless operation for AC-based appliances.

There are five models in the e range, with the names referring to their continuous wattage output: PW150, PW350, PW600, PW900 and PW1800.

The PW600, PW900 and PW1800 models feature a digital display screen that monitors power draw and battery voltage, so users can keep an eye on power levels.

These models can also be switched on and off via an optional remote control, enabling the user to remotely conserve battery power when not in use. With the exception of PW150, all Pro-Wave inverters feature an automatic temperature-controlled cooling fan and a low battery alarm / shut down to prevent battery drainage.

To make it easier for consumers to select the inverter model that best suits their

requirements, Projecta provides an application guide on all Pro-Wave packaging, with thumbnail illustrations of suitable appliances that can be run from each model of inverter.

This is designed to ensure users do not under-power their appliances or spend more money than is necessary for their applications. Projecta recommends users check the wattage of their appliances to ensure inverter power output exceeds the power draw of the appliance.

All Projecta inverters are designed in accordance with Australian and NZ standard AS4763 (Int): 2006-Safety, covering portable inverters. They are also engineered to electrically isolate the DC circuit completely from the AC circuit, ensuring maximum safety and peace of mind.

NZ Manufacturer September 2014

Success is most often achieved by those who don’t know that failure is inevitable.

— Coco Chanel

29

WORKSHOP TOOLS

Mitsubishi Laser “A Game Changer in CO2 laser Operation Costs” Mitsubishi CO2 laser with the latest Crossflow resonator design lowers the operation and future maintenance costs associated with CO2 type industrial lasers.

Mitsubishi Laser

The new Mitsubishi Crossflow resonator is such a major improvement over conventional types that Mitsubishi has taken patents in Japan and USA to protect this new technology.

Compared to conventional CO2 lasers the Mitsubishi Crossflow resonator has considerably less laser gas flow requirements thereby reducing overall operation costs.

along with high processing speed. Cut quality is exceptional considering the much reduced operation cost.

This all adds up to the most efficient CO2 laser on the market and when future resonator maintenance costs are included the Mitsubishi laser is a game changer in CO2 laser ownership cost.

In New Zealand Mitsubishi laser is represented by Revolution Precision Machinery who offer a high level of product support from their factory trained service engineers.

Contact the sales team at sales@rpmcnc.co.nz or phone Auckland 2650380 Christchurch 9600892

www.rpmcnc.co.nz

To further reduce the operation costs the power consumption on the Mitsubishi laser has been reduced by “Just - On - Time” laser discharge so the beam is on for the minimum of time to produce the required cut quality.

Another feature “Idle mode” along with “Beam off mode” has reduced the power consumption even more, all this adding up to drastically reduced power consumption over older technology laser cutting machines.

At the same time as power savings are achieved the cut quality has also gained from the increased beam stability of the Crossflow resonator low speed laser gas circulation flow so that power stability variations are within +/- 1%.

Another important feature of this Mitsubishi Crossflow resonator is the rectangular pulse wave output that gives low heat input into the sheet material

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30

NZ Manufacturer September 2014

WORKSHOP TOOLS

It takes 20 years to build a reputation and five minutes to ruin it.

If you think about that, you’ll do things differently. — Warren Buffett

CNC system for machines with five axes Designed specifically for developers of small to medium sized machine tools with four or five axes, the Flexium+ 8 CNC provides an exceptionally cost-effective control solution that in many cases eliminates the need for a second CNC kernel.

By very accurately controlling the machine’s rotary axes, such as a dual rotary tool-head or a table and cradle holding the part, the function enables the tool to be held in contact with the part, and at a constant angle, throughout the machining process.

The Flexium+ 8 CNC kernel offers two CNC channels and accommodates up to five axes, four of which can be interpolated. At any one time, either CNC channel can be used to control a spindle motor and four axes, instead of the full complement of five axes.

This control flexibility helps designers to lower the cost of machines with complex synchronisation requirements.

For example, on a grinding machine, one channel could control two X/Z axes and a spindle to perform the grinding functions while the other channel controls two rear mounted U/W dressing axes.

Each channel can either run its own part program asynchronously and operate autonomously – much as if it had a dedicated CNC kernel – or the two channels can be synchronised.

Control of one to five axes, or a spindle, can be passed on-the-fly from one channel to the other, to maximise use of available hardware resources.

Like all NUM CNC systems, the Flexium+ 8 firmware includes RTCP (rotation around tool centre point) and Inclined Plane functions. Pioneered by NUM, the RTCP function provides enormous advantages for precision 5-axis machining applications.

The RTCP function is even more beneficial if the part is not flat; it automatically computes all the offsets due to factors such as tool head mechanics and tool length that are needed to maintain accurate tool contact.

As its name implies, the reference point for all RTCP calculations is the tool’s centre, or contact point – and not the tool-head position, which would require the contact point to be determined mechanically.

The difference between these two methods has a major impact on machining. For example, if the distance between the tool tip and the centre of the rotary head is 600 mm, a head positioning error of just one-hundredth of a degree will cause a tool tip error of 0.1 mm; without the RTCP function, this can result in tool or part damage.

Another significant advantage of the RTCP function is that the programmed coordinates are those of the part contour, not the machine, which makes the programs machine independent and means that tool offsets can be applied without program modification.

The RTCP function is implemented as part of the Flexium+ CNC post-processor, which further helps to ensure part program portability.

Customised surface inspection Before a workpiece leaves the production plant, it is subjected to rigorous inspection: because even the most infinitesimal fracture or impact point could diminish the reliability or durability of a component.

And when it comes to safety-critical applications – such as in the automotive or aerospace industries – manufacturers can only use the most impeccable parts. But esthetic aspects also count - for example, with ceiling panels or components for the cabin of the automobile.

In order to check a component, manufacturers apply image processing methods.

Multiple cameras take pictures of component surfaces from various angles, which are analyzed by a software programme.

“Every material substance has its own unique surface structure. In order to evaluate its quality, the testing procedure has to be gauged precisely to these specific properties,” explains Markus Rauhut of the Fraunhofer Institute for Industrial Mathematics ITWM. Even the size and shape of a component play a role – as well as the desired resolution of the images. Even though there is an array of surface inspection systems on the market already, these are only configured for specific materials and dimensions.

Standard solutions cannot cover the entire spectrum of possible testing objectives.

The researchers at ITWM have closed this gap: The scientists from Kaiserslautern engineered a modular inspection system they have dubbed “MASC: Modular Algorithms for Surface InspeCtion,” which can be modified to customer-defined specifications.”

“Our system is suited for the most diverse materials – like metals, leather, textiles or paper – and covers a size range from tiny components for medical technology through to entire sheets of rawhide or ceiling panels,” Rauhut adds.

MASC-STeX for the inspection of cover plates and MASC-Dehnzelle for the inspection of

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expansion cells are already in practical use in the industry.

Basic version with over 300 algorithms First, the surface of the workpiece is illuminated and scanned using multiple cameras set at a wide range of angles.

“This is important, so that you can also pick up impact points or fractures that are only visible from one side,” explains Rauhut. With free-formed surfaces, regions are also recorded in this manner that are covered by curvatures or corners. The more complex the geometry, the more cameras are needed, as a rule.

“To keep the costs within limits, we are concentrating on areas in a practical setting in which a defect would actually have negative implications,” the researcher said.

Once all testing parameters are set, the procedure is integrated into the production process with the customer. The cameras are either installed directly on the assembly line for this purpose, or applied using robots. When a defect is found, the production process automatically stops; at the same time, the machine operator is notified. The detected defects are classified and the test object is divided into quality classes.

Source: Phys.org News

NZ Manufacturer September 2014

Someone is sitting in the shade today because someone planted a tree a long time ago.

— Warren Buffett

31

REAR VIEW

Neglect: Knowing an issue and not addressing it!

According to Serres, Yashiro and Boulhol from the Organisation for Economic Cooperation and Development, Economics Department, “New Zealand lags behind advanced OECD countries in productivity and per capita income levels.”

The comment comes from the New Zealand Productivity Commission Working Paper 2014/01: An International Perspective on the New Zealand Productivity Paradox. It’s a paradox because according to many of the fundamentals, what they call “generally favourable policy settings, GDP per capita in New Zealand should be 20 per cent above the OECD average rather than 20 per cent or so below.”

This is not such a big issue for a large company with deep pockets like Fonterra but is a massive inhibitor for the mass of small-to-medium size businesses that make up most of our economy. But being remote also means being far from trade fairs, conferences and leading research institutions, which feeds into the second point regarding the quality of management.

In other words, we should be much better off than where we are and the report attempts to identify the main determinants of New Zealand’s economic under-performance.

In other words, we should be much better off than where we are and the report attempts to identify the main determinants of New Zealand’s economic underperformance.

They identify three major contributors to this underperformance: The distance we are away from markets, the quality of management and the amount we spend on research and development.

Some might argue that we don’t need a report to tell us that since most of us intuitively already know those things.

However, what the report does do is to try and quantify how much each contributes. They say that perhaps half our problems come from being remote from markets, which means that we need to find lead users domestically to trial new products and then have to sell them to customers who are a long way away.

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If managers are not exposed to contemporary thinking and practices, and don’t see them being used by their peers and competitors, they are unlikely to adopt them which probably contributes to why we spend so little on R&D, and subsequently the innovation that drives new products and services into markets.

If we have too few big companies with the resources and motivation to drive high-value exports and close the distance gap, we clearly need to grow our current companies to a size and sophistication that they can invest in R&D and management development to compete. Fortunately, particularly in the high-value manufacturing space we have a lot of companies wanting to do just that.

What works against them isn’t just the distance, it’s also government policies that try to keep the taxation and other systems simple by applying one rule to all companies. However, while everyone likes a tax break, not everyone operates in the high-value manufacturing sector where support is needed to mitigate the distance gap.

According to the authors, “Distance cannot be changed but its impact can be minimised” What is needed is support for market access and development, product development and technology demonstration and

Nick Inskip, HERA Industry Development General Manager

the enablement for management and technicians to go to as many trade fairs and conference as their less isolated cousins in the markets they want to compete in.

R&D spending is much lower that our OECD cousins. Also, we do a lot of things here that while they might earn foreign currency, are actually below the break even line in terms of dollars per person employed.

We know what the issues are and how as a country we can address them, we must take action because we cannot afford to continue to ignore and neglect. If you have any comments about this matter, feel free to email me at indev@hera.org.nz

NZ MANUFACTURER • OCTOBER 2014 Issue • Features

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