Manufacturers' Monthly March 2011 by Prime Creative Media

CELEBRATING 50 YEARS IN MAY 2011 Years

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March 2011

INSIDE Latest Products >> Industry News >> Industry Opinion >> Coming Events >> Compressors & Pneumatics >> Fasteners & Adhesives >> Safety in Action Preview >> Supply Chain Management >> Process Control & Sensors

SHE'LL BE RIGHT >> Spotlight on 'Australian-made' product claims p.12

ABN 80 132 719 861 Average Net Distribution Period ending Sept’10 15,273 ISSN 0025-2530

Inside MARCH 2011

For daily news visit manmonthly.com.au

4 Editorial ■

Industry green as fund scrapped.

6 Comment ■

Spotlight on immigration.

8 Analysis News ■ ■ ■ ■

What is ‘Australian-made’? Women in manufacturing. Endeavour Awards sponsors. Demand for engineers rising.

18 Supply Chain Management ■ ■ ■

Delivering the perfect order. Reducing energy wastage. Finite element modelling.

Locally-made solar panel shines.

23 Insider Series ■ ■

Sunny future for solar alliance. Taking paper out of the equation.

35 AUSPACK PLUS Preview ■

A snapshot of the new packag ing products to be showcased at the event.

26 Safety in Action Preview

38 Fasteners & Adhesives

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28 What’s New ■

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All the latest products.

CELEBRATING 50 YEARS IN MAY 2011 Years

manmonthly.com.au

Est. 1961 March 2011

42 Compressors & Pneumatics ■ ■ ■

New safety gear at the show.

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Editor Sarah Falson Ph: (02) 9422 2480 Fax (02) 9422 2722 sarah.falson@reedbusiness.com.au Journalist Annie Dang Ph: (02) 9422 2964 Fax (02) 9422 2722 annie.dang@reedbusiness.com.au Editor-at-large Alan Johnson Ph: (02) 9422 2325 Fax (02) 9422 2722 alan.johnson@reedbusiness.com.au Graphic Designer Ronnie Lawrence ronald.lawrence@reedbusiness.com.au Creative Director Julie Coughlan Production Co-ordinator Mary Copland Ph: (02) 9422 2738 mary.copland@reedbusiness.com.au VIC/Overseas Sales Michael Northcott PO Box 3069 Eltham VIC 3095 Ph: 0448 077 247 michael.northcott@reedbusiness.com.au NSW Sales Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067. Ph: (02) 9422 2368 Fax: (02) 9422 2722 Mobile: 0414 644 664 anthony.head@reedbusiness.com.au QLD Sales Sharon Amos PO Box 3136, Bracken Ridge QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@reedbusiness.com.au SA/NT & WA Sales Reed Business Information Ph: (02) 9422 2368 anthony.head@reedbusiness.com.au Associate Publisher Michelle Graves Ph: (02) 9422 2391 michelle.graves@reedbusiness.com.au Head Office Tower 2, 475 Victoria Avenue, Chatswood NSW 2067 Locked Bag 2999 Chatswood DC Chatswood 2067 Ph: (02) 9422 2999 Fax: (02) 9422 2966 Published 11 times a year Subscriptions $140.00 per annum. (inc GST) Overseas prices applyPh: 1300 360 126 Printed by Geon Impact Printing 69 – 79 Fallon Street, Brunswick VIC 3056 Ph: (03) 9387 7477

SHE'LL BE RIGHT >> Spotlight on 'Australian-made' product claims p.12

More strength, lower cost. Fastener capability increased in new coating process. Silver-filled adhesive.

Cutting energy costs. The true cost of air leaks. Partnership improves compressors.

50 Process Control & Sensors ■

Heavy-duty pressure transducer.

Behind the cover MORE than fifty years ago we invented the first liquid threadlocker. We’ve been the leading threadlocker technology ever since. And now, we have made them even better. Leveraging the latest advances in technology, we introduce two Loctite® formulations that deliver the best ever performance – Loctite® 243 and Loctite® 263. They are formulated to deliver best performance on active and passive metals, increased

oil tolerance and improved high temperature performance. We are also please to announce the release of a new range of innovative high temperature Loctite® Threadlockers: 2422 Medium Strength and 2620 High Strength High Temperature Threadlocker and Thread Sealant; and 5770 High Temperature Thread Sealant. Same Loctite® reliability – now even better! www.iLoctite.com

Now direct to you. Faster and smarter. Over 15,000 sensing, connectivity, interface and communications solutions are now available locally and direct from TURCK Australia. 1300-132-566 turck.com.au

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SENSORS | NETWORKS/FIELDBUS | RFID | CONNECTIVITY | INTRINSIC SAFETY Manufacturers’ Monthly MARCH 2011 3

Editorial

SARAH FALSON – Editor

editor@manmonthly.com.au

Firms green as fund scrapped The Government’s decision to scrap the Green Car Fund is bad news for the Australian economy, with car-makers urging Gillard to look to the future.

HE Gillard Government’s decision to scrap the Green Car Fund to support flood relief has come as a shock to Australian car manufacturers. Local companies are outraged at the decision, which will see Canberra removing $429 million that had been guaranteed to support development programs for cars and components. The Green Car Fund, announced in 2008, promised money for local companies to manufacture ‘greener’ cars. Both Holden and Toyota took advantage of the Fund and developed Toyota’s Camby Hybrid – Australia’s first hybrid car – and the Holden Cruze, a new small, more fuel-efficient vehicle. Toyota even built an entirely-new engine plant off the back of the Green Car Fund, manufacturing four-cylinder engines for its locally-made hybrid Camry. Now, three years later, the Government has scrapped the Fund to help Australian families and their communities who have been devastated by the floods in Queensland, regional Victoria and New South Wales. Though the decision to help needy people in noble, the industry says cutting important, jobcreating programs to save the budget surplus is a mad idea

4 MARCH 2011 Manufacturers’ Monthly

Manufacturers will no longer receive grants for greener cars.

that will eventually bite Australia’s economy on the bum. Despite the global financial crisis, Australian automotive manufacturers were one of the few in the industry that continued to turn a profit, and created new, innovative technologies. The automotive sector employs 60,000 people across the country, and continues to drive innovation in materials like plastics, metals and electronics. The Australian Manufacturing Workers Union (AMWU) national secretary, Dave Oliver, says the decision to scrap the Green Car Fund was avoidable, and the Government should dump its

obsession with budget surplus, not industry programs. “The obsession with returning the Federal Budget to surplus is damaging industry and job creation programs which are all the more important to Australia’s economic recovery in the wake of the Queensland floods,” he said. “Australia cannot afford to cancel job opportunities such as manufacturing fuel efficient, hybrid, solar and electric cars.” The Green Car Fund isn’t the only program to be crossed out, with Solar Flagships and other climate change industry programs being dumped. According to Oliver, this news

is not in the long-term interests of Australia. “Australia cannot afford to cancel plans to help our industries gear up for 21st century environmental standards, and job opportunities such as manufacturing fuel efficient, hybrid, solar and electric cars,” he said. “The Government should adapt the budget to the circumstances created by the Queensland floods, rather than altering the future of our economy to suit the nominal goal of a surplus.” Local manufacturing relies on future-looking schemes like the Green Car Fund, and car-makers across Australia are outraged at the news. Not only will future innovation suffer, but those that have already invested in schemes, including Holden and Toyota, are worried that the cuts will threaten projects already in the pipeline and drive them offshore. I urge the Government to rethink these cuts. Gillard should be helping local car manufacturers who make more sustainable vehicles, not leaving them in the lurch after promises of assistance. Scrapping the Green Car Fund is bad news for Australia’s automotive industry, and could result in dire circumstances for the Australian economy in the future. Think forwards, Gillard, not backwards. Do you want to comment on this article? Visit http://bit.ly/fw1m7P or follow us on Twitter @manmonthly

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15,000 space saving pallet locations Safe and ﬂexible operation Fast-tracked implementation

From left: Joe Carmody, Dematic and Paul Fleiszig, Oxford Cold Storage

DEM679

Another logistics result.

Paul Fleiszig needed to ﬁt out a new DC, fast. Oxford Cold Storage, the industry’s third largest 3PL, was looking for an experienced partner – one who could t out a freezer/chiller warehouse with a high level of picking, maximum use of space and a safe working environment. Using ColbyRACK, Dematic put forward an innovative and exible solution that optimised space and safety, and initiative during installation saw the project delivered with enhancements, on time and on budget. Dematic’s solution has helped cement Oxford Cold Storage’s position as an innovator and industry leader. That’s what we call a logistics result.

Ask us. 02 9486 5555 www.dematic.com.au

Comment

HEATHER RIDOUT – CEO Australian Industry Group

editor@manmonthly.com.au

Spotlight on skills shortages The Government’s decision to expedite 457 visas for flood-related work is a reminder of the need for skilled workers, Heather Ridout writes for MM.

KILLS shortages are one of the biggest risks facing the Australian economy. They will not only threaten the progress of our major infrastructure projects and slow the rebuilding of flood and cyclone damaged areas, but also have the potential to put big pressure on business costs and interest rates. In Queensland, the Government responded to the lack of skilled labour in part by expiditing 457 visa approvals for flood-related work. This highlights the important role immigration plays in our economy. Skill shortages are set to further intensify, with the combination of our ageing population and labour demands influenced by the resources boom. Based on the highest growth scenario

under current policy settings, Australia will need an additional 2.4 million people in the workforce with qualifications at Certificate III (trade level) and higher by 2015, increasing to 5.2 million by 2025. Industry is certainly feeling the pressure, with an Ai Group survey finding almost half of all 400 companies surveyed (47.5%) believe there is a high to extreme risk of skills shortages negatively impacting on the operation of their businesses by 2015. If we are to have the right skills at the right time and in the right place, lifting training and participation rates, needs to be the first priority. However, the above figures demonstrate that we need to be willing to complement domestic labour supply

with more skilled migrants. Recently, we contributed our views to the Federal Government, which is considering planning levels for the immigration program in 2011–12. It is our view that the current planning level, set at 168,700 places (down from 190,300), remains below what is required to avoid pressure on our capacity, costs and interest rates. Considering that the economic forecast for 2011–12 is similar to the conditions prevailing when the 2008–09 planning levels were being considered, Ai Group believes the 2011–12 levels should equal this 190,300 level as a step towards meeting our medium-term requirements. This level also takes into account the lag effect related to

permanent migration applications. An applicant applying for permanent migration in 2011–12 may not arrive in Australia until 2014. Consequently, the planning levels need to take this into account and better understand the skill needs expected in the middle of this decade. While the Government's recent decision to focus more on skills in demand in its permanent migration program is a step in the right direction, it is equally important the Government maintain and not further tighten temporary programs such as the 457 visa – a flexible, demand-driven program – and that these programs remain easily accessible to business. We should be assisting skilled tradespeople in their efforts to join our workforce. Heather Ridout is chief executive officer of the Australian Industry group. Visit www.aigroup.com.au

Right people, right volume, right when you need them

Ensuring businesses are equipped with the right people, who are skilled, productive and available in the right composition for peaks and troughs in demand, is critical to the industry’s sustainability and competitiveness. Chandler Macleod Workforce source, assess, develop and manage permanent, casual, on-hire, and limited tenure employees at all levels in the manufacturing sector – from factory floor to boardroom. With over 50 years experience, a national network of offices and an extensive database of outstanding candidates Chandler Macleod is the first choice recruitment partner of some of Australia’s most iconic manufacturing employers. Our expertise for the manufacturing sector includes: Rostering Permanent recruitment Retention strategies

Talent pool management Workplace safety Payrolling

Labour hire Skills and competency assessment

Visit www.chandlermacleod.com for further information on how we can deliver the right people, in the right volume to meet your business needs.

WORKFORCE

RECRUITMENT

CONSULTING

www.chandlermacleod.com 6 MARCH 2011 Manufacturers’ Monthly

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AnalysisNEWS Is it Australian? We’ll see about that Australian Made, Australian Grown Campaign chief executive, Ian Harrison, takes the ‘double-dutch’ out of inconsistent and confusing country-of-origin claims, including labelling laws and customer preferences.

ANUFACTURERS across Australia have much to be proud of. The products they engineer and make are renowned for being innovative, built to withstand Australia’s extreme conditions (as many of us are at present experiencing) and of course to meet our high standards. Research consistently shows that consumers have a clear preference for Australian products. Most recently, a poll by Roy Morgan Research found that an overwhelming majority – 90% – of Australians would be more likely to buy products labelled ‘Made in Australia’. When it came to specific products, respondents, not surprisingly, expressed similar sentiment. This included food (90%), clothing (79%) and wine (77%) but also encouragingly electrical goods (66%), motor vehicles (63% although we know this a lot less in reality) and sporting goods (67%). The problem, however, is that Australia’s labelling laws are inconsistent and confusing, particularly for food, making it difficult for people to decipher what country-of-origin claims actually mean and, for companies,

A formal body needs to be set-up to provide greater clarity for manufacturers – Harrison.

whether their products meet the criteria. Findings by The Australia Institute (TAI) in January revealed that only a quarter of 1,300 respondents understood ‘Australian Made’. Under the new Australian Consumer Law (previously the Trade Practices Act), a product may carry the ‘Australian Made’ claim if it meets two tests: the product is substantially transformed in Australia and at least 50% of the cost of production has been incurred here. The problem emerges with what constitutes substantial transformation. Substantial transformation means there has been a fundamental change in form, appear-

ance or nature so that the final product is new and different from the goods before the change took place. The simple assembly of parts to make a finished product doesn’t meet the test. And that’s fine. But the problem occurs when it comes to the slicing, dicing or mixing of vegetables or the curing of pork to produce ham or bacon. A major problem is that there’s no administrative body set-up to decide which processes constitute substantial transformation. The ACCC produces guidelines, but only that. At present businesses can approach the ACCC , AMAG Campaign or other organisations for advice but if their claim is later chal-

lenged in the marketplace it ends up going to court with a judge making the final decision – which can be both costly and time consuming. We continue to call for a formal body to provide greater clarity for manufacturers and users. It does make business sense for manufacturers, if their products meet the outlined criteria, to clearly label their products as Australian. Research shows that the greenand-gold Australian Made, Australian Grown logo is the most recognised and trusted country-of-origin symbol over any other identifier such as flags, maps or pictures of animals. It’s a certification trademark that clearly points out that the product has been made right here. The green and gold icon is used by more than 1,700 businesses and on over 10,000 products sold here and in markets around the world, making it a strong, collective marketing effort that’s good for business, good for manufacturers, good for consumers, good for exports and ultimately, good for Australia. Australian Made, Australian Grown 1800 350 520, australianmade.com.au

China PMI booms while Aussie business drops BY SARAH FALSON

WHILE manufacturing in China and South East Asia continues to boom, local manufacturing had a soft start to 2011 with the January Australian Industry Group – PwC Australian Performance of Manufacturing Index (Australian PMI) reflecting a general feeling of caution from manufacturers during the month. The Australian PMI remained relatively unchanged at 46.7 8 MARCH 2011 Manufacturers’ Monthly

points, up 0.4 points and remaining below the critical 50 point level for the fifth consecutive month (readings below 50 indicate a contraction in activity). Manufacturers remained cautious in the month, driving down inventories rather than ordering new stock. New orders fell in seven of the 12 sub-sectors. In China, the headline seasonally adjusted HSBC China Manufacturing Purchasing Managers’ Index (PMI) posted 54.5, up slightly from 54.4 in

December. This ensured the Chinese manufacturing industry help relatively steady at the start of 2011, signalling a solid improvement in manufacturing sector operating conditions. PMI survey data signalled that China’s manufacturing sector started 2011 on a strong footing, with both output and new business rising steeply since December. This prompted firms to raise their input buying and allocate resources to meeting incoming

new orders, with backlogs of work rising solidly, which in turn encouraged manufacturers to hire additional staff on average. Meanwhile, companies continued to pass on strong cost inflation to clients through increased output charges. This positive move comes during a slump for Australian manufacturing, with the recentlyrecorded Australian PMI of 46.7 points showing caution. Australian Industry Group www.aigroup.com.au manmonthly.com.au

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AnalysisNEWS Women in manufacturing BY SARAH FALSON

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10 MARCH 2011 Manufacturers’ Monthly

PICS NSW, a society for supply chain professionals, has secured State Government funding for its Women in Manufacturing Cluster to support career enhancement opportunities for women working in manufacturing. The funding is part of the Government's Strategic Business Cluster program, which in 2010 delivered over $670,000 to 74 clusters across NSW, helping over 3,200 small businesses. The Women in Manufacturing Cluster is built on the success of the Women in Manufacturing Network and Stepping Up programs that have been championed by Industry and Investment over several years. Like these programs, the Cluster aims to improve the economic growth and sustainability of manufacturing in NSW by recognising and supporting women in the sector. “What is clear is that women are woefully under-represented in the industry. Industry statistics as at 2009 show that women make up approximately 25% of the manufacturing workforce. This is significantly lower than employment figures for all industries where the distribution of employment between the genders is close to 50:50,” apics NSW business manager, Linda Henry, told Manufacturers’ Monthly. The Cluster focuses on providing access to specific skills required for development and success within the sector.

"Through a series of interactive and practitioner-driven workshops, the Cluster will focus on providing practical career success skills for women," said Program Manager, Deborah Rose. "Essential topics like career planning and management, selfpromotion, image, networking and conflict management will be addressed." According to apics NSW’s Henry, the current skills shortage and ageing workforce make this the perfect time to think about gender balance in the manufacturing industry. “This is not simply an issue of ‘gender equality’ but one of real business importance for the sector,” she said. “Employers will need to draw on women to help address the predicted skills shortages. If you’re not considering women then you’re precluding access to half the workforce. “Companies should also be planning to reap the benefits that a gender diverse workforce can bring. Reports from McKinsey & Company, JB Were Goldman Sachs and Catalyst all show a link between gender balance and corporate performance and that having more women in a leadership position correlates with stronger financial returns. It simply makes good business sense to be tapping into female talent.” Applications for the Cluster close 16 March.

What you missed in February… • NMW to become 'Australia's most significant industry event': Reed Exhibitions (go to dlvr.it/G18pT) • Queensland gets it own manufacturing show (see dlvr.it/729Z0) • Signet announces strategic partnership with Richmond FC (see dlvr.it/DlzR y) • ABB robots rock-out on stage with Bon Jovi (see dlvr.it/DG2Jd) • WorkCover GM congratulates Heinz on one year without injuries (go to dlvr.it/7ylw) Never miss out again! Follow us @manmonthly for all the latest news, product information and comment pieces from the industry.

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AnalysisNEWS

And the Endeavour winners are…? BY SARAH FALSON

OMINATIONS for Manufacturers’ Monthly’s 2011 Endeavour Awards program have now closed, so keep an eye on those mailboxes to see if you’ve made it to the list of finalists! All finalists will receive two complimentary tickets to the eighth annual Endeavour Awards ceremony, which will take place at the RACV Club in Melbourne on 25 May 2011. Finalists will be alerted via email this month.

Winners and highly commended recipients will be announced at the gala dinner event, and will also be printed in the July edition of Manufacturers’ Monthly magazine. As our panel of expert judges scrutinises all your entries with a fine-tooth comb, the team at Manufacturers’ Monthly wishes you all ‘good luck’ for the eighth annual Endeavour Awards. The Endeavour Awards, proudly sponsored by BlueScope Steel, is the pinnacle event for the Australian manufacturing indus-

try, and is also the only national awards specifically for our manufacturing industry. When we developed the Endeavour Awards eight years ago, we recognised a need to applaud local companies for their manufacturing achievements, and also to help inspire innovation and success among the industry. Now, in 2011, we believe we have achieved this goal, with a record number of companies shortlisted. Come and help us celebrate Australia’s world-class innovation and success. Extra tickets can be

Finalists will be announced in the April edition of Manufacturers’ Monthly.

purchased by contacting Alex Evans on 02 9422 2890. The 2011 finalists will be announced in the April edition of Manufacturers’ Monthly, and also online. Visit www.manmonthly.com.au/awards for more information.

Celebrating a lifetime of achievements IFM EFECTOR is proud to sponsor the Lifetime Achievement Award category for the 2011 Endeavour awards. As a company with a focus on innovation and solution solving, ifm efector are always enthusiastic supporters of industry excellence and awards that recognise companies and individuals making a difference in industry. “On a personal note, this category actually holds great significance to us as a company, with the recent retirement of our managing director, Albrecht Baer,” said ifm efector’s new managing director, Dave Delaney. “Abi has had an outstanding career, having joined the company in Germany in 1973 as prod-

Delaney is the new managing director of ifm efector.

uct manager, before moving to Japan to set up a new subsidiary there. He started working for a small company that employed a

Supporting new technology PHALANX Consulting Group is proud to continue its sponsorship of the Consumer/Trade Product of the Year Award which is representative of the company’s overarching support of the 2011 Manufacturer’s Monthly Endeavour Awards. “Driving innovation and product improvement is fundamental to the growth of any manufacturing business and the industry as a whole. There is no better way to recognise a manufacturer’s pursuit of excellence than 12 MARCH 2011 Manufacturers’ Monthly

handful of people. Three decades on, the same company employs more than 3,300 workers in over 70 countries worldwide, with a

product range expanding to over 7,000. “He [Albrecht] has held many leadership roles around the world within ifm, relocating to Australia as managing director in 2003. For ifm, words cannot express or explain the value that he has contributed during his outstanding career with the company, and the positive influence he has had on all of us.” Delaney moves up from his post as sales director, with over 10 years experience with ifm efector. “We wish all finalists the best of luck both now and for the future, and look forward to presenting the award to the winning entrant on awards night,” he said. ifm efector www.ifm.com

Safety number one for SICK

through this award,” said Michael Dietrich, Phalanx Consulting Group's managing director and CEO. “Innovation in product development and design can be the guiding light for true industry growth. Phalanx Consulting are specialists in business improvement strategies and processes and regard the Endeavour Awards as key to promoting this message. Phalanx Consulting Group 1300 731 245, www.phalanxgroup.com.au

SICK Pty Ltd is proud to again sponsor the Manufacturers’ Monthly Endeavour Awards’ Safety Scheme Award. SICK has been a technology leader for more than 60 years. Leveraging a history of innovation, the company has pioneered a long line of industry firsts – such as the first safety light curtain. As inventors and innovators SICK identifies with the spirit of the awards to recognise the drive to change unsafe systems, work

practices or processes. “These awards bring to the fore initiatives undertaken by manufactures’ to ensure that continuous safe working environments are provided to all staff,” said SICK managing director, David Duncan. “SICK as a global leader in innovative safe technologies is pleased to be involved in assisting organisations to protect their personnel and machinery, while increasing productivity.” SICK www.sick.com.au manmonthly.com.au

Paid Parental Leave: What employers need to know

On 1 January 2011, Australia’s ﬁrst national Paid Parental Leave scheme was introduced. It’s a new entitlement for working parents, funded by the Australian Government. Taking time away from work for a new baby is a common part of working life. Paid Parental Leave will help employers retain skilled staff and help parents spend time with their new baby. What is Paid Parental Leave? Eligible working parents of children born or adopted on or after 1 January 2011 may get 18 weeks Governmentfunded pay at the National Minimum Wage, currently $570 a week before tax, to help them care for a new child. What do I need to do? From 1 July 2011, you must provide Parental Leave pay to your long-term employees. These are employees who have been with your business for at least 12 months before the expected date of the birth or adoption of their child. The Family Assistance Ofﬁce will contact you to initiate this process.

Your role in the scheme can start earlier if you and your employee agree. You can contact the Family Assistance Office for more information. How do I pay my employee? The Family Assistance Office will advance you funds to pay your employee. You can receive these funds in three instalments or fortnightly. You don’t have to change your employee’s usual pay cycle, set up any special bank accounts or report back to the Family Assistance Office. You just have to pay the Parental Leave pay to your employee with the usual tax deducted. You will not need to make superannuation contributions on Parental Leave pay. It will not increase your payroll tax liability or workers compensation premiums. What about existing entitlements? The Government’s Paid Parental Leave

scheme will help employers enhance the family friendly workplace conditions many already offer. Paid Parental Leave pay is provided in addition to existing employer-funded paid parental leave schemes. The existing minimum entitlement to 12 months unpaid parental leave for long-term employees is unchanged. Eligible parents can receive Parental Leave pay at the same time, before or after other employer-provided paid leave or entitlements. What should employees do? Employees can apply up to three months before the expected birth or adoption. If your staff need help, you can direct them to the website or phone numbers below. Employees are encouraged to apply early.

To learn more about Paid Parental Leave visit the website or call the appropriate number below.

Employers 13 11 58 Parents 13 61 50

Authorised by the Australian Government, Capital Hill, Canberra Printed by Geon Print and Communication Solutions, 69-79 Fallon Street, Brunswick, VIC 3056

PPLM3/MM

www.australia.gov.au/paidparentalleave

’ S R E R TU RDS C A F U N A A W M A R R O F OU E V L A A E S D N N E O L W A O U N RS' N E S N R T A U E T C H A TICKTHLY’S 8T MANUF HLY S YEAR MON MONT HI NS 50 T TUR

The Endeavour Awards, hosted by Australia’s leading manufacturing magazine Manufacturers’ Monthly, is the pinnacle event for Australia’s manufacturing industry where innovation and achievement is celebrated.

Manufacturers’ Monthly turns 50 this year and will be presenting a special award at this year’s event: The Most Innovative Manufacturing Company formed in the last 50 years. Come and celebrate the magazine’s anniversary and the outstanding achievements made by the industry at the 2011 Endeavour Awards. Date: Wednesday 25 May Time: 6.30pm Venue: RACV Club, Melbourne Tickets: $150 per person or $1,200 for a table of 10 exc GST Book tickets at www.manmonthly.com.au/awards or contact Alex Evans on 02 9422 2890.

Proudly brought to you by Manufacturers’ Monthly and the following sponsors:

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AnalysisNEWS

Advanced support for Endeavours

RECISION sheetmetal manufacturer Advance Metal Products (Aust) has once again thrown its support behind the Endeavour Awards by continuing its sponsorship of the Australian Industrial Product of the Year Award. Managing director Ian Stone says the company is proud to continue its association with the

Endeavour Awards, having been involved with the manufacturing awards program since 2006. “The Endeavour Awards provides Australian manufacturers with the opportunity to showcase their business, communicate the challenges and be rewarded with recognition for achievements,” Stone said. “We are all competitors in the

We need to foster a culture of innovation – Stone.

key mechanism for driving growth and a long lasting competitive advantage. “Australian companies must foster a culture of innovation to raise productivity and create sustainable, highly skilled operations and deliver economic growth and prosperity.” Advance Metal Products 02 8796 6222, www.advancemetal.com.au

global race, with innovation a

Skilled support for young workers SKILLED is once again proud to be sponsoring the Young Manufacturer of the Year for the 2011 Manufacturers’ Monthly Endeavour Awards. Greg Hargrave, Skilled Group’s managing director and CEO, said the company is pleased to continue its involvement with the Awards. “Despite the recent tumultuous economic climate, manu-

facturing is still a workable industry and valuable to the Australian economy,” he said. “Support for manufacturing at all levels is important and attracting young people to the industry is crucial to its growth. “For over 45 years Skilled has been helping manufacturers navigate their way through difficult times and during the current economic climate, more compa-

Manufacturing is still valuable to the Australian economy – Hargrave.

nies are turning to outsourced labour. “When times are tough, it pays to be flexible and Skilled can

ensure any business is ready to react quickly to changing economic conditions.” Hargrave said Skilled has the experience, know-how and capacity to streamline a company’s workforce. The firm also helps manufacturers reduce fixed overhead costs and increase production levels. Skilled 1300 366 606, www.skilled.com.au

Manufacturers’ Monthly celebrates 50 years! HELP us celebrate 50 years of providing all the latest news, new products, technical tips and opinion pieces to the Australian manufacturing industry, by sharing with us your manufacturing histories. Developed in 1961, Manufacturers’ Monthly has been a key medium keeping the industry up-to-date over the years, and we’d like you to share this celebration by sharing your stories. We are looking for old footage, images of factories and workers, and old advertising to feature as part of our 50th celebratory issue. We are also looking for local success stories, technical feats and and any other yarns about the Australian manufacturing industry from 1961. The May edition of Manufacturers’ Monthly will feature coverage of the last 50 years, along with forecasts for manmonthly.com.au

Years Wanted: old manufacturing footage, photographs and stories.

the next 50 years of manufacturing in Australian and the world. Chosen entries will be used as part of a video which will be broadcast at our 50th Anniversary Endeavour Awards on 25 May, and also published in the special 50th Anniversary edition of the magazine in May. Help us make our 50th birthday the best ever! Please contact the editor, Sarah Falson, on sarah.falson@reedbusiness.com.au or 02 9422 2480. To buy tickets to the Endeavour Awards, contact Alex Evans on 02 9422 2890. Manufacturers’ Monthly MARCH 2011 15

AnalysisNEWS

Demand for engineers rising BY ALAN JOHNSON

RECENT survey of engineering and manufacturing companies in Australia reveals hiring activity is increasing across all key sectors, with more urgency around recruitment decisions to support growth plans and revenue targets. Data taken from a survey of 3,200 employees, which was conducted by Michael Page International – a leading professional recruitment consultancy – was published in the company’s recent Employee Intentions Report Australia 2010/2011. The report provides an insight into what strategies would be most effective for company attraction, retention and market growth. Of the companies surveyed, 32% reported increasing their employee numbers in the last six months. Although general business confidence is returning, the automo-

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tive, aerospace and chemicals sectors have experienced limited growth due to the closure of manufacturing sites in Australia as a result of the global financial crisis. With strong pressure from Asian and global competitors who can produce at a lower cost offshore, some operators have moved overseas for the financial benefits. According to the survey, the sectors showing most demand for engineering professionals include rail and infrastructure. Affecting this is Government stimulus spending through the downturn, which has contributed to the resilience of these industrial sectors. With respect to manufacturing, demand is said to be strongest in areas that are not significantly impacted by the business cycle, such as the consumer, food and beverage and pharmaceuticals industries. These industries have been the most resilient during the down-

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Of the companies surveyed, 32% reported increasing their employee numbers in the last six months. Demand is strongest in consumer, food and pharmaceuticals companies.

turn due to the consistent market demand for these products.

Skills in demand The survey reveals a strong business focus on hiring professionals who can achieve cost savings through business efficiencies. This is said to be driving demand for roles such as lean engineers, manufacturing engineers and production and operation managers. There is also a focus on production and operations professionals to run plants in the FMCG sector due to increasing growth. Some 48% of companies surveyed for this employment forecast indicated that a professional skills shortage is likely to become an issue in the next 12 months. If the economy continues to strengthen during this period, a rise in the need for Six Sigma, mechanical, manufacturing and project engineers is also said to be likely, as well as increased demand for talent in the operations and plant management areas.

Salary expectations The survey reveals consumerfocused areas of manufacturing such as food and beverage, and pharmaceuticals are recovering well from the impact of the global financial crisis. The demand for professionals in these areas is strong, and salary increases of 5-10% are common for people moving to new roles. However, the survey shows the

engineering industry is taking longer to recover from global market uncertainties, so companies are under less pressure to increase salaries by more than 2–4%. In general there is limited pressure on engineering and manufacturing companies in Australia to provide salary increases to retain staff, as they have the advantage of drawing employees from a large talent pool. Other benefits such as people management opportunities or the chance to work in more challenging roles or on interesting projects are suitable non-financial alternatives. Of the companies surveyed, 42% reported the intention to increase employee salaries in the next six months. The average percentage salary increase is likely to be 2–4%.

Employment outlook For the early part of 2011, jobs growth is expected to remain steady, with 58% of companies surveyed indicating that their employee numbers will remain stable in the next six months. However, business confidence is strong enough to warrant a gradual lift in demand for engineering and manufacturing staff if the international financial markets remain stable. Hiring activity will be focused on replacing people in the junior and mid-level markets. Michael Page International 02 8292 2000, www.michaelpage.com.au Comment at manmonthly.com.au manmonthly.com.au

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TechnologyIT@MM

Delivering what your customers want, how they want it and when they want it, is no longer an added bonus – it is expected.

Delivering the perfect order Delivering the perfect order has clear benefits for manufacturers, and their customers. As Andrew Casey reports, a happy customer is a loyal customer.

N the current economy, retaining your most profitable customers – and making the most out of your relationship with them – has become more important than ever. There are many ways to measure how well you serve your customers, including customer satisfaction surveys, analysis of sales data, and tracking of individual performance indicators like shipped on time. However, what really matters is how effective you are at reliably supplying your customers with what they want. The perfect order metric measures your ability to do this. It gives a big-picture view of how good you are at serving your customers – from your customers’ perspective. It also gives a good indication of how well your supply chain is performing as your ability to create the perfect order hinges on how well you can anticipate and respond to demand. The Supply Chain Council 18 MARCH 2011 Manufacturers’ Monthly

defines perfect order fulfilment as the percentage of orders: • Delivered on time to the request date and/or commit date • In full • With no quality issues • With the correct and matching invoice, PO, and receipt. The perfect order index is one way of determining your ability to meet the above. Rather than monitoring the individual components separately, it multiplies them together to give a comprehensive view of how well you serve your customers. For example, while it’s nice to know that you deliver on time 95 times out of 100, what you really need to understand is why you didn’t make it 5% of the time. Was the SKU not available in the warehouse? Did poor quality materials cause a production delay? Were there issues with a third party logistics provider? And more importantly, are there any patterns to these issues? Looking at your perfect order

process in this way allows you to identify problem areas in your supply chain and highlight opportunities for improvement. In effect, tracking the metric is a way to drive continuous improvement. This is especially crucial for the manufacturing industry where you are dealing with a mix of sales channels and customer categories.

Achieving the perfect order The processes involved in delivering the perfect order include all stages of the order-to-cash cycle – from capturing the order, through sourcing or manufacturing and fulfilment to the collection of the resulting receivable. To improve your perfect order rate, you need to improve these business processes. And since the processes involved in delivering the perfect order cut across many functions within your business, visibility along the cycle and across these functions is key to success. Many manufacturing compa-

nies struggle with delivering the perfect order because they are burdened with disparate systems and integration challenges. This makes it difficult to have a coordinated view of the order management process across internal divisions and the extended supply chain. And it is just this visibility that is key to a successful perfect order process. Increase your visibility, and you increase your odds of being able to deliver the perfect order. You also need to empower the people who execute these processes day to day with the information they need to make informed decisions – and the ability to act on them. For example, if you’re running low on product, your warehouse personnel should be able to prioritise those orders from your most important customers. The seven steps to perfect orders are: 1. Decide what to measure 2. Define how to measure it 3. Track performance 4. Highlight opportunities for improvement 5. Determine the value of those improvements 6. Prioritise what to do and in what order 7. Track and adjust Delivering what your customers want, how they want it and when they want it, is no longer an added bonus – it is expected and even essential in today’s customer-driven economy. Focus on your perfect order performance and you will see benefits that extend well beyond a loyal customer base. You can also expect to see operational efficiencies, increased sales and market share, and ultimately bottom line growth. You’ll also improve collaboration with your trading partners at both ends of your supply chain. Remember, visibility across your extended supply chain is key to achieving high perfect order rates. [Andrew Casey is a supply chain specialist with Lawson Software.] Lawson Software www.lawson.com/manufacturing manmonthly.com.au

Where you want More flights, more often With more flights to more places across Australia, you can travel pretty much wherever your business takes you, whenever you need to. And you can do so with the comfort of knowing we were ranked first among the major domestic airlines for on-time performance for 2010. Make your next destination qantas.com

Enjoy the journey

When you want

Source: Bureau of Infrastructure, Transport and Regional Economics, Airline On Time Performance Reports Jan – Dec 10. Qantas Airways Limited ABN 16 009 661 901

TechnologyIT@MM Finite element modelling software

Reducing energy wastage BY ROD ELLSWORTH*

SIEMENS PLM software has released the latest version (10.2) of Femap software, a PCbased finite element modelling component of the Velocity Series portfolio of PLM solutions. According to the company, Femap 10.2 makes it faster and easier to create the meshed models used by engineers to simulate and analyse product performance using finite element analysis (FEA). The latest release is said to add a wide variety of customerdriven enhancements and exclusive new features to improve the entire computer-aided engineering (CAE) process. The process, from pre-processing model creation, to solver integration, to post-processing data handling, visualisation and analysis, are all said to be improved when using the software. The Interactive Meshing Toolbox introduced in Femap version 10 has added functionality to the software that reportedly enables faster, interactive creation of the finite element mesh model. It also includes a new feature editing capability that is designed to allow the user to move features, such as holes or surfaces, while the meshed model is automatically updated to reflect the change. A new topology optimisation capability allows the user to apply loads and constraints to material, encompassing the entire available design envelope. This is said to minimise weight, and maximise stiffness by removing unnecessary material to create an optimised shape. The suggested shape can reportedly serve as a starting point for successive iterations, significantly reducing the time needed to arrive at a final design. Siemens PLM Software www.siemens.com/plm/femap

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HILE many manufacturers are taking measures to reduce their energy consumption, attempts are often limited in what they can achieve. Typically, companies tend to start by looking at a utility bill and set objectives to reduce the total figure at the bottom. Some might even combine this figure with supply chain costs such as warehousing and transportation to get a more comprehensive figure to work from. However, though this might sound like a logical place to start, this figure represents only a crude measure from which to instigate the process. Any objective to reduce energy wastage cannot be achieved by just measuring the energy usage by a commodity, but must focus on how that commodity is consuming energy. This ‘energy bill down’ approach does not include the detailed energy consumption patterns of individual plant assets which can identify when and where most wastage occurs. Without this detail, there is no way of knowing how much of the energy consumed is being wasted, and therefore what can be eliminated without impacting the running of dayto-day operations.

Getting energy intelligent As with any business change, a shift in both culture and processes are central to making improvements. To reduce energy bills, these questions must be answered: 1. How committed are we to improving energy consumption? 2. Where is the majority of our energy consumed? 3. How much energy should we be consuming? 4. How much wastage is involved? With the exception of (1), most organisations are unlikely to be able to answer the above questions fully and accurately. The old adage that “you can’t manage that which you can’t

Warehousing and transportation costs should be included in total energy costs.

measure” is true; if a company does not know which assets are inefficient, it is impossible to act to improve energy use.

The tools for the task Having committed to the concept, it is technology which presents the real opportunity to deliver cost savings, as the necessary actions simply cannot be undertaken manually. Unfortunately no spreadsheet is capable of capturing and processing the millions of pieces of data necessary to effectively monitor, measure and analyse the energy consumption and performance of the broad range of machinery, involved in running a manufacturing plant. Organisations tend to assume that once an asset is installed, the biggest cost has been expended -– when in fact it is the ongoing running costs instead which far outweigh the initial outlay. Advanced asset management systems harness data from a number of sources to assess how efficiently a machine is operating on a continuous 24/7 basis.

They show the actual energy being consumed in the course of production, and the units, parts or processes which are consuming disproportionately more energy than they should. Such systems also provide warnings when consumption gets too high and present red flags when maintenance, routine or otherwise, is required. Sub-meters are also crucial, as they measure energy consumption at the asset level in order to feed asset management software. However many pieces of equipment are now being fitted with built in smart-metering at the point of manufacture. Microprocessor chips fitted onto assets can provide information to asset management software directly. The level of information provided by asset management systems can facilitate the action required to remove inefficient processes, parts and machines which are disproportionately energy-hungry, and the lifecycle of an asset can often be extended through evaluation of its running costs against >> manmonthly.com.au

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TechnologyIT@MM AutoCAD for MAC AUTODESKâ&#x20AC;&#x2122;s AutoCAD is now available for Mac users; AutoCAD for Mac has an intuitive interface that will feel familiar to Mac users and takes full advantage of Mac OS X, including graphical browsing of design files with Cover Flow and use of Multi-Touch gestures for pan and zoom on Mac notebooks, Magic Mouse and Magic Trackpad. With native creation and editing of files in the DWG file format, AutoCAD for Mac also supports easy collaboration with suppliers, customers, clients and partners. Autodesk www.autodesk.com.au

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efficiency levels.

Green and lean As the escalating number of pressures facing manufacturers continues, any potential to strip out costs must be exploited par-

22 MARCH 2011 Manufacturersâ&#x20AC;&#x2122; Monthly

Ethernet switch for military applications THE ToughSwitch 3 is a dedicated, ruggedised ethernet switch designed to meet MIL-STD environmental and electromagnetic requirements. It operates from 24 VDC vehicle power in accordance with MIL-STD-1275B, making it ideally suited for use in military vehicles. The ToughSwitch 3 is painted with Chemical Agent Resistant Coating (CARC) paint, meaning it will resist the effects of biological and chemical decontamination agents, including DS2 and STB, applied to external surfaces and components using standard decontamination procedures and

methods. It is also said to meet MIL-STD-108 requirements for steam and waterjet cleaning. The ToughSwitch 3 is outfitted with two MIL-STD connectors, one for power and a second for ethernet connectivity. Since all the ports are auto-MDI/MDIX, any port can be connected to another ethernet switch as an uplink. The ToughSwitch 3 is designed to minimise collisions and network loading. Unlike an ethernet hub that broadcasts all messages out all ports, it automatically determines and remembers where an ethernet device

ticularly where expensive energy wastage is occurring. An increase in energy bills seems inevitable, and while part of the cost is fixed, a large part of it is not. Asset management software, in conjunction with sub or smart metering, can reduce

energy consumption and can equate to big savings year-onyear for businesses. Of course, long term targets and legislative measures are integral to reducing carbon footprints. For businesses, the cost savings associated with substan-

The switch is suited for use in military and other defence vehicle use.

is located and routes messages only through the appropriate port. Metromatics 03 9872 4592, www.metromatics.com.au

tial reductions in energy consumption and wastage, are increasingly compelling in the quest to be both green and lean. [Rod Ellsworth is VP for Global Asset Sustainability at Infor.] Infor 1800 260 2640, www.infor.com.au

manmonthly.com.au

InsiderSERIES

REDUCING YOUR ENERGY CONSUMPTION

Solar power brings Mark Leckenby (left) and Klaus Langer together.

Sunny future for alliance A new locally-made solar panel and mounting system allows users to establish energy alerts to optimise usage in line with set targets. Kevin Gomez writes.

vative communications for a complete residential energy management system," he said. In 2009, the Australian Government set an ambitious renewable energy target of 20% by 2020, which means that onefifth of Australia's electricity must be supplied by renewable sources such as solar power. Teamed with the implementation of numerous government-based incentives and the soaring energy prices over the next decade, Auzion and Latronics are gearing up for increasing demand. "We live in one of the sunniest places in one of the sunniest countries in the world, with an average of seven hours of sun a day, an ideal climate for solar panels," Leckenby said. "People can make real contributions to the environment and also save money by installing efficient solar grid connect systems." [*Kevin Gomez is editor of Manufacturers’ Monthly’s sister publication, PACE.] Auzion 0409 478 199, www.auzion.com

WO Sunshine coast businesses – Auzion, a supplier of solar systems, and Latronics, a local manufacturer of inverters – have announced a strategic alliance to provide the country with greater access to solar systems. Auzion began operations just over two years ago and have been involved in sustainability research with the University of the Sunshine Coast. "We have developed AuziMax Energy Maximiser which will be fully commercialised in the first quarter of 2011 after the completion of a pilot study," Auzion managing director, Mark Leckenby, told Manufacturers’ Monthly. For customers with a solar grid connect system, AuziMax can help maximise the amount of power fed into the grid. AuziMax allows users to monitor all of their building's energy needs (including incoming mains, power circuits, lights, hot water and air conditioning) in conjunction with the solar power generated. Through a secure web portal, users can view an accurate manmonthly.com.au

breakdown of their energy usage. The device allows users to establish energy alerts to optimise usage in line with set targets. Auzion is keen on using Australian-made products wherever possible. This drove Leckenby to develop AuziRack – a solar panel mounting system made from anodised aluminium which is rated for all Australian cyclone zones. He believes locally developed and produced systems are better than available imported products. "We were able to reduce the number of components needed, making the system more streamlined," he noted. The only component not made in Australia is the solar panel. "And these come with a 25-year performance warranty," he adds. According to Latronics CEO Klaus Langer, their research and development efforts come off the back of 25 years of manufacturing experience. "We can't say too much about current projects until they are ready for release to the market but we are collaborating on inno-

S2 & S3 VACUUM CLEANERS The NEW range of Heavy Duty single phase industrial vacuum cleaners have been specifically designed with the robust needs of the manufacturing world in mind. The patented electronic control board allows an easy to use & continuous monitoring of the vacuum efficiency. It also allows functional control of options such as solid or liquid cut off. The S2 & S3 family are lightweight, yet sturdy which allows easy manoeuvrability in crowded workshop or manufacturing sites. They also come in L, M & H certified versions.

Manufacturers’ Monthly MARCH 2011 23

InsiderSERIES

Taking paper out of the equation THE Metal Manufactures Group (MM) incorporates a number of businesses involved in electrical wholesaling, PVC, plastic products and distribution. The Group produces high value invoices for goods that are shipped around the country. Often deliveries are disputed, which makes proof of delivery (POD) documentation crucial to ensure invoices are paid. MM had employed a dedicated full time resource to manage POD documents, which were manually stored in a cumbersome hard copy filing system. Group IT manager Trevor Batten felt the burden of maintaining a widely distributed and aging fleet of printers in over 200 locations across Australia. “The logistics of internally managing the supply, maintenance and replacement of all our printers was expensive and complex,” explained Batton. “At the end of the day our core business is not printers, and I didn’t want to have to waste

resources looking after them.” Because the majority of printers were dot matrix, pre-printed stationery was required to produce forms and corporate documents. Each time a pre-printed form had to be updated, all old forms were thrown away and new versions brought in. “The forms just cost too much; they were wasteful and gave us an unnecessary administrative hassle,” said Batton. Technology supplier Upstream was engaged to overhaul the Group’s printing processes, including its proof of delivery (POD) documentation system and forms production. With Upstream’s uscan solution, a new POD docket was designed incorporating two encrypted barcodes, one on each half of the docket. Upon delivery of goods, the truck driver leaves one half of the docket with the customer. The other half of the docket, containing the customer’s signature, is returned to the distribution point where it is scanned and uploaded

Electronic invoices and POD ensure better control.

to the central head office document storage server. In addition, high volumes of transactions are ‘counter based’ and these also form part of the POD process. POD documents are made available to head office, all branches, and even customers within minutes and archived electronically for ease of retrieval and storage. To complete the process Upstream tailored uscan to automatically update the legacy ERP

system with the POD number and close off the job. “The new uscan system means we have instant recall of PODs, which couldn’t be lost once filed on our server. And because external freight operators are only paid once they return the signed POD docket to the local warehouse, we don’t have a problem with missing documentation,” said Batton. Upstream 1300 772 772, upstream.com.au

Our isolators are very ﬂexible and so are we. Mackay has the largest range of rubber vibration isolator and equipment mounts in Australia. We are the ﬁrst choice for both original equipment and replacement parts. More importantly, our design and manufacturing facility is capable of producing mounts for delicate electronic equipment to very large engine mounts.

We are certain that Mackay can provide a solution to your rubber requirements – it’s amazing just how ﬂexible we are. T (03) 9555 6500 F (03) 9276 8882 E info@mackayrubber.com.au w mackayrubber.com.au

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Preview

SAFETY IN ACTION & MELBOURNE MATERIALS HANDLING: 2-5 April 2011

Getting tough on conflict

The safety vests are visible in the dark.

Workplace conflict is now considered a safety risk, and manufacturers should get prepared for tougher laws in the future. Marian Macdonald writes.

LTHOUGH often considered the ‘soft’ side of safety, workplace conflict can be very tough to manage and will come under greater scrutiny when the new model workplace health and safety laws are rolled out in 12 months. Workplace conflict specialist, Stuart King of Kings Workplace Solutions (KWS), says his consultancy will work hard to correct some commonly held misconceptions at Melbourne trade show Safety In Action in April. "People have the idea that specialist HR and risk control services such as ours are warm and fuzzy and a cost driver to business," King says. "On the contrary, our work is highly skilled and can make or break organisations and their reputations. "It’s all about leadership and inappropriate or unlawful workplace behaviours must be treated no differently than we treat a trip hazard or a missing machine guard." The role of a workplace conflict consultancy is to help protect the workplace culture and people working within it from employees who choose to behave inappropriately. The consultancy supports clients in identifying, reducing and responding to the business

Our work is highly skilled and can make or break organisations – King.

and personal risk associated with inappropriate workplace behaviours. King says most clients approach KWS for: prevention, including education and policy development; response, including access to a telephone intervention and help line; and management, which covers support services that control complaint and manage outcomes. King, who established KWS after a 30-year policing career, says the case that has most affected him personally involved an apprentice and his supervisor. "We were conducting an investigation into a workplace bullying complaint lodged by an apprentice who was bullied during remote field work and physically assaulted by his mentor tradesman," he said. "The bullying was long suffered and the apprentice com-

mitted suicide after the investigation had concluded and remedial action taken against his bullies. I was involved with the family and my client organisation, who were blind-sided by the complaint and resultant suicide. "Jobs were lost, the family lost a loved one and colleagues wondered how could this happen. There were no winners. It was so preventable. People knew it was going on but did not do enough to stop it." King says good workplace conflict management systems are a wise investment for even the most hard-nosed risk managers. "Organisations and their executive teams are naive if they think they are immune to employees and managers behaving inappropriately or unlawfully," he said. Kings Workplace Solutions will be on-hand to provide expert advice on workplace conflict at Safety In Action from April 5 to 7, 2011, at the Melbourne Exhibition Centre. Safety In Action will run concurrently with Melbourne Materials Handling and, for the first time, Clean Scene. Safety In Action, Melbourne Materials Handling & Clean Scene 03 9654 7773 www.safetyinaction.net.au www.materialshandling.net.au www.cleansceneshow.com.au

High-vis wearables SAFETY vests that can be seen up to 800 metres away at night will be the feature of Baker & Farrow’s Exelite Safety stand at Safety In Action this year. The Exelite Safety range allows users to be seen clearly and safely at night to increase workplace safety and reduce workplace injuries. Exelite Safety Products are self-illuminating and require no other light source to be seen. Manufacturers of the technology say the safety vests offer a 400% increase in visibility compared to using standard retro-reflective tape. Exelite Safety offers a range of products including safety vests for road and rail operations through to harness-style vests and Zone 0 intrinsicallysafe-rated models for refuelling depots, manufacturing plants and coal mines. The Exelite Safety stand at Safety In Action from 2 to 5 April will also showcase a range of recreational products designed for cyclists, joggers and hikers. Visit stand 016. Exelite Safety 02 4960 1222, www.exelitesafety.com.au

Drug-safe induction program VISITORS will get their first look at Frontline Diagnostics' unique and easy to use DrugSafe Induction program for new staff and contractors at Safety In Action. The Drug-Safe Induction kit allows recruiters and HR/HSE management to deliver a fast and informative program for new 26 MARCH 2011 Manufacturers’ Monthly

staff/contractors that clearly outlines the company’s policy on alcohol and drugs in the workplace. The 12-minute DVD presentation suits most Australian workplaces and the information given is easy to comprehend. A simple questionnaire paired with a register for signatures confirms

applicants understand the company’s requirements. While Safety In Action will host the Victorian launch of the Drug-Safe Induction program, it has been trialled and refined for over two years in NSW and Queensland where it has been proven as an excellent defence against unfair dismissal claims.

The first on-site drug screening service to be accredited by NATA, Frontline Diagnostics is said to have the largest fleet of mobile clinics in Australia. These allow for confidentiality to be maintained. Visit stand K11 for more information. Frontline Diagnostics 1800 888 852, www.frontlinediagnostics.com.au manmonthly.com.au

Tue 5 - Thu 7 April 2011 Melbourne Exhibition Centre

Wireless OHS apps

Resistant to a broad range of chemicals.

Outdoor chemical storage THE Global Chemshed for outdoor bunded storage of oil and chemicals will be the focus of Global Spill Control's stand at Safety In Action this year from 5 to 7 April. Designed and manufactured in Australia, the Global Chemshed suits the Global 4 Drum Bund or Bunded Pallet (DB4) and the

Global Bulk Container or IBC Bund (DB1150). This allows companies that have already purchased a DB4 or DB1150 to convert their existing bunds to an outdoor dangerous goods storage unit. Rotomoulded from tough UVresistant polyethylene, the Global Chemshed is resistant to

a broad range of chemicals and weather conditions. The units have been moulded with integral tie-down points for high wind areas. Front and real roller door access is lockable to prevent unauthorised access. Visit stand S13.

MOBILISING OHS safety compliance for field staff will be the feature of Retriever Communications stand at Safety In Action. The Retriever wireless OHS safety compliance applications reportedly allow field workers to increase jobs per day by 30%, while integrating health and safety controls into field data collection processes. Retriever’s mobile safety management solutions integrate controls into field data collection processes enabling the highest levels of field technician safety, as well as providing risk updates, incident capture and on-demand management reporting. Retriever Communications will present its field mobility solutions from April 5 to 7.

Global Spill Control 03 9335 5366, www.globalspill.com.au

Retriever Communications 02 9006 8600, www.retrievercommunications.com

Range, quality, and expertise consistently comes from a Mackay mould. Mackay makes rubber moulding for a variety of industries, from small to large and everything in between. However it’s our technical know-how and high standards that make us the supplier of choice. Mackay’s design and manufacturing expertise allows us to incorporate materials not commonly associated with rubber mouldings. This helps us achieve superior performance, weight saving and improved service life.

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What’sNew See more new products at manmonthly.com.au

Customisable whiteboards THE Quartet InView solution is designed to allow customers to create a customised whiteboard that adapts to their specific communication or organisational needs, bringing people together to collaborate and communicate to large audiences more effectively. Quartet whiteboards offer a choice of planning or tracking systems, calendars, workflow charts and personnel boards, or users can create their own system using a variety of on-line tools. Alter text, add logos and even upload photos onto an existing whiteboard. Users can print their file and place in

the whiteboard where a hinged, steel frame secures custom printed artwork. A clear and flexible patented lens sits on top of the custom artwork and provides an erasable magnetic writing surface that resists staining and ghosting. Quartet will also provide a customer’s first design print for free. Users can choose and order the whiteboards online at the below website. Quartet InView www.quartetboards.com.au

The whiteboards are designed to suit specific requirements.

Small object inspections MICRO-POLYVIEW is a 360°, 3D, multi-image optics solution designed to measure and inspect small objects whose dimensions range

from 1 to 10 millimeters, using a single lens. Opto Engineering’s Micro-Polyview lens is reportedly capable of observing

and measuring an object from different angles by using an array of mirrors interfaced to a bi-telecentric lens. Keeping the top of the object directly imaged at the centre of the field of view, the company says the lateral views feature exactly the same magnification and the images remain in perfect focus even when the object is displaced. All views can be used to measure the dimensions of components from different angles with only one camera and without moving anything. The Micro-Polyview lenses are customisable and versions can be

The lenses are available in customised versions.

manufactured with a different number of views, different mirror inclination angles and asymmetric or special mirror arrays. Adept 08 9242 5411, www.adept.net.au

No-lift stackers save backs WAREQUIP distributes a wide range of Walkie Stackers from manual units through to electric units in both straddle legged and forkover units. The manual units have hand or foot lift operation and level release, while semi electric stacker units have electric lift and manual push capabilities. As the stacker requires no lifting, it is 28 MARCH 2011 Manufacturers’ Monthly

said to reduce the pressure on backs as workers no longer have to use their backs to lift and transport packages. The stackers have capacities ranging from 500kg to 1000kg with lift heights ranging from 1600mm to 3000mm. Warequip 1800 337 711, www.warequip.com.au manmonthly.com.au

TUV emergency stop buttons

Plasma cutting fabrication system The buttons can be used for protection degrees up to IP 69K.

The system can handle a range of structural shapes and part sizes.

THE new SNH emergency stop buttons have been approved by TÜV and reportedly satisfy EN ISO 13850 of EN 60947-5-1 and EN 60947-5-5 standards. Depending on the design, the emergency stop buttons can be used for jobs up to safety category 4, performance level e, or SIL 3 in accordance with the new machine directive 2006/42/EG. Available as built-in or surfacemount versions with a standardised installation diameter of 22 mm, the

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buttons can be integrated in an operator panel or be directly mounted to a machine using a surfacemounted housing. All emergency stop buttons are contacted using detachable screw connection terminals. The seven different sizes of the operating component can reportedly be combined with numerous switching options resulting in a variety of switching variations. Treotham Automation 02 9907 1788, www.treotham.com.au

POWER MACHINERY’s 6-axis robotic PythonX CNC plasma cutting fabrication system automates structural fabrication tasks into a single machine. The new technology brings automated 3D fabrication to processing beams, channels, HSS, angle, plate and bar. The system is said to have unprecedented flexibility and offers huge savings in floor space, labour and materials handling. The PythonX reportedly offers the functions of a beam drill line, band saw, angle line and plate/bar line. It also offers coping machine, marking machine and small burning machine functions.

The torch head probes and measures the piece to be cut and places each feature exactly where it needs to be. The PythonX accepts files via direct download from structural design software, such as Tekla XSTEEL and SDS/2. The machine control then reads the file, probes and measures the piece. The system can cut steel up to 32mm thick in shapes up to 1200mm wide and 400mm high. With conveyor options, the PythonX can handle beams up to 26 metres long. Power Machinery Australia 02 9971 1755, www.powermachinery.com.au

Manufacturers’ Monthly MARCH 2011 29

What’sNEW

The machine eliminates wipe-up.

Heavy metal plate bender MAXITEC has released Schröder MAK 4 EVO UD, a bi-directional (up and down) bending machine which facilitates faster setup, and more precise dimensional part and angular part accuracy. The unit’s performance is based around the POS3000 sheet metal designer operator control which allows direct operator interface with the bender. It features twin ball-screw drives, steel or nylon ball transfers, solid gaug-

ing fingers, and pop-up stops. The back gauge fingers are pneumatically ‘popped’ up, in rows 850 mm (33.46”) apart, and the sheet support surface is outfitted with brushes, steel or nylon ball transfers. According to the distributor, the system automatically calculates the most efficient method of part manipulation, axis positioning and tool setup. Maxitec 02 8536 5800, www.maxitec.com.au

High-gloss surfaces in one cycle KRAUSS Maffei has released their ColorForm technology, a process that integrates injection/reaction moulding in an automated injection moulded single stage process. The technology reportedly provides manufacturers with the ability to produce multi-component parts with high-gloss surfaces from one production cell. The ColorForm system replaces the conventional painting process by reportedly applying a high gloss coating in the closed mould immediately

30 MARCH 2011 Manufacturers’ Monthly

after the part has been injection moulded. According to the company, the thickness of the coating and the surface hardness can be set to suit part geometry and design specifications. It can be used to apply any colour, from glass clear to piano black, including colour management and it can be combined with many different substrate materials such as thermoplastics, thermosets and PUR. HBM Plastics Technologies 02 8814 3100, www.hbm.com.au

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Data loggers monitor anywhere DWYER has announced new model DW-USB -5 thermocouple temperature sensor and model DW-USB-6 carbon monoxide sensor compact data loggers. According to the company, the compact design of the DW-USB Series data loggers offers a thermocouple temperature sensor or a carbon monoxide sensor that can monitor almost anywhere. Users can select the sampling rate, start time, high/low alarm settings, and temperature unit parameters with windows-based application, which is easy to install. Stored data is downloaded by plugging the module into a PC’s USB port with no cable required. Alarm status and low battery is indicated via built-in flashing LED’s. The new models are suitable for calibration labs, pharmaceutical plants, environmental chambers, and storage warehouses.

The system comes with a sensor unit.

Joint track welding with controller ESAB’s GMH joint tracking system reportedly allows the operator to keep an eye on the entire welding process, without having to concentrate on the weld head. Supplied with a joint tracking controller, servo slides and sensor unit, the system can be used to perform a range of weld types, including J-weld, V-weld, double J-weld, X-weld, fillet and double-flanged butt joint. The welding head is supposedly mounted on a motorised X and Y servo slide and can be moved up-

Dwyer Instruments 02 4272 2055, www.dwyer-inst.com.au

The data logger can resist moisture to IP67 standards.

down and left-right. According to the company, GMH is ideal for retrofit to existing installations and can be utilised on all brands and applications for welding by adding the 42 volt isolation transformer. The system also allows for curved details within the working range of the servo slides as well as the use of inductive sensors. The system comes with different mechanical sensor fingers for different applications. ESAB Australasia www.esabasia.com

Water jetting for safer concrete removal A HIGH-pressure water jetting system for removing the build-up of dried or ‘dead’ concrete in cement mixer trucks can reportedly overcome health and safety issues, save costs and lift productivity in the

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concrete industry. Concrete gradually builds up on the inside surface of every truck’s agitator – the mixing drum and blades within the drum – reducing concrete carrying capacity and increasing the

weight carried by the truck. The Agi-Kleen patented water blasting system eliminates occupational health and safety (OH&S) risks by eliminating the need for the equipment technician to work outside

the truck’s mixing drum, the manufacturer claims. The Agi-Kleen system removes the dead concrete without damage or wear to the concrete mixer drum. Agi-Kleen 0409 554 994, agikleen.com.au

Manufacturers’ Monthly MARCH 2011 31

What’sNEW High-force industrial testing MTS Criterion Universal Test Systems have been designed with the capacity to perform a full range of high-force industrial testing. The Criterion comes standard with TestWorks software and features protective rubber matting to improve the maintainability and utility of the system test space. The Series 40 Electromechanical unit, available in four different models, and the Series 60 Static-Hydraulic, available in two models, feature integrated, digital closed-loop controls that test in-load and position control at force capacities ranging from 5 N to 100 kN, and from 300 kN to 1,000 kN,

respectively. Both systems also feature heavy work surface mats, which are designed to protect the load frame base and facilitate easy test space clean-up and maintenance. The Series 40 models are available in compact, high stiffness 1 and 2 column table-top configurations or robust 2 column floor standing configurations. The Series 60 models are available in a variety of high-stiffness 6 column load configurations, supported by an ergonomic Integrated Operations Platform. Australian Calibrating Services 1800 334 183, www.auscal.com.au

The attachments are designed for long, slender loads like pipes.

The Criterion has low vibration MTS electromechanical drives.

Digital manufacturing software Long loads handler attachment MANITOU Australia has released a series of clamp attachments for the company’s MANISCOPIC range of telescopic handlers. These are reportedly a considerably safer alternative to a hook and sling for handling long slender loads. The clamps are available with or without a rotator, which can allow an item to be picked up horizontally, rotated and then placed vertically. The

32 MARCH 2011 Manufacturers’ Monthly

design of the top and bottom jaws of the clamp can be varied to suit the load being handled. A MANISCOPIC telescopic handler is said to provide a stable, manoeuvrable platform for handling loads on and off a paved surface, while the telescopic boom provides long reach for picking and placing loads. The cab is easy to get in and out of. Manitou 02 9517 3174, www.au.manitou.com

SIEMENS PLM Software’s latest release of Tecnomatix – a digital manufacturing software portfolio – is said to assists the user by clarifying industry workflows, delivering more realistic human models. The software also reportedly increases the efficiency of its quality solution and its factory planning and analysis application through enhanced integration with digital product design and data management. Improvements in Tecnomatix contin-

ue to drive planning efficiency through better manual workplace configuration, as well as optimal factory material flow and equipment placement, Siemens PLM claims. Tecnomatix improvements like this new release also reportedly continue to boost manufacturing productivity through optimisation and commissioning of robotics and automation systems, the company says. Siemens PLM www.plm.automation.siemens.com

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The package includes a controller, touchscreen, robot and software.

Robotic welding package ABB is now offering a robotic welding package called ArcPack, designed to offer high-quality welds with minimum downtime. The package includes ABB’s fifth generation IRC5 controller, along with the company’s touchscreen interface FlexPendant, RobotWare Arc programming software, and an IRB1410 industrial robot. The package is said to be an integrated solution for companies that desire hassle-free arc welding. The package is also provided with ABB’s new RPC welding power source suited for MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding automation. The new RPC welding power source is said to offer enhanced control of

welding applications. It enables manufacturers to specify process parameters, such as voltage, current and gas flow, which are managed via the ABB FlexPendant controller. Using fieldbus-based communications, the RPC power source internal digital communication speed is reportedly 10 times faster than previous models. Abb’s new robotic welding package also offers faster reaction speeds and consistently smooth and reliable wire feeding, according to the company. The pack is said to allow manufacturers to gain control in MIG and MAG welding applications, according to ABB. ABB Australia 1300 782 527, www.abbaustralia.com.au

Small, smart vision sensor

Chemical bunds with ramp

SICK’S new Inspector I40 & P30 vision sensor variants offer part inspection at a ‘smart camera’ level of performance.

SPILLDOKTOR’S new low-profile connectable bund range includes a gentle non-slip ramp, which offers approximately a 1-foot, 7 inches slope. When moving 200L drums

The system reportedly offers high performance inspection, flexible setup and complete production control support, without increasing the complexity and cost of the solution. The sensors come with high resolution VGA imaging (640x480 pixels), and powerful inspection tool sets that are said to provide easy-to-configure problem solving abilities, enabling troublefree solutions for tough targets.

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The system operates at a ‘smart camera’ level.

Flexible housing designs with easy lens exchange and easy-to-set-up illumination accessories have been introduced, along with red, green, blue or diffused white illumination. SICK 03 9497 4100, www.sick.com.au

(which weigh up to 300KG) on a drum truck, this is a significant manual handling advantage. These units come in compact ‘2 drum’ modules which can be connected in many configurations to suit almost any application. There are various configurations available to the user, including L and T shape bunds. Users can even build

their own particular ‘footprint’ which suits the available floor space. One key advantage for areas where space is tight is that bunds can be joined in an ‘L’ configuration. So that corners can be used to advantage. Another unique feature is the ‘spill gutter’ around the perimeter of the unit, which has proved popular in other SPILLDOKTOR bund products and eliminates the need for large holes in the poly grate which can be a weak point and a trap for wheels. SPILLDOKTOR 1800 365 867, www.spilldoktor.com

Manufacturers’ Monthly MARCH 2011 33

What’sNEW - BEARINGS, GEARS & LUBRICANTS Ronson Gears appointed KHK distributor.

High temperature, dry lube SKF’s new DryLube Bearing solution contains a specially-engineered graphite mixture that is said to eliminate the need for grease re-lubrication in hostile steelmaking environments. SKF DryLube Bearings are designed to help mills avoid the associated operating costs and productivity limitations that can occur when grease-lubricated bearings are exposed to high temperatures. According to SKF, heat causes grease to deteriorate quickly, leaving bearings without adequate lubrication. This can lead to frequent failures, unplanned downtime, product surface defects, lost productivity and costly maintenance. SKF DryLube Bearings feature an engineered graphite based mixture, which provides very low and constant friction, capable of lubricating at temperatures of up to 350 °C. Almost any SKF bearing type can be supplied as an SKF DryLube bearing.

KHK signs local

The lubricant be withstand temperatures up to 350 °C.

SKF Australia Engineering 03 9269 0858, www.skf.com

Automotive bearing grease for grease guns SKF Australia has introduced LGMT2, a new 450-gram general purpose industrial and automotive bearing grease for standard Australian grease guns. The SKF LGMT2 is a premium-quality, mineral-oil-based lithium soap thickened grease with excellent thermomechanical stability within its operating temperature range. The grease is suitable for a wide range of industrial and

automotive applications including; wheel bearings in cars, trailers and trucks; agricultural equipment; industrial fans; conveyors; and small electric motors. The SKF grease is said to offer excellent oxidation stability, good mechanical stability and excellent water resistance and rust inhibiting properties. SKF Australia Engineering 03 9269 0858, www.skf.com

RONSON Gears, manufacturer of custom gears for the aeronautical, defence, medical, mining, rail, construction and transport industries, has been appointed sole Australian agent for KHK Co Japan. This partnership will reportedly see Ronson Gears increase its 250 stock gear configurations to 7,000, and bring customers faster delivery times and more competitively-priced gears. The new relationship means customers can access a much wider range of gears at much faster turnaround times than previously possible. Both KHK Co Japan and Ronson Gears are family businesses. Ronson Gears 03 9555 9822, www.ronsongears.com

Ready made or Custom made

www.ronsongears.com.au

...now exclusive distributors for KHK 34 MARCH 2011 Manufacturers’ Monthly

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Preview AUSPACK PLUS 2011: 22-25 March 2011

This year is set to be the biggest AUSPACK PLUS exhibition ever.

Packaging industry ‘out of the box’ BY NERIDA KELTON

ITH new exhibitors signing on daily, this year’s AUSPACK PLUS exhibition is gearing up to be the largest biennial multi-platform exhibition of packaging processing and plastics machinery, materials and associated technology in Australasia in 2011. Concept Automation, Satake Australia, the National Distributor Alliance and CDE Design Solutions are just some

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of the exhibitors. According to Richard Roberts, director of Concept Automation, 2011 will be the company’s first exhibition stand at AUSPACK PLUS. “We are very excited about exhibiting at AUSPACK PLUS 2011, as we feel that AUSPACK is the leading event for our industry and that it will provide us with the exposure that we require for our company and our products,” Roberts said. “Concept Automation will be exhibiting its range of

Pharmaceutical, Cosmetic and Food industry packaging machinery, barcode readers, machine vision systems and product inspection equipment. “The Concept Automation Product range consists of Tube Filling, Blister Packaging, Cartoning, De-blistering, Desachet, Film-Wrapping, Case Packing and Palletising and machinery. In addition to, D.O.D. Printing Systems, Turnkey Machine Vision Systems, Bar Code Readers, Check Weighing, Metal Detection, High Shear Mixing and Fluid Bed Systems.” Roger Cook from Satake Australia – a leader in cereal and grains processing equipment – will be exhibiting on stand 776. “Satake Australia are using the AUSPACK PLUS 2011 Exhibition to launch their new full colour RGB optical sorter ‘Evolution’ to the Australasian market,” Cook said. “Satake’s latest optical (colour) sorter brings a new level of safety and security to the inprocess and final inspection of granular products. The Evolution RGB platform is able to detect not only distinct colour differences, but also shade differences between similar colours. Using high speed air ejectors, the Evolution removes unwanted foreign material reliably and with minimal loss of good product.” The National Distributor Alliance, a distributor of packaging equipment and packaging consumable products, such as stretch wrap, protective packaging products, packaging tapes,

specialty tapes, adhesives and all products associated with a company’s warehousing facilities would require, will be exhibiting on stand 752. The Alliance has a number of sites situated throughout Australia and New Zealand, servicing companies involved with manufacturing and distributing goods. On stand 752 will be Carton Sealing and Packaging Equipment. They will be demonstrating one of the Ranpak’s protective packaging systems machines, and will also be launching a range of security tapes and tamper-evident tapes and packaging systems produced by Tesa Tapes. Stand 627 will be occupied by CDE Design Solutions – a full package engineering service complemented with a full design and drafting team. They offer design and engineering services to tackle almost any project with engineers, designers and drafting personnel who are factory and industry based and understand how to work with you to develop your initial process concept thoughts through to final design. AUSPACK PLUS is owned and presented by the Australian Packaging and Processing Machinery Association, and will take place from 22–25 March at the Melbourne Convention and Exhibition Centre. [Nerida Kelton is AUSPACK PLUS public relations coordinator.] AUSPACK PLUS 02 9556 7972, www.auspackplus.com.au

Manufacturers’ Monthly MARCH 2011 35

Preview

Expo attracts global players WITH twenty international companies signed on to exhibit at AUSPACK PLUS 2011, visitors will have the opportunity to view new and innovative products from the global packaging market. This year, companies from China, Japan, Germany, Korea, Singapore, New Zealand, Taiwan, Malaysia, The Netherlands and India – and of course Australia – will be exhibiting at this not-tobe-missed event. Krüger & Salecker (K&S) – a leading manufacturer of processing machines serving the food

industry worldwide – will be travelling from Germany to participate. Since 1948, K&S has been designing machinery for various applications in the confectionary market, and has continually developed its offerings, including adding food moulding and shaping technologies. Visitors to the stand will be able to view unique technology in the form of the company’s GFT/GFW-series, enabling them to detach from the ‘classic’ cereal bar, which is very restricted in shape and binder mixtures. New and creative shapes as

well as sugar and/or fat reduced binders are only a few of the diverse advantages of the K&S technology. Another international exhibitor coming from China is UTIEN Pack, which specialises in manufacturing and developing vacuum packaging machines, sealer series and filling machines. The company will be showcasing a packaging machine on stand 320. The machine is a fully-automatic vacuum packaging unit applicable for vacuum, gas-filling and skin packaging of foods and medical products.

Packaging association THE Australian Packaging and Processing Machinery Association (APPMA) is an Australian organisation representing leading manufacturers, importers and exporters of pack-

36 MARCH 2011 Manufacturers’ Monthly

aging and processing machinery and allied products. The Association is the brains behind AUSPACK PLUS, which alternates biennially between Sydney and Melbourne. Visit the website

for a membership application, or see them at the exhibition on stand 526. Australian Packaging and Processing Machinery Association (APPMA) 02 9371 2769, www.appma.com.au

Provides short-run labelling.

Proofing, prototyping AUSPACK PLUS 2011 will see Roland DG focusing on packaging proofing and prototyping and short-run labelling solutions, with its VersaUV series UV-LED inkjet printers. Across a vast array of substrates, the Roland VersaUV series prints CMYK, White and Clear Coat, and automatically contours cuts. It reproduces realistic textures and 3D effects, and creates a variety of graphics from design prototypes to layouts and small-lot production of specialty graphics. Roland DG 02 9975 0000, www.rolanddg.com.au

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Fill weigh doser TECHNO-Pak will be showcasing a new entry-level semi-automatic fill weigh doser machine on stand 432 at AUSPACK PLUS 2011, which will be held on 22 to 25 March at the Melbourne Convention and Exhibition Centre. According to Jimmy Calderaro from Techno-Pak, the fill weigh doser can fill premade bags, pouches, jars, tubs, containers and trays. “The fill weigh doser machine is stainless steel, wash down, and also modular. It is fully programmable and can weigh powder and granular products from 10 grams to 3000 grams,” he said. The stainless steel version machine includes: all food contact parts in stainless steel construction Inox AS 304; washdown; fully-programmable with touchscreen interface; and more. The dosers are easy-to-manoeuvre in workshops and production

The doser is semi-automatic.

areas and a demonstration model will be available during the show on the Techno-Pak stand.

Blow, injection moulders

The vision system offers colour inspection.

Machine vision system

A & J AUSTRALIA will be exhibiting blow moulders and injection moulders, jerricans and cubes from 500ml to 110 litres, pails from 1.2 to 23 litres, and inmould labelling on stand 358. A & J Australia is a manufacturer of Titonwrap pre-stretch – bioriented and uni-oriented with and without a reinforced edge. They are also manufacturers of cast and blown wraps, conventional wraps from 12um to 35um plus high metallocene wraps. In addition, the company makes wrapping and carton sealing machines.

ADEPT Electronic Solution will be showcasing a DALSA Boa Machine Vision system, iNspect software and a Boa vision system on stand 442 at AUSPACK PLUS 2011. The Boa is said to set a new standard for colour-enhanced smart camera solutions. Colour inspection is often a requirement in the packaging industry and Adept’s highly-integrated Boa smart camera offers the ability to be deployed in a broad range of colour inspection applications, such as identification of parts or assembly features, sorting, counting, and verification of colour hue. The camera delivers an extremely capable colour solution and great performance.

A & J Australia 03 9318 0886, www.ajaustralia.com.au

Adept Electronic Solution 08 9242 5411, www.adept.net.au

The company distributes moulders and cubes.

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Manufacturers’ Monthly MARCH 2011 37

Fasteners& ADHESIVES The technology is expected to go to market before the end of the year, subject to industry regulation and standards approval. It will reportedly be available to the construction industry within the next six months, and within the next two years for the automotive sector.

Choosing the right adhesive

Poor selection of adhesives can lead to premature ageing of surfaces and products.

Meeting market needs Choosing the right industrial adhesives can improve speed of the production line, along with saving money on the production budget, writes Annie Dang.

DHESIVES can provide a range of opportunities to manufacturers and product assemblers to help speed up their manufacturing processes, ensure performance consistency, and reduce customer complaints and warranty claims by stabilising assemblies. The benefits are seen particularly in the case of pre-applied adhesives, when used as a complimentary additive to a fastening system. Headquartered in Melbourne, Belmatic Industries, a leading applicator of chemical locking material, is currently working on a number of new adhesives technologies, mainly targeting 38 MARCH 2011 Manufacturers’ Monthly

the construction and automotive industries. The company is currently trialtesting a new, yet-to-be-named fastener coating technology which has reportedly been specifically to fill a void in the current Australian market. The new application technology, a nylon-based adhesive, is said to provide improved strength and durability at a lower price compared with other technologies available on the market. It was reportedly designed not to react with plastic surfaces, thus preventing the occurrence of corrosion and falls within the category of

environmentally sustainable industrial products. “In the construction and automotive sectors, demand for adhesive products centres around the need for efficiency and functionality in the manufacturing process. Fasteners that are pre-coated are dry to handle with no fumes or mess, thus reducing OHS risks,” David Strutt, managing director of Belmatic Industries, told Manufacturers’ Monthly. “The fact that the technology can also be applied to various applications makes it attractive for the wider industry,” Strutt said.

To maximise the potential in adhesive application, Strutt advises manufacturers to carefully study the material data sheet, understand the basic component of the compatibilities within the assembly, along with the temperature rating and the performance of the adhesives both at hot and cold temperatures. Choosing the right pre-coated fastener adhesives can provide a wide range of benefits to the production line as well as the budget. Uncoated fasteners or poor selection of adhesives can lead to breakdown in production systems, premature ageing of surfaces and products, and can also lead to faster wearing of materials used in the material line. To ensure that that right adhesive has been chosen, manufacturers need to assess the assembly to ensure there is no conflict with components and materials, the temperature rating is adequate and the torque required is at the right level. According to Strutt, the right adhesive technology should meet the requirements for the applications and work well enough so that the application can be disassembled when required. “Durability and flexibility is essential to adhesive fastener applications. In manufacturing, joining and disassembling applications are generally part of the production process,” he said. “If you have a good technology that works so well that you can’t disassemble when you need to, then it may not be the right sort of product for your production,” says Strutt. Belmatic Industries 03 9459 8097, www.belmatic.com.au manmonthly.com.au

Bonds everything Loctite® Advanced Bonding Technologies No matter what kind of substrates* or assembly you have, we’ve got adhesives that can bond them. In fact, the variety of products and technologies we offer is unrivaled. Does your application demand high-speed manufacturing? Bonding versatility? Gap filling? Long-term durability or chemical and moisture resistance? Whatever the application, we’ve got adhesives that can hold it.

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1300 88 555 6 or visit

Adhesives & FASTENERS Fastener capability in coating processes BELMATIC Industries are now offering Henkel’s Loctite fastener coating processes, which reportedly expands processing capability and employment. The company has installed a dedicated processing line to apply Loctite coatings to any manufacturer’s fasteners. According to the company, pre-applied fastener coatings ensure faster assembly, precise tensioning without sheering and no leaks, loosening or rattles to cause warranty claims. With a dry-finish application there are reportedly no fumes, no drips and reduced OH&S risks The addition of this processing capability to handle the Loctite coatings means that the company can now supply fastener adhesives, sealants, lubricants or anti-friction coatings from all leading brands. Belmatic Industries 03 9459 8097, www.belmatic.com.au

Silver-filled epoxy adhesive MASTER BOND has released the EP21TDCS-LO, an electrically conductive silver-filled epoxy for the electronic, electrical, computer, semiconductor, aerospace and optical industries. The epoxy passes ASTM 595 for NASA low outgassing specifications, making it suited for demanding applications where superior electrical conductivity and NASA low outgassing certification is required. The adhesive cures at room temperature in 24 to 48 hours. If the temperature is raised to 200ºF, curing time drops to one to two hours. The adhesive creates strong bonds, and features a tensile shear strength of more than 1,800 psi, a T-peel of greater than 5 pli, and outstanding adhesion to similar and dissimilar substrates. The volume resistivity of the system is less than 10–3 ohm-cm. According to the company, the EP21TDCS-LO epoxy is serviceable over the range of 4K to

The adhesive can withstand thermal cycling.

275ºF, making it suitable for cryogenic applications. It withstands thermal cycling and is resistant to chemicals, including water, oil and most organic solvents. The epoxy is activated by a 1 to 1 mixing ratio by weight or

volume. It is low drip and can be applied with a syringe, knife, spatula or trowel to vertical surfaces without sagging and only contact pressure is required for curing. Master Bond jbrenner@masterbond.com, www.masterbond.com

Super Seal Total prevents leaks

Increase productivity in your manufacturing process by pre-coating all your threaded fasteners. Stop the shake, rattle and roll…. Microencapsulated coatings available for: every type of threaded fastener all applications every assembly process Dry finish, Easy handling No drips, no mess, no fumes, NO WORRIES Extensive range includes: Loctite, 3M, ND …

Ask Belmatic to provide the ideal solution for your needs. Belmatic Industries Pty Ltd 12 Kylta Rd, Heidelberg West VIC 3081 P: 03 9459 8097 W: www.belmatic.com.au

APPLIED FASTENER COATINGS • SPECIALISED PRECISION ENGINEERING 40 MARCH 2011 Manufacturers’ Monthly

CLIPLIGHT Manufacturing Company has released Super Seal Total, a preventative maintenance system designed for HVAC/R systems to lower energy costs and reduce carbon footprint. Super Seal Total combines three products, Dry R, Super Seal and a ultra-violet tracer dye, to prevent the formation of refrigerant leaks, which drain energy and pollute the environment. It is a low viscosity, particlefree liquid formulated to circulate with the oil and refrigerant throughout the system until it encounters a leak. According to GO Distribution, Super Seal Total can help avoid expensive overhauls or replace-

The product is suitable for micro leak repairs and larger leak detection.

ment of heating, ventilation, air conditioning and refrigeration systems (HVAC/R) used in factories and industrial and processing plants. Super Seal Total is suitable for existing micro leak repairs and larger leak detection simultaneously. GO Distribution 1300 544 369, www.cliplight.com manmonthly.com.au

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Compressors& PNEUMATICS

Proper maintenance can help to reduce energy inefficiency in compressed air systems.

Cutting the cost of energy Choosing the right compressed air system for your manufacturing needs can lead to significant energy savings in the plant, writes Annie Dang.

HE most costly part of running a compressed air system is energy and with the cost of energy rising steadily, Australian manufactures are now more than ever looking at more concrete measures to cut their electricity, water and gas bills. In Australia, compressed air systems reportedly consume up to 10% of all industrial electricity and can consume up to four times their energy budget compared to their initial purchase price. But depending on the application, this ratio can reportedly be even higher. According to Michael Knowles, national marketing manager for Sullair Australia, a leading manufacturer of rotary screw air compressors, the biggest contributor to energy waste in compressor systems is poor design. “Choice of air compressor design determines energy efficiency,” Knowles told Manufacturers’ Monthly. “The wrong compressor for the 42 MARCH 2011 Manufacturers’ Monthly

job often results in energy inefficiencies. A compressor that is too small for the task will run at a higher level than it is designed making it energy inefficient, while a compressor that is running below its recommended parameters is not being used to its full potential will also be inefficient,” he says. In terms of design, Knowles says there are four key areas that constitute any compressor: the drive and motor, the method of compression, the method of heat removal and the air-end intake point. The other is the removal of heat. “By its very nature, compressing air generates heat. Any compressor therefore requires the input of cooling air or liquid and the output of heat energy,” said Knowles. “The efficiency of both of these processes combined with the design elements previously noted determines the overall energy efficiency of the system.

“All these components are designed to achieve two things: reduce the amount of energy required to drive the compressor, and minimise the energy wasted through heat generation, pressure losses and poor compression techniques.” Kaeser national sales manager, Mark Dudman, says that the best approach for manufacturers looking to cut their energy costs is to undertake an assessment of their production processes and requirements. “Choosing the wrong compressor for the application may result in poor energy usage, higher energy costs and potentially higher maintenance costs,” Dudman said. Assessments, such as airaudits, can help firms analyse their current compressed air usage as well as helping to determine load variations and potential weak points in the system. While the audit process can take up to two weeks, including

observations, site visits, evaluations and recommendations, Dudman says the benefits of getting a proper assessment can reap significant savings on energy bills as well as overall cost of production by enabling the right system is chosen. The findings from the analysis will not only determine the correct sizing, but the system configuration in terms of utilising either one or more compressors which is often referred to as base load splitting, he says. The control of a compressor system is also a major consideration and can again result in significant energy savings, with many options available on the market enabling multiple unit stations to be set up where compressors are load matched to meet the demand. Poorly positioned compressors can also result in higher maintenance cost due to such issues as bad ventilation, resulting in higher running temperatures, clogging of filters and reduced life expectancy of parts. The key thing to remember, Dudman says, is not to be misguided by the conception that the bigger the compressor, the more powerful and efficient it is for the task, but to fully assess the plant air usage in order to determine the correct solution. According to Sullair’s Knowles, there are a number of steps for manufacturers can take to help to reduce the amount energy consumed of running compressors. These include: providing a clean and appropriate environment for the compressor; choosing the right compressor for the application; maximising efficiency improvements on existing equipments; signing-up for regular servicing; and continually looking for heat recovery savings where these can be applied. “It is essential that manufacturers and people in the industry understand the importance of choosing the right compressor for the task,” says Knowles. Sullair Australia 1300 COMPRESSOR, www.sullair.com.au Kaeser Australia 1800 853 133, www.kaeser.com.au manmonthly.com.au

Compressors &PNEUMATICS Compressed air dryer prevents condensation

The true cost of air leaks The value of compressed air as an energy source is several times higher than that of electricity so even small leaks add cost over time, writes Lars Akerlund.

The system’s refrigeration cycle is controlled by a hot gas bypass.

DONALDSON Australasia has released a range of refrigeration-compressed air dryers suitable for any industrial area where compressed air is used to run the plant. The Buran range is reportedly ideal for various industries, including general manufacturing and processing, food sector, pharmaceutical and hospital. By refrigerating compressed air, the Buran reportedly dries the air to prevent condensation and corrosion damage. The dryers are equipped with electronic-level-controlled condensate drain and a dew point indicator. The cooling capacity of the refrigeration cycle is controlled by a hot gas bypass, which is said to assure secure functioning, even during partial loading. According to the company, the addition of an aluminium heat exchanger reduces pressure loss as well as operating costs. The unit has a user-friendly control panel for easy monitoring of operating status. Donaldson 1800 345 837, www.donaldsonfilters.com.au

44 MARCH 2011 Manufacturers’ Monthly

OMPRESSED air is often taken for granted in most manufacturing facilities. Yet the cost of this source of energy is easily overlooked or underestimated. In fact, the value of compressed air as an energy source is several times higher than that of electricity. So, even small leaks add cost over time. In addition to finding and plugging the leaks, it is important to have a regular maintenance schedule, as well as ensure ongoing awareness. It’s the old saying, ‘If you can measure it, you can improve it’. Large air leaks are rarely difficult to identify, but once the obvious leaks have been eliminated, finding the smaller ones is not always as simple. The sounds generated by smaller air leaks are often not detectable by the human ear, especially in a noisy factory environment. So a more effective and practical approach is to use a hand-held ultrasonic leak detector with good-quality earphones. Such devices are available with extension kits to reach around corners or fitted with parabolic antennas to detect leaks further away. In terms of keeping track of and trending the flow of air, there are several methods and instruments available. However, one very important aspect is to ensure that the readings provide meaningful information. The volume of air is sometimes referred to as actual volume. Since air expands and contracts with changes in pressure and temperature, measuring just the volumetric air flow provides only part of the picture. The term standard or normal volume is a more useful parameter as it provides a reference measurement. For example, 1 normal cubic metre (Nm3) of air is generally defined as 1 actual m3 of air at a pressure of 1013.25 mBar (a) and at a temperature of 0°C. So, measuring and logging air consumption in Nm3 provides

The sounds generated by smaller air leaks are often not detectable by the human ear.

an easy way to, as they say, compare apples with apples. One interesting aspect of the term normal volume which is often overlooked is that, despite the terminology, it is in fact not a unit of volume but a unit of mass. Consider the example of a balloon which holds 1m3. If the pressure inside the balloon is 1025 mBar (a) and the temperature is 0°C, then you have 1 Nm3. Squeezing the balloon will increase pressure and make it smaller, but the content (mass) inside the balloon will remain the same. As normal volume is a unit of mass, consequently measuring the mass flow of air provides a practical method of determining the flow in Nm3 without the need for pressure or temperature compensation, or the associated cost of installation and upkeep of such gauges. There are several types of mass flow meters on the market. One example is the insertion mass

flow meter which can be fitted and removed from the pipe work under pressure using a simple ball-valve assembly. This simplifies regular testing as the same sensor can easily be moved between different testing points, providing a stream of valuable datalogging with timestamps and flow rates directly in normal volume. Kits with a GSM modem are available to upload the data directly to a website. One starting point when deciding to evaluate air losses is to first measure the normal air flow on a day or at a time when the compressor is running, but with no factory production. The results can be surprising. Regular measurements, as the leaks are gradually identified and plugged, will provide a quantifiable measurement of cost savings to the bottom line and to the environment. [*Lars Akerlund is managing director of Pricam Automation.] Pricam Automation 03 9532 2235, www.pricam.com manmonthly.com.au

Compressors &PNEUMATICS

Partnership improves compressors Variable speed drive (VSD) technology is increasingly being deployed in air-compressor applications to cater for variable loads, with the components continuing to improve. Sean Richardson and Andrew Dove write.

TANDARD electrical motors are usually in one of two states – on or off. In these cases, the speed of the motor is fixed. Single speed motors typically drive fans, pumps, compressors and the like. The principal drawback of this type of on/off, fixed speed motor is that the speed may not be optimised to the demand of the application: it may be running too fast and wasting energy or, too slow and struggling to perform, creating undue stress on components. The motor will always be in a state of compromise. Single speed motors are most suited to applications when running at 100 per cent capacity for fixed periods and then turned off when no longer required. In many instances, an air-compressor application may have varying demands, for example changes in production shifts or ramping up or down of specific machines in a plant. In a typical facility there may only be a short time of the day during which the full 100% of air compressor capacity is required. For a fixed speed load on/load off motor, maximum efficiency only occurs when operating at 100 per cent capacity—the remainder of the time these devices will consume energy unnecessarily. Variable speed drive compressors alleviate these issues by better aligning the power intake and energy demand to the load variances of the specific application. Historically, traditional VSD compressors were perceived to have limited usage. Drive life was a concern if heat from the drive was not adequately dissipated. Low speed operation was inefficient resulting in motor derating. Overall, drive life was not great and drive replacement costs were comparable to the replacement of the entire compressor. Motor life insulation issues compounded the problems for the drives. In some instances 46 MARCH 2011 Manufacturers’ Monthly

A VSD compressor may increase energy efficiency by as much as 30–35 per cent if applied in the right circumstances.

VSD compressors could not easily be run from power generators due to problems with harmonic interference with the drive. The initial costs of a VSD system and the reduction in efficiency when used at full capacity were also key shortcomings. When used appropriately the system gains of variable speed drives outweigh any restrictions. The positive outcomes include reduced mechanical stress on the motor and consequently reduced maintenance and repair costs; greater control and automation allowing the operator to finetune response to specific application demands, and significant energy savings in varying load situations. In recent years, government and industry have promoted the use of machinery with greater energy efficiency, particularly with respect to compressors. It is estimated that as much as 10 per cent of the electrical power consumed by Australian industry is expended on compressed air. A compressor typically is the largest single user of energy on site and an estimated 86 per cent of the cost of a compressor over its lifetime is spent on energy. The installation of a VSD compressor may increase energy

efficiency by as much as 30-35 per cent if applied in the right circumstances. WEG design and manufacture variable speed drives and motors and have developed several patented technologies including Optimal Flux Technology and the WISE Insulation System to overcome the deficiencies of traditional VSD technology. WEG have partnered locally with Sullair – a global manufacturer of compressed air technology – to develop the Champion range of VSD air compressors made here in Australia. The key feature of WEG’s Optimal Flux Technology is the ability to maintain the torque at low speed by optimising the flux density of the motor. The WISE Insulation system is designed to protect motor windings and limit voltage pulse intervals and peaks typical of the VSD application. Motor torque is a function of voltage, frequency and current. In order to maintain torque at low motor speeds, earlier versions of VSDs increased the current at lower motor output frequencies. The downside to this approach was a significant rise in operating temperature since fans were directly coupled to the motor shaft. As the speed of the

motor slowed, the motor fan would slow, compromising the fan’s cooling efficiency. WEG has solved that problem by increasing the voltage/frequency ratio, thereby minimising the temperature rise associated with increased current. For every 10oC decrease in operating temperature, the motor life is doubled. WEG’s Optimal Flux technology eliminates this issue making forced external cooling and ventilation requirements redundant. WEG has developed the WISE Insulation System for all its industrial motors to insulate against high voltage spikes and rises associated with the use of VSDs. The technology is designed to reduce stresses on the motor windings thereby prolonging motor life. Whenever air demand is less than the full capacity of the air compressor, the Champion VSD range achieves energy savings compared to traditional on/off load compressors. Given the significance of compressed air to industrial power bills, users have found that the Sullair Champion range of VSD compressors can save thousands of dollars per annum. Installing a VSD compressor may have higher up-front >> manmonthly.com.au

Compressors &PNEUMATICS continued from page 44

costs, but the energy consumption savings achievable may see a payback period of as little as six months. The benefits of the Optimal Flux Technology, WISE Insulation, variable speed and removal of external cooling requirements translates into a more energy efficient and reliable compressor. To benefit from the energy savings available from the VSD range, the size of the compressor needs to be chosen to match those requirements. Sullair Australia offer air audits to assess the overall air demand of an installation. From an air audit, air demand, load variation and usage levels are calculated to determine which compressor system is appropriate. This is the safest, surest way of selecting the most suitable compressor. *Sean Richardson is product manager with WEG Australia; Andrew Dove is product development manager with Sullair Australia. Sullair Australia 03 9703 9014, www.sullair.com.au WEG Australia 02 9616 3900, www.weg.com.au

Intelligent controller COMPAIR has launched the DELCOS XL, a built-in, easy-touse touchscreen controller designed to ensure the reliable and efficient operation of its rotary screw compressors. Fitted to CompAir’s L30–L132 range of fixed and regulated speed compressors, the company says the DELCOS XL displays detailed system analysis, including network pressure and weekly average volume flow, in the form of on-screen trend diagrams and graphs. No additional monitoring devices are reportedly required. Analysis of these trends enables users to set precise operating parameters for their compressor. The multilingual control system will then continuously monitor these settings, helping to reduce overall running costs. The controller’s real time clock enables users to start and stop their compressor at pre-set times. This allows the system to

The controller features a real time clock.

be pressurised prior to production, meaning users can have instant availability of compressed air. All of the controller’s functions are clearly structured within just

“Whether Le Mans, Sebring or Daytona to win here is a question of efficiency; of the team, the cars and the equipment. And for that reason, when it comes to our compressed air supply it has to be BOGE.” Franz Konrad, Konrad Motorsport

five main menus on a userfriendly high-resolution touch screen display. All menus can be code protected to eliminate any misuse or incorrect operation. CompAir 03 9212 5800, www.compair.com

BOGE AIR. THE AIR TO WORK.

www.boge.net.au

Who wins a race is not just decided at the ﬁnishing line but also in the preparation stages. No one knows this better than Franz Konrad, owner of Konrad Motorsport. For 35 years he has successfully raced, including winning the team title at the Porsche Mobil 1 Supercup. He now wants to repeat this success with 3 ultra-powerful “Porsche GT 3 Cup”, a feat only possible with absolute precision and perfection in every detail. That’s why a BOGE RM series piston compressor is essential to him.

48 MARCH 2011 Manufacturers’ Monthly

manmonthly.com.au

Screw compressor power BOGE has extended the C series range of screw compressors up to 22 kW. The extended range has been engineered to generate high free air deliveries in continuous operation and in an incomparably efficient manner. The C 15 to C 30 is said to provide a quiet, compact and efficient compressed air solution to the medium sized compressed air user. According to the company, all essential components have been integrated into the compact module to eliminate pipework and reduce flow losses. The C series models feature low sound pressure levels from 63-69 dB(A) with energy demand ranging from 7.08 â&#x20AC;&#x201C; 7.16 kW/m3/min, according to ISO1217AnexC/PN2 CPT2. It is available in the standard pressure of 8, 10 and 13 bar. Output capacities range from 1.36 â&#x20AC;&#x201C; 3.62 m3/min and motor power 11 to 22 kW.

manmonthly.com.au

Compressed air upgrade maximises efficiency

The units power a number of the company's processes.

An installation surface of less than 1msq is sufficient.

The new range is also available with an integrated refrigerant dryer. Boge 08 9528 2157, www.boge.net.au

WEIR Minerals Multiflo, a manufacturer of mine dewatering pump-sets, has recently upgraded its ageing compressed air system with a new solution from BOGE Compressors. Compressed air was required at the company's new facility to power a number of processes including die grinders, pneumatic drills, air wrenches and spray booth. Pacific Compressed Air was commissioned to provide an

improved compressed air efficiency solution and subsequently recommended BOGE S 40-2 and S 502 screw compressors. A complete compressed air treatment system was also installed into the facility. The S series screw compressors reportedly features a compact design to ensure maximum efficiency and a specially designed airend to provide high output volumes. BOGE Compressors 08 9528 2157, www.boge.net.au

Manufacturersâ&#x20AC;&#x2122; Monthly MARCH 2011 49

ProcessCONTROL & SENSORS Image with colour camera vs. grey image using white illumination.

Machine vision in full view BY SEAN CARTER

ACHINE vision has come a long way in the last thirty years. In the early days of computing it was difficult to process even moderately large sets of image data. But by the late 1970s technology had advanced to the point where more focused studies could occur and technological spin-offs for industrial purposes began to appear. Early machine vision systems often consisted of bulky cameras and separate controllers using processors, such as the Motorola 68000. Even in these early days, equipment developers realised that the possibilities for applying this technology were almost limitless and very quickly appreciated that almost any material handling or logistic process that involved object inspection would suit a vision system. From rudimentary beginnings, machine vision suppliers have developed machine vision systems into ‘smart cameras’, integrated vision systems which, as well as possessing image capture capability, are able to extract information from captured images and make decisions that are used in wider machine automation systems. Modern smart cameras are

50 MARCH 2011 Manufacturers’ Monthly

self-contained, standalone units with built-in image sensors, communication interfaces, and industry standard outputs for connection to PLCs where processing of the image takes place. Most units are now no larger than an ordinary industrial or surveillance camera, but rival PCs in terms of their processing capabilities. Typical applications have grown to include detection of faults and flaws, non-contact measurement, part sorting, code reading, continuous flow dimensional gauging, and position detection and rotation. Industries where these applications are commonly used are automotive, electronics, food and beverage, logistics, manufacturing, packaging, pharmaceuticals, steel and wood.

Label checking on soap packages Commonly used techniques used include edge detection, template matching, thresholding, segmentation, blob extraction, pattern recognition, barcode reading, and optical character recognition. However, most smart cameras remain expensive and require extensive integration by developers to be effective. Custom programs often need to be devel-

oped for applications or off the shelf software from third parties must be adapted. This is why machine vision system suppliers have more recently developed cost effective and user friendly 2D vision systems – now commonly known as vision sensors. Vision sensors are compact, practical, and have reliable 2D imaging with integrated lighting, image evaluation and Ethernet interfacing. They are designed for trouble-free and fast solving of a diverse range of part inspection applications, are capable of inspecting parts in any orientation and position and have a predictable response time, making them ideal for packaging and small part assembly. A vision sensor’s robust design is suited for industrial applications and its intelligent and fast evaluation algorithms enable it to keep up with high processing speeds. In large production plants that have the need to solve a variety of inspection tasks with different set-ups, it is important to have a flexible solution as well as a complete centralised control of the production. This is normally not possible to achieve with a vision sensor. Therefore, customers may have to choose from more complex and expensive

smart camera solutions. However some newer vision sensors offer part inspection at smart camera level of performance. This means high performance inspection, flexible setup and complete production control support – without increasing the complexity and cost of the solution. More importantly they are able to offer high resolution VGA imaging (640x480 pixels), which provides improved image quality and enables inspection at higher accuracy or on wider areas without compromising speed. Powerful inspection tool sets provide for straightforward, easy-toconfigure problem solving abilities, enabling easy solutions for tough targets and a common unit across a number of solutions. They come in the flexible housing designs for easy lens exchange, and to make them even more adaptable, a number of easy-to-set-up illumination accessories are available. This concept combines built-in illumination with different front windows, resulting in red, green, blue or diffused white illumination – without any extra wiring – illumination has never been easier! [*Sean Carter is product market manager at SICK.] To view the full article, go to bit.ly/eWiFYs. SICK www.sick.com.au Comment at manmonthly.com.au manmonthly.com.au

Dead-weight testers

Heavy duty pressure transducer NOSHOK 640 Series Precision Heavy Duty Pressure Transducers with Serial Interface feature advanced diffused semi-conductor and sputtered thin film technology which reportedly provides maximum stability. The transducers were designed for industrial and laboratory applications requiring high accuracy and repeatability, including research and testing, aeronautical, precision controls, marine, power generation, and medical. The Transducers’ compensation systems are said to virtually eliminate temperature-induced errors from 50°F to 104°F. They offer a standard digital output with an RS232, 8N1/9600 Baud serial interface (other outputs and electrical connections are also available). The units offer vacuum ranges through 15,000 psi, and absolute ranges from 15 psia to 300 psia. They also offer high over-range

The testers meet primary pressure standards.

THE DH-Budenburg 583 series of dead-weight testers meet primary pressure standards, with metrology-class pistons, giving an uncertainty of better than 0.005% with DH-Budenberg effective area and mass certification. The 583 series comes in a range of pressures from 200 to 5000 bar, and features a new hydraulic base which will reportedly offer easy priming and highpressure generation, from the integral dual area screw-press.

The transducers offer high accuracy and repeatability.

protection, and a standard -inch NPT process connection.

AMS Instrumentation & Calibration 03 9017 8225, www.ams-ic.com.au

Powerful strain gauge converter for industrial applications WEIDMULLER’S new ACT20P Bridge is a strain gauge converter designed for signal isolation or conversion in industrial applications. The unit features the latest in microprocessor technology and is said to deliver outstanding performance and reliability. The Bridge is reportedly compact and lightweight, with a width of 22.5mm and weighing only 150 grams. Via a 10-60Vdc power supply, the ACT20P Bridge powers the strain gauge using selectable 5 or 10V excita-

manmonthly.com.au

tion supply. The device converts the mV signal to an industry standard of 0-(4)-20mA, or 0-10V signal with an accuracy better than 0.05% within an operating temperature range of -40-+70ºC. The ACT20P Bridge can reportedly be configured quickly and simply, and offers push-button calibration with the ability to skip previous calibrated points. All calibration points are stored in non-volatile memory ensuring secure retention. It also features a tare or zero

DH Budenburg 08 9562 7150, www.dh-budenberg.com.au

Precision flowmeter

offset function, which can be activated from the front panel or by external contact closure.

COX Flow Measurement’s COX LoFlo Series turbine flowmeter is a rugged, precision axial turbine flowmeter with repeatability of ±0.25% of reading. Constructed of 316 stainless steel with -6 AN (MS) end-fittings, the meter employs a proprietary Si3N4 ceramic ball bearing system, which makes it well suited for the demands of water, hydrocarbon and cryogenic fluid applications.

Weidmuller 1800 739 988, www.weidmuller.com

COX Flow Measurement www.ntkinternational.com

Manufacturers’ Monthly MARCH 2011 51