manmonthly.com.au
MANAGEMENT >> TECHNOLOGY >> SOLUTIONS
JUNE 2021
Global leader in energy efficient compressed air solutions
Sales experts who speak your language! Atlas Copco are leading the
development and manufacturing of air compressors, industrial gas
generators and many more compressed air products. We can guarantee that our compressed air products bring
operational benefits to all industries,
while still maintaining a low total cost
of ownership. Buying an air compressor that meets the needs of your facility is a big decision - for you and your
business. We want to ensure you receive maximum benefits from your business
decisions. There are many air compressor brands and models available in the
market, which can make buying the right air compressor tricky.
Luckily, we speak your language!
What we can offer you!
Service is our strength!
> Air compressors > Gas compressors > Gas generators > Air blowers > Air dryers > Air filters > Air receivers and aftercoolers > Energy recovery > Easy service > Spare parts (including competitors) > Lower total cost of ownership
Our highly skilled technicians are available Australia wide. Project planning, optimisation, servicing and maintenance are just a few of the pillars of our service philosophy: * Compressed air management and energy saving concepts * Audits to determine the compressed air requirement * Certification * Remote monitoring * Original spare parts with manufacturer’s guarantee www.atlascopco.com 1800 023 469
manmonthly.com.au
MANAGEMENT >> TECHNOLOGY >> SOLUTIONS
JUNE 2021
BATTERY PRODUCTION TO KICK OFF NEW ERA IN AUSTRALIAN MANUFACTURING
Official Industry Partners
INSIDE >>
Print Post Approved PP100007882
24
38
31 OT cybersecurity – the key to operational resilience
Hoists that are unique in the market
Committing to sustainability in manufacturing
>>
manmonthly.com.au twitter.com/Manmonthly facebook.com/Manmonthly
Inside
For daily news visit manmonthly.com.au
JUNE 2021
linkedin.com/showcase/manufacturer’s-monthly/
CEO: John Murphy
34
Publisher: Christine Clancy Group Managing Editor (Northern): Syed Shah syed.shah@primecreative.com.au Journalist: Caroline Tung caroline.tung@primecreative.com.au Production Coordinator: Michelle Weston michelle.weston@primecreative.com.au Art Director: Blake Storey
20
Design: Kerry Pert, Madeline McCarty Sales/Advertising: Danilo Cortucci Ph: 0434 419 663 danilo.cortucci@primecreative.com.au Subscriptions Published 11 times a year Subscriptions $140.00 per annum (inc GST)
Manufacturers’ Monthly Contents 6 Editor’s Note
30 Machine Maintenance
37 Compressors
8 Comment
31 Lifting Solutions
38 Sustainability in Fabrication
12 News@MM
32 Compressors
39 Sensors
20 Industry Focus
33 Women in Industry
41 What’s New
24 Network Security
34 Compressor Maintenance
44 The Last Word
26 Energy Savings
35 Bulk Handling
28 IIoT and Connectivity
36 Welding
Overseas prices apply Ph: (03) 9690 8766
Copyright Manufacturers’ Monthly is owned by Prime Creative Media and published by John Murphy. All material in Manufacturers’ Monthly is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy
PACE Contents
of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on
3 News
8 IIoT in Business
6 Bearings
9 Drives & Belts
10 New Products
information published. The opinions expressed in Manufacturers’ Monthly are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2019 Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format.
Behind the cover
manmonthly.com.au
JUNE 2021
Head Office
South Melbourne VIC 3205 P: +61 3 9690 8766 enquiries@primecreative.com.au www.primecreative.com.au Sydney Office Suite 3.06, 1-9 Chandos Street Saint Leonards NSW 2065, Australia P: +61 2 9439 7227
Printed by: Manark Printing 28 Dingley Ave Dandenong VIC 3175 Ph: (03) 9794 8337
4 JUNE 2021 Manufacturers’ Monthly
There have been numerous calls yearly for a cap on carbon emissions – something that is virtually impossible to avoid given the nature of the production chain for many goods and services. Manufacturing requires a lot of energy in the form of fuel or electricity and there are a lot of unwanted by-products as a result. One solution is to look for more efficient sources of energy. There has been great interest in lithium as a fuel source, since lithium is said to be crucial for the transition to renewables, but mining it has been environmentally costly.
A nanotechnology company, VPSC, a developer of advanced cathode powders for lithium-ion batteries (LIB), has a new product, LFMP, a high-capacity LIB cathode powder that contains no nickel or cobalt. It will be made available to battery manufacturers for testing in June 2021. More on that story in PACE. The main story in Manufacturers’ Monthly is also about the increase in the interest of lithium-ion battery manufacturing, and what it could mean for Australia moving forward. Read more about both these stories in this edition.
BATTERY PRODUCTION TO KICK OFF NEW ERA IN AUSTRALIAN MANUFACTURING
Global leader in energy efficient compressed air solutions
Sales experts who speak your language! Atlas Copco are leading the
development and manufacturing of air compressors, industrial gas
generators and many more compressed air products. We can guarantee that our compressed air products bring
operational benefits to all industries,
while still maintaining a low total cost
of ownership. Buying an air compressor that meets the needs of your facility is a big decision - for you and your
business. We want to ensure you receive maximum benefits from your business
decisions. There are many air compressor brands and models available in the
market, which can make buying the
What we can offer you!
Service is our strength!
> Air compressors > Gas compressors > Gas generators > Air blowers > Air dryers > Air filters > Air receivers and aftercoolers > Energy recovery > Easy service > Spare parts (including competitors) > Lower total cost of ownership
Our highly skilled technicians are available Australia wide. Project planning, optimisation, servicing and maintenance are just a few of the pillars of our service philosophy: * Compressed air management and energy saving concepts * Audits to determine the compressed air requirement * Certification * Remote monitoring * Original spare parts with manufacturer’s guarantee
>>
www.atlascopco.com 1800 023 469
right air compressor tricky.
Luckily, we speak your language!
0621 Atlas Copco Full Page Inside Front Cover.indd 1
Official Industry Partners
INSIDE >>
Print Post Approved PP100007882
11-15 Buckhurst St
MANAGEMENT >> TECHNOLOGY >> SOLUTIONS
24 OT cybersecurity – the key to operational resilience
31 Hoists that are unique in the market
38 Committing to sustainability in manufacturing
14/05/2021 2:30:21 PM
manmonthly.com.au
We bring colour into view! Compact capacitive level switches with 360° custom-colour status display
256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction
15 cm
Compact design
Hygienic adapter system
Adjustment via smartphone
$ 243 VEGAPOINT 21 G½"
www.vega.com/vegapoint
Comment
SYED SHAH – Managing Editor, Manufacturers’ Monthly
New budget, smart moves
T
HE federal government recently unveiled $74.6 billion dollars in tax cuts, as well as spending on mental health, aged care, childcare, disability services and infrastructure. Definitely a win for Australia on the whole. When the nation was hit hard on the economic front, relief packages in the form of JobKeeper were rolled out to keep as many businesses in the game as possible. But it was a stopgap that dug into the coffers of the federal government to alleviate a desperate situation. On the manufacturing front, governments rediscovered some purpose in that sector, encouraging many to “pivot” and innovate based on their strengths – to some degree of success. What the industry really needed following the start of the pandemic was a shot in the arm and that came with the $1.5 billion Modern Manufacturing Strategy in 2020 that focused on six key industry areas. Now, the 2021 budget is adding on $475 million to drive industry growth and scientific development, helping to create high paying, sustainable jobs for Australian workers. According to a press statement by Minister for Industry, Science and Technology, Christian Porter, the new funding is part of the federal government’s drive to make the country a globally recognised, highquality, sustainable and innovative manufacturing nation. Part of that funding includes $117.8 million over the next four years to deliver Australia’s first Artificial Intelligence (AI) Action Plan, as part of the Government’s Digital Economy Strategy. This will support businesses who adopt AI and the development AI projects – with the high-skilled jobs that are created in line with these projects along the way. Whether or not that is enough, is debatable, globally, the adoption of AI is still quite far off. According to a PWC research paper Digital Factories 2020: Shaping The Future of Manufacturing,
6 JUNE 2021 Manufacturers’ Monthly
globally, only about nine percent of manufacturing organizations are leveraging AI today. But what else can AI play in industrial and process transformation? For sure there are lots of businesses cases that deliver reasonable value today. Then again, how essential is artificial intelligence in the context of manufacturing? One of the most adopted use of AI in workplaces is screening and safety, driven primarily by the pandemic. It could be used for employee identification, thermal screenings, contact tracing and/or the sanitisation of a facility. Then comes machine maintenance – all
manufacturers hope to keep their facility and production equipment at optimum operational capacity. AI leads to machine learning and can move a maintenance structure from a responsive one towards a predictive or prescriptive one. This could potentially lead to reductions in maintenance windows, annual maintenance spends and parts maintenance. Aside from this, AI can help with cybersecurity issues – by autonomously detecting intrusions, malware, fraud, employee behaviours outside normal baselines, and ultimately elevating threat intelligence within networks
and protect data from cyber attacks. Included within the Budget plan is the establishing of a new national network of Artificial Intelligence Centres to drive business adoption of these new technologies. This will expand Australia’s cyber security innovation fund to train the next generation of cybersecurity experts, and undertake a digital skills cadetship trial, which combines workplace and vocational training. Will there be much to look forward to in 2021 for manufacturing? Definitely some bright moments ahead and hopefully a lot more innovations from local manufacturers.
manmonthly.com.au
GO BEYOND – EXPLORE NEW HORIZONS FOR YOUR INDUSTRY.
Overcome the limitations of known systems and leave the beaten path of those who follow. With SICK at your side, you are always one step ahead. Because intelligent sensor technologies enable better processes and new opportunities for your Industry 4.0 business models. Use trend-setting SensorApps, Deep Learning, and other AI applications, as well as integration and analysis solutions. Let’s go beyond together. We think that’s intelligent. www.sick.com/gobeyond
Comment
GEOFF CRITTENDEN – CEO, Weld Australia
Welders need to be safe at work – both physically and mentally
W
ELDING can and should be considered a safe occupation; when proper precautions are taken, welders have no cause to fear accident or injury. But when safety isn’t taken seriously in the workplace, the risk of a severe incident becomes a real concern. Education is the key to ensuring a safe and productive working environment for everyone. Employers need to invest in thorough and up-to-date training for all their employees to ensure that they understand the risks associated with welding, the mitigation strategies they can use, and the equipment available to prevent accident and injury. Additionally, recognising the risks posed by mental health challenges and addressing these is vital to maintaining a healthy workforce.
Physical risks to health and safety Welders are exposed to both physical and chemical hazards in the course of their work, and they utilise tools that can result in injury and electric shock if used incorrectly. Some of the most common hazards in a welding workplace include exposure to dangerous chemicals and fumes, injuries to the eyes through sparks and vapours, fire and explosions, and electric shock. The process of gas welding involves the burning of chemicals such as argon, hydrogen fluoride and carbon monoxide, opening up the possibility of dangerous chemical exposure. To avoid exposure to chemicals, proper engineering controls (such as local exhaust systems) must be implemented to ensure sufficient ventilation throughout the welding workshop. The welding arc can reach temperatures of up to 5,530°C, 8 JUNE 2021 Manufacturers’ Monthly
posing a risk of fire and explosions. All flammable and potentially explosive materials should be kept well away from welding areas, and workplaces need to ensure that proper emergency procedures are in place. Additionally, welders must always wear PPE in optimal condition to prevent an arc flash, or a burn caused by the ultra-violet radiation of electric welding arcs.
Dangers posed by welding fume In recent years, the welding industry has become increasingly aware of the hazards posed by metal fume produced during the welding process. This fume, comprising of microscopic particles of hot metal and gases, poses serious risks when inhaled by welders. Some of the known health effects caused by welding fume exposure include fever, stomach ulcers, kidney damage and damage to the nervous system. Welders can suffer from asthma, eye, nose and throat irritation, and even lung infections that can lead to pneumonia. In early 2017, the International Agency for Research on Cancer classed welding fumes as “carcinogenic to humans”. It is vital that appropriate strategies are in place to reduce welder exposure to fumes and prevent the long-term health effects that can result from exposure. All welders should receive training on methods to mitigate the effects of metal fume, including positioning themselves to reduce exposure and investigating less toxic alternatives where possible. Local Exhaust Ventilation (LEV) systems capture and extract welding fume at the source and are a proven way of reducing exposure. All workplaces should have fit-forpurpose LEV systems installed and regularly maintained. Weld Australia has released a Technical Guidance Note Fume Minimisation Guidelines: Welding,
Cutting, Brazing and Soldering, which includes all the information required to help protect workers from the hazards associated with welding fumes.
Electrical safety precautions in welding Electrical safety is another area which must be seriously considered when reducing risks to welders. Electricity is a vital part of welding work, but when mishandled it can result in serious injury and death. Between 2014 and 2016, 7 people died due to electrocution while working. According to Safe Work Australia’s Welding Processes Code of Practice, electric shock or electrocution can occur through direct contact with an electrode, live parts, a work piece, or through contact with a device such as an unearthed cable or tool. The risk of electric shock can be exacerbated by moisture and high humidity, both common in welding environments. All welding professionals need to familiarise themselves with processes to minimise the risk of electric shock. Simple actions such as checking that equipment is dry and well maintained and installing shut down mechanisms such as fuses and low voltage safety switches can save lives. Ensuring that all employees are equipped with the knowledge and safety equipment required is key to preventing incidents in the workplace.
Non-compliant welding equipment Welding safety requires constant vigilance to ensure that all equipment is maintained, operating correctly and being used with best practice in mind. Before starting any welding operation, a complete inspection of all welding equipment should be undertaken. The ten minutes required to complete a
thorough check can prevent serious injuries and fatalities within the workplace. Weld Australia has developed a Daily Inspection and PreStart Check List for welders to use, assisting users to check all equipment, connections, and power sources before beginning work. It is important that welders feel empowered to report any unsafe equipment to their supervisor and to ask for new equipment and PPE where it is not provided.
Mental health: a crucial part of keeping welders safe It is well understood that to work effectively and safely in a welding workplace, employees need to be mentally sharp and engaged in their environment. A positive headspace does more than making a workday more enjoyable; it prevents the kind of mental lapses that can result in mistakes and accidents. But the welding industry, along with many other industries relating to construction, is suffering from a mental health crisis. Our workers are struggling with issues including anxiety and depression, and often not getting the help they need from within their workplace. Fifteen per cent of Australians will experience depression in their lifetime, according to Beyond Blue. Men are more likely to die by suicide than women, with the number of men who die by suicide every year double the national road toll. Right now, our industry is predominantly male, and we need to be taking the risks posed by depression and anxiety seriously. Recent statistics show that workers in construction and similar trades are more at risk, with 25 per cent of workers experiencing mental illness over the last twelve months according to research conducted by the National Electrical and Communications Association manmonthly.com.au
(NECA). Workers in these industries are 70 per cent more likely to die by suicide than office workers. Why is our industry more susceptible to mental health problems? There are several theories, predominantly that the stress and pressure associated with working in high-risk environments. Welding, like other construction jobs, is physically demanding and puts pressure on workers to perform to a high standard or risk potentially fatal accidents. Welders are facing increased job insecurity due to the rise in contractual work and fluctuations in the national economy. Additionally, research shows that many in our industry experience a poor quality of life. The divorce rate in the construction industry is 6 per cent higher than the national average. Australian construction workers have double the rate of life-threatening drinking habits, compared to the national average, and a drug use rate that is
an important first step. Educating workers on the prevalence of mental health problems, and the risks posed by these, helps to stop stigma around these issues. It’s vital that all workers feel comfortable expressing problems without fear of judgement, and good leadership will involve demonstrating this at the highest levels.
10 per cent higher. In addition, the construction industry is known to be an environment in which traditional perceptions of masculinity persist. Masculine ideals are founded on toughness, control, autonomy and competence. Seeking help, or even admitting a need for help, can be both confronting and challenging for people (men in particular) working or living in such a setting. How can we change these perceptions and create a safer environment for welders? How can we better support people facing challenges in their mental health and personal lives? These problems are complex and not easily solved, but it is vital that employers begin to seriously consider what they can do to improve the mental fitness of their workforce. Encouraging all employees – from apprentices to the most experienced on site – to ask for help and even time off if required, is
Creating a safer workplace In 2019, Weld Australia established the Welding Safety Council to provide a forum for industry and legislative safety authorities to identify solutions to safety problems. The mission of the Council is to maintain the infrastructure required to identify and analyse welding risk and formulate and execute mitigation strategies. To help build the mental fitness of Australian welders, Weld Australia has partnered with Gotcha4Life and Man Anchor. Gotcha4Life’s vision is
to strengthen social connections between people so that they can be comfortable expressing themselves and supporting friends who are struggling. They fund training programs across Australia. Man Anchor focuses on educating Australian men on mental illness, and facilitates a range of educational workshops and a mental health first aid course. Through these partnerships, Weld Australia is helping member companies to facilitate workshops and talks for their employees. Additionally, the Weld Australia website offers resources for individuals and businesses to access mental health assistance and encourages everyone working in welding to support their colleagues and remove the stigma associated with mental health issues. Together, we can find innovative solutions to ensure that everyone involved in the welding industry is kept safe every day, both on and off the worksite.
Treotham Automation is a leading supplier of high quality components and products to the industrial automation sector
Flexible Cables
Chainflex Cables
Energy Chains
Connectors
Flexible Conduits
Cable Accessories
Safety Products
Sensors
Measuring Systems
Bearings
Gear boxes
Linear Units
Australian owned & managed manmonthly.com.au
|
1300 65 75 64
|
www.treotham.com.au
|
info@treotham.com.au Manufacturers’ Monthly JUNE 2021 9
Comment
DR JENS GOENNEMANN – Managing Director of the Advanced Manufacturing Growth Centre
Manufacturing: Moving Australia from a lucky country to a smart country
J
OBS top the agenda of most nations – and what a lucky country we have been. For decades, we have leveraged our abundant natural resources, turning our bounty into wealth and employment, with one direct mining job creating more than six indirect jobs in adjacent sectors. It doesn’t take a prophet to see that we will eventually run out of our largely commodity-based luck. But as long as we are a lucky country, we have some runway left to transition to a smart country – one that is resilient and provides well-paid jobs. A smart country can make complex things. A country that cannot do so, while still doing well, is a lucky country. Manufacturing is the single most promising capability that can transform a lucky country into a smart country. Harvard University’s Economic Complexity Index (ECI) ranks a country’s ability to manufacture and export diverse and complex products and components. Currently, Australia ranks 87th, between Uganda and Burkina Faso. Growing our manufacturing capability would improve our ranking. It is the key to money and the jobs of the future. We need to manufacture complex products instead of only extracting their base elements. For example, compare the
Dr Jens Goennemann, Managing Director of the Advanced Manufacturing Growth Centre. extraction stage versus the valueadding stages of manufacturing lithium batteries. Projections value the world market for mining and concentrating lithium at US$12 billion in 2025. At the same time, the market for refining and processing is projected to be worth US$41 billion, electrochemical processing a further US$297 billion, cell production
Australia has about 45,000 manufacturers, and 95 per cent of them employ fewer than 20 people.
10 JUNE 2021 Manufacturers’ Monthly
US$424 billion, and battery assembly US$1.3 trillion. Manufacturing is not a sector. It is a capability that spans all other sectors in which things are being made – like transforming extracted commodities into components or products, adding value along the way. This is evident when comparing the value of one kilo of lithium with a one-kilo battery. Often, manufacturing is confused with production. But manufacturing involves seven steps along a value chain – Research & Development (R&D), design, logistics, production, distribution, sales and services. The six most valuable steps take place before and after the production step. Making a vaccine – to take a timely example – involves all seven of these steps. First, R&D identifies the components of an effective vaccine. Design deals with how to make the vaccine to scale. Logistics sources the ingredients. Production is the actual making of the vaccine in volume. Distribution and sales follow. Finally,
servicing refers to administering the vaccine, monitoring recipients, and supporting customers such as physicians and hospitals. The industrial sector in the vaccine example may be health or pharmaceuticals, but manufacturing is the enabling capability for these and every other sector that makes things. Narrowing the definition of manufacturing to production alone grossly underrates and underestimates its capability and value for a nation. Creating jobs and encouraging manufacturers to make complex products or components along the broad value chain has topped the Advanced Manufacturing Growth Centre’s agenda for the last four years. Our collaborative industry research projects target commercialisation. Through these projects, we have created real jobs that pay well and lift the technical nature and complexity of Australia’s output. The manufacturing jobs we have created extend across the country’s winning sectors: medical technologies and pharmaceuticals, food and agriculture, mining, oil and gas, defence, energy and space. These jobs include IT specialists, supply chain managers and communication professionals, as well as the more familiar roles of welders, machine operators, fabricators and many more. We want to create more jobs through our projects and move Australia closer to the top of the ECI leader board. We also want to have more of our manufacturers competing for global customers against companies from the likes of Germany, Japan and South Korea. Australia has about 45,000 manufacturers, and 95 per cent of them employ fewer than 20 people. Australia’s manufacturing industry has demonstrated that it does not lack ingenuity. What it lacks is scale. Scale matters for jobs. Take Germany, which largely ran out of commodities decades ago, as an example. It is an industrial manmonthly.com.au
Manufacturing is not a sector but a capability that spans all other sectors in which things are being made. powerhouse, with mid-sized companies (called “Mittelstand”) employing almost half of the population in highpaying manufacturing jobs. If we want a future in which we don’t sell fossils (which will inevitably drop in price), we must do two things: help our many small yet most innovative manufacturers to scale up, and to make more complex and globally competitive products.
A good start would be to complement coal and iron ore extraction by adding value to commodities such as lithium. We should also accelerate our engagement in the field of hydrogen. These fields are admittedly complex, yet they are economically most viable. They create resilient jobs, while also addressing climate change rather than adding to it.
We do not need to look any further than our experiences over the past year to see how smart we can be. Australian manufacturers responded to the COVID-19 pandemic by tapping into their capabilities and turning them into solutions for our people. Investing in manufacturing is not about subsidies. It is about investing in our capabilities and building on
our strengths. Market mechanisms alone will not help us when other countries are also investing in their manufacturing capabilities. Putting jobs at the top of our national agenda is the right goal. Smart jobs and many more of them will lift our competitive profile and keep our GDP per capita ratio high as we move from being a lucky country to a smart country.
OIL-FREE TECHNOLOGY FOR PREMIUM AIR QUALITY Premium, clean and reliable compressed air is crucial in many industries.
DSP190521
Sullair’s oil-free scroll and screw technology provides premium compressed air to a diverse range of them, including Food & Beverage, Medical, Pharmaceutical and many more.
Make the switch to oil-free today Call 1300 266 773 or visit sullair.com.au
manmonthly.com.au
Manufacturers’ Monthly JUNE 2021 11
News @MM Energex truck to mobilise storm recovery in Stafford Energex has delivered Queensland’s first fully electric bucket truck at the Brisbane Truck Show this week to mobilise the state’s storm recovery and network maintenance. The 15.5 tonne Mobile Elevating Work Platform (MEWP) will be based at Energex’s Stafford depot. Minister for Energy, Renewables and Hydrogen Mick de Brenni said the MEWP will almost silently service 150,000 homes and businesses north of Brisbane.
“Our Energex crews work around the clock to keep Queenslanders safe and connected and are some of the first on the frontline when storms strike,” de Brenni said. “The arrival of the MEWP puts them on the forefront of technology in the heavy transport space, with this electric motor producing up to 2,500nm of torque. “A 138kWh battery pack sits where fuel and air tanks traditionally would, saving around 30 tonnes of
diesel emissions each year. With more Queenslanders getting behind the wheel of electric cars, heavy transport is the next logical step in our efforts to decarbonise.” Energex CEO Rod Duke said the new addition to the company’s fleet is an exciting insight into the future of electric vehicles in Queensland. “While we’ve had electric and hybrid cars in the fleet for many years, this truck is the first of its kind for us and we’re looking forward to putting it
through its paces,” Duke said. “It’s a real game-changer for our emergency response in a number of ways and has a range of 200km once fully charged, which will obviously have benefits in terms of reduced carbon emissions. “Additionally, significantly reduced noise levels make the crew’s essential work activity less intrusive for the community, particularly in times of storm and emergency response, which often occur at night.”
University of Sydney develops artificial retina using biomedical printing press A researcher at the University of Sydney is developing a low-cost, 3D printable device that acts like a retina and could one day restore sight to those who have lost the capacity to see. Created by Dr Matthew Griffith from the Australian Centre for Microscopy & Microanalysis and the School of Aerospace, Mechanical and Mechatronic Engineering, the electrical device was produced from multi-coloured carbonbased semiconductors which uses absorbed light to fire the neurons that transmit signals from the eyes to the brain. The retina is the thin layer of tissue lining the back of the eye which functions to receive light, convert it into neural signals and send them to the brain for processing. “Worldwide, the number of people living with vision impairment is at least 2.2 billion. Our research aims to provide a biomedical solution to those experiencing blindness from retinitis pigmentosa and age-related macular degeneration (AMD), the second being one of the leading causes of blindness in the world,” Griffith said. The goal is to apply this type of neural interface – a device that records or stimulates an individual’s 12 JUNE 2021 Manufacturers’ Monthly
The electrical device was produced from multicoloured, carbon-based semiconductors which uses absorbed light to fire the neurons that transmit signals from the eyes to the brain. nervous system – to restore sensory function to those with spinal cord injuries and treat people with neurodegenerative diseases. “Among other functions, neurons are the body’s signal conductors. A missing neuron link, which can be caused by, for example, a spinal cord injury, can cause severe problems. It can also be debilitating if neurons misfire – this can cause blindness and deafness, as well as diseases like Parkinson’s and epilepsy, for which there is no cure,” Griffith said. “Neural interfaces can bridge this neuronal divide, or, in the case of misfiring, re-program the neurons.” The device can be printed via the same method as newspaper printing.
“Similar technologies are being intensively developed, though our device differs in that it is made of carbon – the same building block as human cells. Other devices tend to be rigid and usually made of silicon or metal, which can present problems integrating with the human body that is soft and flexible. Our organic device is designed with this issue in mind,” he said. The intention is for the device to be printed onto soft, flexible surfaces from water-based inks containing nerve growth factors, then inserted into the patient’s retina. Once the neurons reconnect to it, the retina will regain lost functionality when stimulated with light. So far Griffith has conducted
experiments using neurons from the eyes and spinal cord of mice. “Not only did these cells survive – they grew and maintained neural functionality. The next step is to control where they grow by printing nanopatterns. This is so in future, we can direct them to grow into specific bodily locations, like a spinal cord or retina,” Griffith said. What sets this device apart from other sight-restoring technologies is the form – others attempt to replicate the eye and brain to restore sight, which only produces large blurry shapes in black and white. Additionally, Griffith’s device does not require electricity, instead using light from the outside world to generate power internally. “If successful, our device will help us progress towards solving one of the great scientific challenges of the 21st century – communicating with the human body’s sensory network. We hope to achieve this using nothing but light, which opens up some really exciting prospects for the future of bioelectronic technology,” Griffith said. Griffith has received a NHMRC Ideas grant to continue work on the project with colleagues from the University of Sydney and neurobiologists from the University of Newcastle. manmonthly.com.au
News @MM Orbital UAV’s prototype engine delivered to Lycoming engines Orbital UAV has hit a major milestone on a prototype engine development program for Textron Systems’ Aerosonde program. It is Orbital UAV’s first major milestone in its engine development program with subsidiary of Textron Systems, Lycoming Engines, providing Lycoming with an initial prototype engine for evaluation. Following the contract confirmation and program kick-off, the delivery of this early core engine represents a key step in the 12-month development program. In next steps for the program, Lycoming will assess the engine to inform further requirements for integration and design customisation. The Lycoming engine development program will enable the integration of an Orbital
UAV-designed 150cc core engine, including proprietary fuel and engine control systems, into Textron Systems’ Aerosonde program. Textron Systems is an international leader in unmanned aircraft systems and one of the
largest suppliers of tactical unmanned aerial vehicles to the US armed forces. “This represents good progress on our newest engine development and integration program,” CEO and managing director of Orbital UAV
Todd Alder said. “Working closely with Textron Systems and Lycoming, we are driving the development timeline to ensure we are able to smoothly transition into production and the agreed supply contract in 2022.”
The development of Orbital UAV engine development program with Lycoming Engines is a major milestone.
Compressed Air and Power Generation Specialists AIR COMPRESSORS POWER GENERATORS BLOWERS / DRYERS AIR TOOLS
• 24/7 AUSTRALIA WIDE SERVICE • BESPOKE ENGINEERING & DESIGN
NITROGEN GEN
• RENTAL & FINANCE OPTIONS
OXYGEN GEN
• PREMIUM BRANDS
1800 800 878 manmonthly.com.au
caps.com.au
C E L E B R A T I N G
1 1980 9 8 0 -2020 -2020
Manufacturers’ Monthly JUNE 2021 13
News @MM Federal government plans to fund apprenticeships for clean energy The federal government is taking steps to help Australia thrive in a global zero-emissions economy, with plans to invest $100 million to fund apprenticeships in clean energy and manufacturing and $10 million for funding and education programs. “As one of the sunniest and windiest countries on Earth, Australia has everything it needs to prosper in a clean energy economy and unlock thousands of clean jobs,” Climate Council campaigns director Alix Pearce said. “We urgently need a plan to reduce emissions to capitalise on the job opportunities this presents. Funding apprenticeships in sectors like clean energy and clean manufacturing will help young Australians seize emerging opportunities in the clean energy jobs
Funding apprenticeships in clean energy and manufacturing sectors can help young Australians. marketplace, and businesses have access to highly skilled workers. “Support for apprenticeships in sunrise industries also offers retraining and upskilling opportunities for experienced workers and will help protect jobs as the global economy transitions away from fossil fuels to renewable energy,” she said. According to the Climate Council’s Clean Jobs Plan, investing in
renewable energy and other lowcarbon industries has the potential to rapidly generate 76,000 jobs, reboot the economy and positively impact climate change in the long term. “Apprenticeships alone won’t guarantee job creation at the scale Australia needs. Both major parties must give business the policy certainty to establish and expand clean industries. That means strong emissions reduction targets across
New 15-26kW Air Compressor Range Solid, Simple, Smart: Advanced reliability in compressed air
sectors focused squarely on this decade,” Pearce said. “It’s also critical that this announcement is part of a bigger plan to ensure the clean economy jobs of the future are secure, good quality jobs that provide a long-term pipeline of work for Australians.” The Climate Council’s targets for Australia include reducing emissions by 75 per cent by 2030 and reach net zero emissions by 2035.
Ceccato Compressors New 15-26kW Air Compressor Range!
DRB
DRB IVR
CSM – Simple Belt Drive Solution for General Industrial Applications DRB – Solid Gear Driven Solution for more Robust Industrial Use
CSM
DRB IVR – Advance Direct Drive Variable Speed Drive Machine for optimum energy savings
AV AI
SERV IC E
H
IP
TY
RS
TECHNOLOGY YOU CAN TRUST
RELIA BI LI
PARTNE
0621 Half Page Ceccato Man Monthly.indd 1
14 JUNE 2021 Manufacturers’ Monthly
TY ILI AB
LITY BI LA
SIM
P LI CIT Y
18/05/2021 8:21:56 PM
manmonthly.com.au
News @MM Moderna vaccine manufacturing capacity confirmed in Budget The federal government has secured 25 million doses of the Moderna COVID-19 vaccine, providing access to a booster or variant vaccine if it is required in the future. It was confirmed in the 202122 Budget that the government will commence an approach to market for mRNA manufacturing capacity in Australia. There are also discussions related to establishing a manufacturing facility within Australia for mRNA vaccines. This would ensure a secure, long-term supply of the vaccines for potential future pandemics. The second messenger RNA (mRNA) vaccine purchased by the government, providing access to the current Moderna vaccine or variantspecific versions of the vaccine developed by Moderna. This will
address long term immunity and emerging viral variants in the first half of 2022. Overall, the Moderna vaccine has shown efficacy against symptomatic COVID-19 of 94.1 per cent and 100 per cent efficacy against severe COVID-19. It has also shown strong protection of 90 per cent efficacy against COVID-19 for at least six months after the second dose. Also, it has been approved by leading regulatory authorities worldwide and used successfully in the UK, Canada, the European Union, the US and Singapore. The agreement includes 10M doses in 2021 and 15M doses of Moderna’s updated variant booster vaccine in 2022. Once the vaccine is approved as safe and effective by Australian
regulator the Therapeutic Goods Administration (TGA), supply will commence. The federal government’s expert group advising on vaccine purchases, the Science and Industry Technical Advisory Group, has recommended purchase of the Moderna vaccine. A complete course of Moderna’s vaccination is likely to be two doses given 28 days apart. It will provide more flexibility for the national vaccine rollout and secures early access to possible vaccinations for new COVID-19 variants. Australia has five separate agreements to secure more than 195M doses of Moderna vaccines if proved to be effective and safe. Approximately $6B has been invested to support the rollout of the vaccine.
The Moderna vaccine has shown efficacy against symptomatic and severe COVID-19.
If you’ve got If you’ve the opportunity, got the opportunity, Banjo Loans Banjo will Loans help transform will help it transform it If you’ve got the opportunity, into an outcome. into an Our outcome. local experts Our local experts Banjo Loans will help transform itto help your will find the will right findloan the to right help loan your into an outcome. local experts business take business theOur next take step. the next step. will find the right loan to help your So if you’re So ready, ifthe you’re we’re ready, ready. we’re ready. business take next step. So if you’re ready, we’re ready.
1300 22 65 65 |1300 banjoloans.com 22 65 65 | banjoloans.com
manmonthly.com.au
1300 22 65 65 | banjoloans.com
Manufacturers’ Monthly JUNE 2021 15
News @MM Business Growth Fund grants open for small and medium businesses Queensland’s small and medium businesses can now apply for grants of up to $50,000 to help them grow and create jobs, due to $2.5 million allocated for the Business Growth Fund. “The Business Growth Fund grants are the first in a package of $25 million of new grants unveiled as part of Queensland Small Business Month,” Minister for Employment and Small Business Di Farmer said. “The package also includes new programs, Business Basics and Business Boost, which will open for applications later this month and next financial year.” This investment is a response to direct feedback received from the state-wide Small Business Roadshow and an online survey. There will be increased assistance with the application process for small business owners, as well as greater lead in time after the release of criteria for each grant program. “We know that small businesses across Queensland are at distinctly different stages and that’s why our new support programs reflect this and will deliver additional funding, to ensure more businesses bounce
The Business Growth Fund aims to help evolving smalland medium-sized businesses buy highly specialised equipment to accelerate growth opportunities.
back better [from the COVID-19 pandemic],” Farmer said. Applicants for the Business Growth Fund will also receive a mentoring session to better explore their business proposition and how to proceed with it. “The Business Growth Fund aims to
Best new technologies to meet tomorrow’s challenges services
ent system m
sport, ications,
We currently provide for over 50 units of heliport to offshore and connecting bases worldwide. Major for ship building includes: • Special marine type alloys in prefabricated modules (decking panels, T-bars, etc) • Tailor-made units and living cabins for offshore platforms • Any fabrication enquiries from general CNC machining to Friction Stir Welding (FSW) • Certified by Classification Society Certifications of CCS (China), ABS (America), DNV (Norway), BV (France), and NK (Japan). • Capable of development and production capability for 5xxx, 6xxx, 7xxx Aluminium alloy series
16 JUNE 2021 Manufacturers’ Monthly
help evolving small-and medium-sized businesses to buy highly specialised equipment to accelerate growth opportunities,” Farmer said. “We want to make it as easy as possible for more businesses to apply for the $25 million in grants on offer over the next two years.
As a result, we have simplified and streamlined application processes for small businesses.” Applications are open for the Business Growth Fund as of 11 May. Business Basics applications are due to open 31 May and Business Boost in late July.
Devoted to meeting the industry’s best standards through technology and quality. Flexibility, standing side by side, and being involved with our customers’ needs is our promise. PMIT provides customers with the best-in-class services and products because we use the following: 1) ISO / TS 16949 automotive quality management system 2) ISO14001 environmental management system 3) ISO45001 occupational health and safety management system 6) OA paperless office platform 7) SAP ERP information management system In addition, we support other industries like transport, building, renewable energy, computer, communications, consumer-electronics, and many others.
Time to check for something new. pressmetal.com.cn
Australia | Malaysia | China wilson@pmaa.net.au yumi.lin@pmitech.com.cn
manmonthly.com.au
News @MM IBSA Group report finds a way forward for skilled manufacturing industry post-COVID Manufacturers, union leaders and peak bodies have identified skills development priorities essential to building sovereign capability and economic growth in an IBSA report to be presented to the federal government this week. The report, Scaling Up. Developing Modern Manufacturing Through a Skilled Workforce, is the result of extensive national industry engagement by not-for-profit workforce skills organisation the IBSA Group. The report was be presented to Industry and Education and Skills departmental officials in May. “I would like to thank IBSA Group for the work that has led to the Developing Modern Manufacturing through a Skilled Workforce Report,’’ Minister for Employment, Workforce, Skills, Small and Family Business Stuart Robert said. “The report is welcomed for its extensive collaboration with industry, unions and the training sector, as well as government, to help inform the skills agenda. We are looking forward to continuing to drive the Australian economy forward with a skills-led approach.” IBSA Group CEO Sharon Robertson said there was strong and clear consensus from manufacturers, training organisations, peak bodies and unions operating within the sector to provide more work-based learning and apprenticeship training opportunities that create pathways to higher skills development. “To build sovereign manufacturing capability in the post-Covid era, industry wants a workforce skilled in product manmonthly.com.au
Skills are fundamental to the delivery of a modern manufacturing industry, according to the report.
development, new technologies, design and prototyping, along with gaining efficiencies through sustainability and collaborative skills,’’ Robertson said. “The clear need for the development of advanced skills from the platform of work-based learning was identified. One of the key recommendations of the report is greater recognition of apprenticeships as pathways to higher qualifications and higher learning. The manufacturing sector wants to see a system of apprenticeships that incorporate extensive STEM-based skills that provide qualifications equating to a diploma or advanced diploma.’’ More collaboration between the VET and Higher Education sectors and industry to create more synergistic skills development pathways was also recommended. “The focus on apprenticeships in last week’s Budget will be welcomed by manufacturers because in real terms, investment in the VET sector is currently at its lowest in a decade,’’ Robertson said. “Development of workbased learning should align and integrate VET with the Higher Education sector, rather than compete against it.’’ In the development of the report, roundtable panellists
Ai Group chief executive Innes Willox, Business Council Australia CEO Jennifer Westacott, Australian Chamber of Commerce and Industry chief economist Ross Lambie, and ACTU assistant secretary Scott Connolly all agreed on the renaissance-like opportunities facing the sector but that skills were fundamental to the delivery of a vibrant modern manufacturing industry. Robertson said manufacturing could not grow without a skilled workforce. “If the recovery out of COVID has shown us anything, it’s that we can’t be slow in responding to the need for change,’’ she said. “Manufacturers have been responsive and flexible in responding to the challenges of 2020. The skills sector needs to be just as responsive to take advantage of the opportunities that lie ahead for Australian manufacturing and the industry’s current and future employees.’’ Other recommendations of the report included: - Prioritising the reskilling and upgrading of skills of existing workers. - Allowing micro-credentials to be recognised across industry and easily incorporated into broader qualifications. - Extending apprenticeships in a nationally consistent manner to support the development of new occupational areas such as space and minerals processing. - Creating a national, forwardlooking body to identify and support skills development for new and emerging industries. - Supporting sustainability and the circular economy by making energy efficiency skills more widely available within existing and new qualifications.
NEW full feature oil injected screw compressors 4-22kW
NEW generation series-4 screw compressors up to 160kW
Oil free scroll compressors Medical, instrument, dental
High pressure piston and booster up to 40 bar(g)
Refrigerated and Desiccant Air dryers from 15-6,000 cfm
For sales and service support contact your nearest BOGE partner www.boge.net.au or (03) 5940 5913
Manufacturers’ Monthly JUNE 2021 17
News @MM Volgren and Volvo electric CAT buses to begin trial in January The first electric CAT buses for Perth will commence use in Joondalup in January 2022, spawned from a partnership between Volvo and local manufacturer Volgren. The first of the four buses have been built, with the second under construction.
With the manufacture of the two buses being undertaken in Melbourne, on-road testing will begin by October in anticipation of January’s trial. As well as the Joondalup CAT network these vehicles will service some
The WA government expects Volvo’s partnership with Volgren will allow for future electric buses to be fitted out locally.
northern suburban routes. “Many local residents have raised the idea of an electric bus trial in Joondalup – I presented the idea to the Minister for Transport and am so pleased that we have confirmation this will start early next year,” Joondalup MLA Emily Hamilton said. Modifications to the Joondalup bus depot including changes to the parking layout, maintenance facility and high-voltage EV charging system installation are estimated to be 75 per cent complete. Four trial vehicles will be supplied to the Public Transport Authority by Volvo through their existing bus supply agreement. Volvo currently holds a $549 million contract to deliver 900 new buses between 2019 and 2029, with the potential to deliver electric vehicles in future if the trial is a success.
The Western Australian state government expects Volvo’s partnership with Volgren will allow for future electric buses to be fitted out locally. The Volgren facility is located in Malaga, which will support local jobs and apprenticeships. “This is about supporting our public transport, cleaner transport and ensuring we partner with industry for the best employment outcomes. This is part of our vision of not only supporting cleaner transport, but also local manufacturing,” Transport Minister Rita Saffioti said. Hamilton said the partnership will ensure the buses are reliable and proven to perform well over time. “Our government is transforming the transport options available in the northern suburbs, and this provides another option for people to choose how to travel.”
NSW Jobs Plus Program focuses on medical technology The NSW government’s first round of the Jobs Plus Program focuses on medical technology, delivering around 280 jobs. Baxter Healthcare and biotechnology company SpeeDx are the first businesses to join the program. The $250 million program from Investment NSW was acknowledged as an opportunity to invest in nurturing industries, technology and stimulating job creation by NSW Premier Gladys Berejiklian. “Jobs Plus is focused on propelling NSW into post-pandemic prosperity by incentivising the private sector to invest in job creation opportunities and support through the critical stages of business development,” Berejiklian said. “Supporting Baxter Healthcare and SpeeDx to take their NSW operations to the next level will support approximately 280 18 JUNE 2021 Manufacturers’ Monthly
direct jobs in medical equipment manufacturing and biotechnology over the next four years.” Baxter Healthcare is Australia’s only local manufacturer of intravenous (IV) medical fluids. They plan to invest in a major expansion of its advanced manufacturing facility in Western Sydney, supporting more than 600 existing jobs in NSW and creating approximately 80 new jobs by June 2024. SpeeDx will look to establish a new global headquarters, including relocating manufacturing capabilities from the US to Sydney and improving supply chain bottlenecks, creating almost 200 jobs by June 2024. “The pandemic put a spotlight on the value of these high-growth, essential industries and backing their growth is crucial to ensure our economy is fuelled by sustainable, knowledge-based jobs that are here
for the long run,” Minister for Jobs, Investment, Tourism and Western Sydney Stuart Ayres said. “As Australia’s only local manufacturer of IV medical fluids, Baxter is committed to supporting our hospitals and healthcare professionals with reliable supply of medicines during the pandemic and beyond,” Baxter Healthcare General Manager for Australia and New Zealand Steven Flynn said. “This major expansion of our medical manufacturing facility in NSW will help to strengthen our national supply chain resilience and support continued export growth of Australian Made medicines.” Meanwhile SpeeDx has recently grown over 50 per cent in over a year. They plan to continue growing by creating diagnostic tools that improve patient care with infectious disease and antibiotic resistance.
“This government support comes at a pivotal time for the company, as we expand into new headquarters and significantly increase our manufacturing capacity, improve supply chain security and increase Australia’s sovereign capacity for important diagnostic tests,” SpeeDx CEO Colin Denver said. The Jobs Plus Program will provide eligible companies with support, including payroll tax relief, streamlined planning approval and subsidised training programs and the provision of free or subsidised government spaces and accommodation. Australian businesses that employ 20 or more staff and international companies with at least 80 employees looking to create a minimum of 30 jobs before June 2024 are eligible to apply for Jobs Plus. manmonthly.com.au
Protect critical assets. Mitigate cyberthreats inside your industrial networks.
A comprehensive cybersecurity solution designed to secure industrial networks from both an OT and IT perspective. 9 Detect and mitigate cyberthreats for system integrity
9 Centralised management to simplify monitoring and perform updates
9 Protect networks with integrated OT-IT technologies
Extensive Moxa products Australia wide Madison Technologies has been distributing Moxa’s reliable networking infrastructure Australia wide for more than 14 years. Our team is dedicated to ensuring our Moxa portfolio is fully supported with an extensive range held locally across our national supply chain, and a team of Moxa certificated sales and technical support engineers.
Sales Enquiries 1800 72 79 79
www.madison.tech
Industry Focus
The “nerve centre” of Energy Renaissance batteries will be manufactured in Tomago, New South Wales.
Kicking off a whole new world of energy production Caroline Tung speaks with Energy Renaissance development director, Brian Craighead, and Innovative Manufacturing CRC CEO, David Chuter, about the advent of lithium-ion battery manufacturing in Australia, and how it could spur an entire industry.
L
ITHIUM has been touted as the new power source that will revolutionise energy production in Australia. The big ambition for Energy Renaissance, Australia’s first lithium-ion battery manufacturer, is to use Australian resources to build great batteries, while reducing the country’s climate footprint. Energy Renaissance technology and development director, Brian Craighead, said the current demand for batteries was “incredible”, and the company was already in the early stages of talking about building a second facility. After surveying the market,
20 JUNE 2021 Manufacturers’ Monthly
We have a module system where we can plug any chemistry – LFP, NMC, NMC+ which plugs and plays into our system,”
the company sought to produce batteries that would work well in Australia’s hot climate, are easy to transport and deploy, are safe, and less expensive. “When we first started the business, we didn’t come up with the ideas, or the design, the market
did,” he said. While lithium batteries are optimised at 25°C worldwide, making batteries in Australia that can operate in harsh conditions meant adding more cooling to the battery. “We have a module system
where we can plug any chemistry, LFP, NMC, NMC+, plugs and plays into our system,” Craighead said. “It’s the same battery management system that runs everything.” Although the company has become what Craighead calls a “five-year overnight success story” their business idea was initially met with a lot of resistance. He believes the attitude that Australia cannot manufacture batteries is inherited from the cultural scar from the 80s – that Australia thinks it can no longer manufacture, based on cars and various products that have been offshored. manmonthly.com.au
Industry Focus and their customers. Communicating through an inverter, the system will enable secure real time data, analytics and remote management to drive down the risk of battery failure and operating costs for grid-scale energy storage users. Chuter said the export potential for the batteries was an important criterion in their selection process, as the IMCRC focuses on projects that present the opportunity to contribute to global supply chains. “I don’t think there’s any project across the 50 we’ve funded that hasn’t required a strong focus on the global market,” he said. “From our perspective, it is critical that Australia manufacturing looks at the world despite covid.” Chuter recalls in the automotive industry, it was galling to see Hyundai put an advert on TV saying their cars were made
Energy Renaissance superCube.
“When we first said five years ago, we’re going to build a battery manufacturing facility, people thought it was just Powerpoints and enthusiasm, and nothing was going to happen,” Craighead said. He divides the history of getting to the production stage into three parts. The first part of the journey was convincing naysayers that manufacturing batteries in Australia was possible. The second part was that people started to see the demand for batteries, and that Australia had all the raw materials to make it happen. And then, COVID-19 happened, and it changed everything. “People could see there was money to be made, and their mindset shifted from we can’t manufacture to we can manufacture,” Craighead said. “We have big ambitions to be a trigger for the upstream in Australia and also encourage export.” Innovative Manufacturing CRC CEO, David Chuter, said was imperative that energy securency is part of Australia’s national resilience against COVID-19. “Battery manufacturing in Australia has got to be part of the broader solution about renewables manmonthly.com.au
from Australian steel. “They were made from ore that was shipped overseas, that was then sent back to us at to us that was probably 3000 times the value of the ore,” he said. “As recently as three years ago, I remember travelling across to Western Australia and trying to enquire why we couldn’t build batteries.” Chuter said Australia has global best-in-class capability in the mining industry, and that the country is more advanced than any other country in terms of advanced manufacturing technologies, Industry 4.0, and IIoT intelligence, in the mining sector. “The challenge is when you enter the critical battery manufacturing, you don’t want to ship these minerals all the way across the world, and find that you have a yield issue, or a quality issue,” he said.
transition,” he said. He believes it is a critical area that requires a national focus. “We have some amazing strength and capability, but we don’t have the value add or complexity,” he said. “We tend to let all that production happen overseas.” An independent study conducted by CIS Solutions for Energy Renaissance has projected $7.3 trillion in export revenue for Australian made lithium-ion batteries. “You need batteries that are going to work well in tough conditions, easy to transport, safe less expensive, so defence was a big part of our early planning,” Craighead said. Energy Renaissance will develop a defence-grade cybersecure Battery Management System (BMS) that is the “nerve centre” of its batteries that will be manufactured in Tomago, New South Wales. The $1.46 million BMS project is a joint venture by Energy Renaissance with the national science agency, CSIRO and the Innovative Manufacturing CRC. The BMS will monitor and report on the battery’s usage, lifespan and faults through a mobile network to Energy Renaissance Manufacturers’ Monthly JUNE 2021 21
Industry Focus (From left): Adam Best, Principal Research Scientist (CSIRO), Senator Hollie Hughes, Brian Craighead, Director of Development and Technology, Energy Renaissance, Mark Chilcolte, Managing Director, Energy Renaissance, Prime Minister Scott Morrison, Karen Andrews, Minister for Industry, Science and Technology and David Chuter, CEO and Managing Director (IMCRC).
“I think to be able to build scale in battery manufacturing, you need to add value at the raw material source, because then you know you’ve got the guarantee, and you’ve got the quality approved,” Chuter said. He believes supporting companies such as Energy Renaissance by funding their research, people will start to recognise Australia as a place to make batteries. “It’s really exciting we’ve got a company committed to making large-scale batteries. “We’ve got lot’s of battery manufacturers in Australia, but not in this space, and not really focusing on the uniqueness that we need,” Chuter said. 22 JUNE 2021 Manufacturers’ Monthly
These rare earths and critical minerals are what literally pulls together the technology we’ll be relying on into the future.”
Minister for Energy and Emissions Reduction, Angus Taylor, said energy storage is one the priority technologies under the federal government’s Technology Investment Roadmap. He said bringing down the cost down for battery manufacturing is key. “As Australia’s energy mix
continues to change, we need all levels of government working together to achieve strong results for consumers,” Taylor said. Earlier this year, Prime Minister Scott Morrison visited the site of Energy Renaissance’s future manufacturing facility. “It is a sovereign and strategic priority for Australia to ensure we
are hardwired into this supply chain around the world and a supply chain that Australia and our partners can rely on,” he told the ABC. “These rare earths and critical minerals are what literally pulls together the technology we’ll be relying on into the future.” For a country of 25 million people, Craighead believes the way to compete in a global market is not on skill. He said the company had assumed the battery manufacturing was an economy of skill business, because every factory they had visited was enormous. “If everybody else is going to be an aircraft carrier, we’ve got to be a speedboat. “That means being much nimbler,” he said. manmonthly.com.au
Customised Lubrication Solutions Your goals, our experience SKF Lubrication Systems Distributor JSG Industrial Systems
Correct lubrication reduces maintenance costs, eliminates machine downtime and avoids premature failures by protecting equipment. Our tailored lubrication solutions keep your machinery running smoothly while providing you with excellent return on investment. Our strength comes from high-quality distribution partners who manage installation, service, technical support & training nationwide. As you plan for the future, let our experience guide your success. Lubrication Management | Flow Management | Fire Suppression
Quality Engineered Systems JSG Industrial Systems | jsgindustrial.com | 1300 277 454
Network Security The key to operational resilience: OT cybersecurity Global industrial connectivity supplier Moxa, distributed in Australia by Madison Technologies, explores the importance of protecting OT networks from cyberattacks by enhancing operational resilience.
S
ECURING operational technology (OT) networks and increasing network durability are key to enhancing operational resilience, as OT network protection still lags behind information technology (IT) cybersecurity. This article explains the reasons behind the lag, and outlines four steps OT operators can take to better protect OT networks from cyberattacks and enhance operational resilience.
Althought IT networks are usually safeguarded with sophisticated cybersecurity countermeasures, there still might be vulnerabilities.
New opportunities bring new threats As new IT technologies and Internet connectivity become available to OT networks, many different opportunities are opened up for greater productivity and efficiency. Although connecting OT networks to the Internet enables new possibilities, it also introduces new threats. With more people working remotely due to the COVID-19 pandemic, companies need to enable more remote connections to their business and production networks. Although these remote connections do enable employees to work from the safety of their homes, they also unfortunately open the gate to new cyberthreats. Although IT networks are usually safeguarded with sophisticated cybersecurity countermeasures, OT networks still include many legacy devices and often have less protection. This is primarily because the systems are complex, and it is quite difficult to effectively implement cybersecurity measures. In addition, these networks often have long lifecycles, where legacy devices are not regularly updated with cybersecurity features. In fact, OT protocols are not usually encrypted and often lack authentication mechanisms. Moreover, hackers are becoming more 24 JUNE 2021 Manufacturers’ Monthly
familiar with OT protocols, networks, and devices, enabling them to target PLCs, HMIs, and SCADA systems more easily.
The cybersecurity gap between IT and OT The reason for the discrepancy between the maturity of IT and OT
cybersecurity is closely related to different business priorities that often conflict with each other.
controlled office environments, and are fairly easy to upgrade, patch, or replace on a regular basis.
Why IT networks are better protected Enterprise IT networks prioritise confidentiality and focus on data integrity. IT assets include computers and servers located in climate-
Why OT networks lag behind Industrial OT networks, however, prioritise availability and focus on controlling processes that cannot tolerate downtime. Unlike
Types of Factories
Traditional Factories
Transforming Factories
Modernised Factories
Status
• Full of legacy systems • Lack of network architecture • Lack of security awareness and resources
• Mixture of new and legacy systems • Complex network environments • Wider attack surface • Have security awareness but it might not be a priority
• High automation and cybersecurity maturity • Assigned cybersecurity resources • Integration with SOC • Holistic cybersecurity
Concern
Cybersecurity is not a priority and they do not have sufficient protection
Managing both legacy and new networks at the same time
Preventing operational disruptions with cybersecurity measures deployed
manmonthly.com.au
Network Security IT assets, OT networks are made up of PLCs, HMIs, meters, and other pieces of equipment that are difficult to upgrade or patch. These devices can be located in harsh environments that are difficult to reach and are often subject to extreme temperatures, vibrations, and shocks.
Different demands in different domains Industrial applications have requirements that differ depending upon the sector, as well as varying levels of cybersecurity maturity. Although industries in the public sector are generally better protected than private manufacturing businesses, the vast majority of OT networks still lag behind their IT counterparts in terms of cybersecurity. In general, IT departments administer the cybersecurity policies for OT networks, but those policies are merely at the IT level, which means they do not take into consideration the characteristics and requirements of OT networks. In addition, many also continue to lack segmentation between their IT and OT networks. Regardless of the industry, many OT networks lack sufficient security controls and are not managed by OT operators.
Factory automation Manufacturers generally have lower levels of cybersecurity maturity and are primarily revenue driven and focused on maintaining availability and uptime rather than on security. Even though the level of security awareness varies depending on whether the manufacturer is traditional, transforming, or modernised, IT and OT roles and responsibilities continue to be vaguely defined in factory automation.
have to ensure their cybersecurity measures are as mature as those utilised in IT networks. The following four steps describe how you can secure your OT networks and increase resilience. 1. Manage your OT networks You cannot protect the assets you do not know you have. That’s why the first step to enhancing operation resilience requires OT operators to monitor everything on their networks in a similar way to how IT network administrators often have complete visibility. Is everything that should be on your OT network actually there? Is there anything on your network that should not be there? For example, OT operators can start to determine who can and cannot access the network by leveraging ACL or other authentication mechanisms. Furthermore, there are simple mechanisms that OT operators can set up to define which PLC can be connected to the network by port access control or sticky MAC. In other words, everything on the trusted list is allowed to go through the network, and anything not specified on the trusted list is blocked. Managing your OT network (instead of relying on the IT department) also allows OT operators to respond more quickly to downtime and troubleshoot issues more rapidly.
2. Segment your OT networks Unlike IT networks that can be segmented by dividing the network into different departments with their own set of permissions, OT networks are essentially one giant Intranet where everything is connected. This makes OT networks more difficult to segment, but not impossible. There are two ways you can segment an OT network: • Vertical segmentation involves adding an Industrial Demilitarised Zone (IDMZ) between the IT network and OT network. Although this separation should be mandatory, many companies still have not segmented their OT networks from their IT networks. • Horizontal or lateral segmentation involves creating and separating cells, zones, and sites on the OT network. A cell is essentially a tiny place where all equipment is stored, such as a cabinet. Several cells can form a zone, and multiple zones can form a site. Segmenting OT networks using either method, or both, allows operators to prevent cyberthreats from spreading to other parts of the network. 3. Patch vulnerabilities Since equipment and devices running on OT networks cannot be upgraded or replaced as frequently as endpoints on IT networks, OT networks still have many legacy devices that may even be running on operating
systems as old as Windows 95. Many legacy OT devices remain unpatched and are relatively easy for hackers to exploit. If no patch is available from the original equipment vendor, consider putting a virtual patch on a device that goes in front of your legacy devices. 4. Secure remote connections Protecting the data that is transmitted from your plant or remote site back to the monitoring and control center is absolutely crucial. Ensure that each remote connection to your OT network is both authenticated and encrypted. Authentication verifies the identity of the user requesting access whereas encryption ensures that the data transmitted is securely encoded and cannot be easily deciphered by prying eyes.
Summary Besides managing and segmenting OT networks, OT operators also need to ensure their systems are properly patched and remote connections are secure. These steps not only help reduce the gap between OT and IT departments, but also protect industrial control systems, which are increasingly being connected to the Internet, from cyberattacks. To learn more about how to build secure network infrastructure, visit www.madison. tech/moxa or phone 1800 72 79 79 to speak with Madison Technologies’ Customer Connect team.
Four steps to enhancing operational resilience Considering how different IT and OT networks are, how can we bridge the gap between these two domains and secure OT networks from cyberattacks? To enhance operational resilience, OT networks manmonthly.com.au
Manufacturers’ Monthly JUNE 2021 25
Energy Savings Atlas Copco’s energy efficient production The experts at Atlas Copco share their thoughts about energy consumption and how reducing one’s carbon footprint can lead to cost savings.
C
OMPRESSED air production consumes a large amount of energy, which impacts a company’s bottom line as well as the environment. However, there are some things businesses can do to immediately and sustainably to make compressed air generation less expensive and more environmentally friendly. Atlas Copco uses a 10-step guide to help companies lower their energy consumption and carbon footprint, which will translate into direct savings. In some cases, these savings will be substantial. Best of all, while all the 10 steps will save money in the long run, some of them cost very little to implement. In fact, after you finish reading this article, you will be able to take meaningful action right away to make your production greener and more efficient.
Why reduce carbon? Not a day goes by without reports on the devastating impact of climate change on our planet – and the increase of carbon in the atmosphere contributes to this problem. More and more people are demanding that their governments take action, which is leading to new legislation in many countries, such as tighter emission standard and carbon taxes. At the same time, many companies have realised that making their production greener beyond government mandates is not just good for the environment but also for business – and that it can shore up their long-term success. For example, reducing their carbon footprint by making their compressed air systems more energy efficient has the following benefits for businesses: • Lower manufacturing costs • Reduced carbon taxes 26 JUNE 2021 Manufacturers’ Monthly
• Improved brand image, which helps attract customers, investors and talented staff • Boost to employee morale • Compliance with increasingly stringent environmental laws
CO2 levels are increasing despite the use of more renewable energy Solely focusing on producing more green energy will not solve the problem. At best, it will slow the increase of carbon in the atmosphere. To address climate change in a meaningful way, we have to pay at least equal attention to energy reduction. That is the only way to allow us to achieve a carbon neutral economy in the near future. Compressed air is a highly effective and safe form of energy for powering production equipment or processes. Unfortunately, generating compressed air traditionally consumes a lot of energy. However, most companies
do not realise that there are also tremendous energy savings potentials here that will allow them to drastically reduce their carbon footprint. In addition to recovering the waste heat from air compression, they can also make compressed air production much more efficient. In fact, many companies waste up to 50 per cent (or more) of the power required for compressed air generation, for example through the inappropriate use of compressed air or inefficient system designs. So how can we eliminate these inefficiencies, design more efficient
compressed air systems and make a meaningful contribution to a cleaner environment? A compressor installation that consumes 90 kW for 8,000 operating hours per year represents a yearly energy consumption of 720 MWh or 509 metric tons of CO2. The possibilities for recovering substantial amounts of waste heat via hot air or hot water are real. Up to 94 per cent of the electrical energy is converted into compression heat. Without energy recovery, this heat is lost into the atmosphere via the cooling system and radiation.
The big question is how to make your production process more carbon neutral while at the same time maintaining a competitive edge.
Compressed air is a highly effective and safe form of energy for powering production equipment or processes.
manmonthly.com.au
Energy Savings 10-step guide to a greener and more efficient production Atlas Copco’s 10-step process allows companies to drastically reduce their energy requirements and their carbon footprint, while also saving money and the environment. Some of these steps can be taken right away and require hardly any financial commitment, while others involve infrastructure investments that will pay off in a big way down the road. This guide should not be seen as a one-off exercise, but rather as a continuous process to maintain peak production efficiency. Scan the QR code now to find out more about our 10-step guide.
We strive for energy efficiency From the research and development of compressors, through production to the project planning of systems and service: as a compressor manufacturer, we always strive for efficiency in the use of resources, for
manmonthly.com.au
the highest possible profitability and sustainability for our customers. Regardless of your industry, we have the right solution for your compressed air, oxygen or nitrogen generation for all.
Our local team We have employees nationwide across Australia available for advice, planning, installation, service, maintenance and the optimisation of existing compressor systems and offer you the range of services of a global compressor manufacturer.
Compressor service Service is our strength: Project planning, optimisation, servicing and maintenance are just a few of the pillars of our service philosophy: • Air energy audits to determine the compressed air requirement; • Compressed air management and continuous energy saving solutions; • Remote monitoring with Smartlink; • Original spare parts with manufacturer’s guarantee; and
DID YOU KNOW? A maintenance solution tailored to a compressor’s workload; application and site conditions reduces the total cost of ownership by an average 35 per cent. A lifetime of maintenance is cheaper than the potential impact of maintenance shortcuts, such as: high energy consumption, production downtime, safety and labor issues, non-compliance fines, purchasing and installing new equipment, etc. A single day of unscheduled downtime due to a compressor failure can cost much more than a year’s worth of maintenance. By having the right maintenance solution, you can gain up to 15 days in machine uptime.
• Tailored service options to suit your production.
The next big thing We know that your next compressed air product purchase will be a huge decision, especially when there are other products in the market. We can assure you, once you chat with one of our friendly salespeople, that you will indeed be onto the next big thing, when you can actually prove that we can save you a
substantial amount of money off your bottom line. As well as cost savings, the next big thing is our future. Together we can reduce your carbon footprint with our proven energy efficient air solutions. So, are you ready to be a part of the next big thing for your business? For more information about Atlas Copco and its products, please scan the QR code.
Manufacturers’ Monthly JUNE 2021 27
IoT and Connectivity Superior connectivity for better workflow To meet market demands and streamline costs, Corex Plastics P/L has stepped up its game in tightening its back-end systems. Manufacturers’ Monthly speaks to John Hughes, automation technician from Corex Plastics and Amit Shinde, technical sales engineer from SICK to find out how.
E
STABLISHED in 1985, Corex Plastics is an independent private business that has grown from extruding semi rigid twin wall sheet into a fully integrated polymer product business involving manufacturing, packaging fabrication and recycling products for its broad range of customers.Today, operating 24/7 Corex’s well-known
brands include Fluteboard, Corflute, Imageboard, Versamount, Stericor to name a few and are used for many applications such as signboards, solar heating panels, automotive tote boxes, fresh produce packaging, bulk packaging, divider boards, vacuum forming, slip sheets, pallets, as well as drum and cable protection products packaging. Supplying to
a national customer base, they also export its products worldwide and have won a number of international innovation awards. John Hughes, automation technician from Corex Plastics, who caught up with Manufacturers’ Monthly, explained that its flagship product is Corflute, a twin wall plastic board used in The IO-Link gives an application a lot more data at the sensor level and can share it upstream to other devices.
a broad range of applications as substitute for derivative cardboard products particularly where reuse, a wet environment or durability is required. Additionally, the company manufacturers other extruded sheet products in semi rigid sheet that then fabricated into downstream fabrication processes into a broad range of products across industry. “We supply sheet product or full turnkey fabricated product directly to end users alike. Utilising a range of processes, some developed in house, we can provide tailored products to meet a unique requirement of a customers from conventional plastic boxes for produce, seafood, distribution centres and other demands of modern supply chains. Then at end of useful like we can take the product back for reprocessing and reuse,” Hughes said. “This is achieved with our recovery process managed by the Corex Recycling division that accepts end of life polymer materials to which we can reprocess back in a useable raw material for use in our sheet extrusion process or on sell back to industry for other applications. “In this way, we offer the full circle of plastic use and recovery.” “It’s a growing business and we’ve worked right through COVID – it hasn’t stopped, so it’s been quite a busy time for us because we supply products to the food industry and other essential industries,” Hughes said.
The importance of a sound automated system For a business like Corex that requires a high volume of output for its customers, speed and efficiency are key while keeping bottom line costs down. So, in the production line, having a sound, error-free and practical back-end system to keep 28 JUNE 2021 Manufacturers’ Monthly
manmonthly.com.au
IoT and Connectivity
John Hughes, automation technician from Corex Plastics.
the workflow smooth, is important, as Hughes explained further. “My role here at Corex is that of an automation technician and I do industrial programming. My goal here is to automate the machines around the plant,” said Hughes. “This has been helped greatly by using quite a few SICK sensors and other devices that got the job done.” He mentioned that he consulted with Amit Shinde from SICK about his interest in getting into the IO-Link connection to improve the current systems with specific applications. “I’ve used other types of networks, but IO-Link is very functional, very practical,” he said. “Typically, you’d run a sensor all the way back to the main cabinet and there would be a lot of wiring involved – you have to rewire it all the way back. However, IO-Link is a universal protocol across the industry, and I was presented with these modules that have a master and also a slave version.” The application of the protocols works out for Corex, as Hughes explained, because instead of running physical cables to each sensor back to the main cabinet, one network (daisy chained) and one power cables can be run from the IO-Link master back to the main cabinet for ease of installation and collection of information needed. “We monitor our air supply to measure the air supply within the plant, where we can calculate the level and usage of air. In another application, we monitor raw materials manmonthly.com.au
silos, so we always know the current capacity and usage of the silos at a point of time. This is all through the SICK IO-Link master via an ethernet connection back to the PLC or central unit,” Hughes said. “Traditionally, I used other applications and had to go out and spend thousands of dollars for a separate PLC which need to separately programme each device to get those signals and send them on, whereas this as an alternative is this case the SICK IO-Link master collects the information from sensors then the centralised PLC does all the heavy lifting at a much lower cost, that does essentially the same thing – data communication.”
The SICK IO-Link master collects the information from sensors, then the centralised PLC does all the rest of the data management.
The speed of data transmission One of the new applications at Corex is to setup production line monitoring across the site that can be displayed on a computer, large TV, table or mobile phone, etc. in real time. This information can be the speed of the line, uptime/downtime, how efficiently we produce the finished products and how many rejects there were. All of this information was hardwired back -to centralised PLC with the SICK IOLink master. “You’re able to get the same or more amount of information at a tenth of the price,” Hughes said. “It’s very cost-effective, when a simple on/ off signal can be used to calculate the rejection ratio you don’t need a fancy device – that’s where it gives the saving and functionality.” Hughes said that his team was going through the motion to monitor each of Corex’s sites and was impressed at the cost savings he got with the quality of efficiency he received. “Instead of spending $5,000, we would spend under $1,000 on each line,” he said. “It is low in cost and a very practical device that meet our requirements.”
Why the SICK solution Hughes said that he had dealt with SICK prior to this enquiry at other manufacturing plants and he feels that SICK would provide very good solutions. “They’ve got so much of the
industrial range covered – like a one-stop shop to get your machine up and running,” Hughes said. “I’ve used them for safety devices and other applications across the plant. It’s not just here, but at other sites as well. Overall, I’ve been very happy with the reliability of the device for the current applications, and I think a lot of thoughts has been put into the product development as well.” He explained that it is not just the IO-Link Master that’s got the power in it but also the sensors. “It’s an industry standard now and you can actually see how many times it has been triggered in the past or what temperature it is running at or whether it is dirty or it is not working at optimum performance because it needs cleaning or if the sensor is failing – that sort of information you were never able to get out a of a standard sensor. “IO-Link is giving me so much more data at the sensor level, let alone at the production level and the Master can pull it out and share it upstream to other devices – it’s just simplified industry as a whole basically,” he said.
Implementation, support and transition Amit Shinde, technical sales engineer from SICK who was in touch with Hughes through the implementation
said that when it comes to after support, Hughes was provided application videos, as well as Shinde’s personal technical expertise to support the implementation and installation. “Apart from this, we also have a technical department to help John in simplifying the understanding of our new products,” Shinde said. “As a team from SICK, we supported John so he can upgrade IO-Link connectivity in his factory.” “They’ve been very supportive, and their software is fairly intuitive, and I believe that I’ve picked it up fairly quickly,” Hughes said. “It is not over complicated to understand, really, because once your device is connected to a network, you can connect via a web browser. “Any questions I have, if I think whether I should be doing it this way or that way, I’ll get on the phone and I can get the answers pretty quickly, so I’d say on the whole, it’s very simple. “There’s a couple of different modes you can use, so anybody who has a technical background won’t have a problem with using the module itself – I wasn’t waiting weeks and months for an answer,” Hughes said. “That’s one of the things about SICK. It is a good product and a good company, and they stand by that product.” Manufacturers’ Monthly JUNE 2021 29
Machine Maintenance Reducing the cost of poor lubrication Manufacturers’ Monthly speaks with the John Sample Group and SKF Australia about educating customers on good industrial lubrication practices through their business partnership.
A
CCORDING to industry studies and data, lubrication contributes approximately one to three per cent of the overall cost of a manufacturer’s maintenance budget. However, the impact that poor lubrication can have on equipment in terms of premature failures can amount to 50 per cent at its highest and become very costly, causing unnecessary downtime for manufacturers. JSG Industrial Systems (JSG), a John Sample Group business, uses its vast application engineering resource base, as well as OEM factory specifications, to determine the correct lubrication system needs for customer applications. The company provides access to a complete service for the supply of lubrication systems covering system scoping, design, installation and commissioning through a national installation network with comprehensive after sales support. JSG has been a distributor for SKF’s Lincoln lubrication systems since 1961, and is SKF’s largest lubrication system partner globally. JSG takes to market, the complete range of SKF lubrication solutions and combines this with inhouse engineering expertise and extensive application experience to deliver solutions tailored specifically to address customers’ needs,” JSG Industrial Systems national sales manager, Italo Marcantonio, said. JSG became strongly linked with SKF when SKF acquired the Lincoln Group in 2010. JSG has been involved in the delivery of high-quality lubrication systems to various markets for more than 50 years. Since the acquisition, SKF has maintained a strong relationship with JSG – forming a business partnership that has flourished and 30 JUNE 2021 Manufacturers’ Monthly
grown over the past ten years. SKF Australia Business Development Manager, Cenk Ozbilgen, said JSG’s engineering expertise and design capabilities, installation and servicing – as well as its stockholding and presence in the Australian and South East Asian regional markets – are factors that make the company valuable as a distributor. “The only way to approach a lubrication problem is to understand the application, know the options available to address the problem, and then have the capability and expertise to design and engineer a system solution,” he said. “JSG Industrial Systems has vast experience and knowledge in all
facets of industry, and when they’re onsite with a customer can identify the right lubrication practices for that customer.” One of the key causes of machine failure occurs when incorrect quantities and type of lubricant make its way into a machine, Ozbilgen said. He believes not enough attention is paid to good lubrication practices. “Correct quantities of lubricants are essential for optimum bearing performance. If you over lubricate a bearing, it can cause increased heat due to the bearing having to work harder to push through the grease,” he said. “Over lubricating can also cause seals to fail, thereby, starting to introduce contamination.
One of the key causes of machine failure happens when the wrong quantity and type of lubricant makes its way into a machine.
Conversely, under lubrication can cause increased heat due to metal to metal contact.” Ozbilgen said achieving optimum lubrication is all about preventing metal to metal surface contact. The two main ways to improve lubrication are associated with storage and handling, and the correct application of the lubricant.
Educating the customer SKF strives to educate its customers about the importance of good lubrication. The company has conducted studies for as long as they have manufactured bearings to investigate the causes of premature bearing failure. “Our studies and other independent studies indicate that up to 50 per cent of premature bearing failures are a result of poor lubrication,” Ozbilgen said. “So, what is poor lubrication? Basically, it’s contamination of the lubricant, it’s over and under lubrication, it could be incorrect storage of lubricants, incorrect handling of lubricants and any cause of cross contamination.” SKF, in conjunction with its distributors, provides knowledge in relation to handling and storage of lubricants. “One of the things I’ve noticed since working in this industry is that lubrication is extremely important for the operation of machinery and rotating equipment,” Ozbilgen said. “Delivery can come simply in the form of a grease gun, or a single point lubricator, or it could be a fully automatic lubrication system, depending on what the application is and what the customer’s expectations are. “In terms of storage and handling, it’s trying to eliminate the introduction of contaminants into the lubricant prior to being introduced into the rotating parts of a machine”. manmonthly.com.au
Lifting Solutions Three standard features of a KITO Electric Chain Hoist that are unique in the market KITO PWB national hoist specialist, Glenn Morgan, tells Manufacturers’ Monthly about the standout features of KITO’s electric chain hoist.
W
HEN searching for an electric chain hoist to lift high-mass items at your business premises, you need to make safety and efficiency your top priorities. This means putting the right solutions in place to guarantee the right results every time. KITO heavy-duty hoists are the answer here. Some of the features you’ll find on a KITO Electric Chain Hoist, you won’t find as standard anywhere else in the market. These features keep operating costs low, while boosting workplace safety and equipment longevity.
Condition monitoring The built-in Count Hour (CH) metre is a standard feature on KITO Electric Chain Hoists. This feature records the hoist’s operating time, delivering crucial insight that can be used to schedule maintenance and monitor usage levels. An accurate CH meter data history is important for managing inspection periods, including the timely replacement of gear oil, brakes, load chains, and other components. This means you can perform maintenance exactly when it is required — not too early (taking the equipment out of commission unnecessarily) or too late. Users will also be able to plan when they need to retire the hoist. Retiring the hoist when it reaches its design life is crucial in guaranteeing ongoing safety and effectiveness at your facility. Most hoists do not have the capability to advise users when the end of the design life is approaching, but KITO Hoists include this as standard. Many hoists are in fact retired too early by overcautious facility managers — the CH meter provides the data required to avoid this. This feature is fully compliant manmonthly.com.au
with Australian Standard AS 2550.1.2011, which specifies the general requirements for the safe use of cranes, hoists, and winches.
State-of-the-art chain Most hoists in the market use zinc-plated chain, which is soft and easily worn down. KITO is the only manufacturer to use original superstrength nickel-plated case-hardened chain certified by the German Institute. Its shorter and narrower link profile allows for greater surface area contact, optimizing its resistance to wear and tear, as well as its overall tensile strength. In addition, this chain is highly
resistant to rust and other forms of corrosion and is designed to combat hydrogen embrittlement. The KITO team manufactures and designs both the KITO Hoist body and the chain. We can personally guarantee the quality of the load sheave and the chain, as well as the accuracy of the engagement between the two. This is very different from the majority of KITO’s competitors, who design and manufacture their hoist bodies, but order in chains from third-party suppliers.
The dual-speed inverter achieves smoother transitions than a simple
pole change motor, reducing load swing. The drive can also be safely started and stopped, with smooth transitions between. Thus, there is less chance of damage to the product or equipment. Users will be able to accurately adjust the high-to-low speed ratio according to their needs. The inverter will set the phase rotation automatically, meaning that the hoist can be deployed across numerous locations and positions with no need to rewire the phases. The drive also features Thermal Overload Protection as standard, which protects the hoist motor from overheating and related damage.
The KITO electric chain hoist allows the user to perform maintenance as required.
Find the perfect heavy-duty hoist for your purposes
Variable frequency drive
Safety is always paramount, and the hoist you choose has to reflect this. When you choose a good-quality piece of hoist equipment, you will notice features such as emergency stop functionality, automatic braking, friction clutches, thermal protection for the hoist motor, nickel plating on the load chain, upper and lower load limit settings, and other elements that keep your hoist functioning as it should for longer. Most importantly, it provides necessary maintenance when required, not before or when it’s too late.
KITO is the only manufacturer to use the original super-strength, nickel-plated, case-hardened chain. Manufacturers’ Monthly JUNE 2021 31
Compressors The history and story of BOGE Compressors BOGE have released the new generation of small oil injected screw compressors up to 30kW.
M
R Otto Boge founded the company BOGE in 1907 and started by manufacturing door closers and later expanded into motorbikes. Otto quickly made a name for himself producing speciality tools for the emerging automobile industry. Finally, BOGE became a specialist manufacturer of compressors and compressed air appliances. Now, more than 110 years later BOGE is still a family-owned business with the Great Grandson of Otto, Mr Wolf Dietrich Meier-Scheuven as the managing director. During all this change, and many challenges, the company values have never changed. They remain innovative, customer focused and a fiercely independent family-owned business. Today they are a worldwide leader in the compressor market. BOGE Compressors are not just assembled in Germany but almost all of the required components are manufactured locally in Germany. This is unique and truly the brand can say they represent the “Best Of German Engineering”. Today, in 2021, BOGE have released the new generation of small oil injected screw compressors up to 30kW. These innovative new models are available as a base mount
The new range of small oil injected screw compressors includes variants up to 30kW. 32 JUNE 2021 Manufacturers’ Monthly
Ergonomic controls bring a new level of competence to BOGE’s range. unit, base mount with integrated refrigerated air dryer or both of the above on a 500L air receiver. All of the fixed speed models are available as belt drive with 8 or 10bar options. The variable speed models are direct coupled and again available in several pressure options also as base mount, integrated dryer or both of the above on a 500L air receiver. The new range includes: 12kW, 15, 18.5 and 22kW variants in either fixed speed belt drive, or the variable speed direct coupled options. These new and innovative designs introduce a new class of competence in compressed air production with “ergonomic controls”, anti-vibration mounts, air intake filtering and low sound emissions as standard. You would expect that such German engineered precision would command a premium price, but due to the efficiency of the manufacturing process, these machines are very
These new and innovative designs introduce a new class of competence in compressed air production with “ergonomic controls”, antivibration mounts, air intake filtering and low sound emissions as standard. modestly priced compared to many other competitors in the market.
About BOGE Compressors Reliable, clean compressed air has been BOGE’s trademark for more than 100 years. The quality and efficiency of our compressors and compressed air solutions have led us to enjoy the trust of over 100,000 users in 120 different countries. Based in Pakenham, Victoria – BOGE Compressors Australia have been established in this market since
2006 and was incorporated as an independent subsidiary in 2010. BOGE Australia import and distribute BOGE high-quality German machines, spare parts and all ancillary equipment through a comprehensive network of fully-trained sales and service partners throughout Australia, New Zealand, Papua New Guinea and Fiji. To find out more about these new innovative products got to www.boge.net.au or call (03) 5940 5913 for your nearest BOGE sales and service partner. manmonthly.com.au
Women in Industry Striving for success with a team ifm marketing manager Rachael Ashfield reflects on her career and encourages women to celebrate their small wins.
I
ifm marketing manager, Rachael Ashfield.
N this month’s column as Women in Industry Ambassador, I wanted to reflect on my secret to success – my team. I truly believe that your success is only as good as the team structure, rapport and networks that you build, all of which lend themselves to the overall success of the company. Hearing that I work for a highly technical automation company that sells complex automation and cloud solutions is not what people expect when they meet me at an event and ask what I do. Especially when I begin by explaining that I am in marketing. Eyebrows are quickly raised, and I know everyone wonders how I ended up here.
If I think back on my career, I too sometimes ask, “How did I get here?” From the outside, it might seem like a slow rise to such a senior position, but the journey to head of the marketing division at ifm has been so quick in my eyes. My career has seen me travel pathways filled with triumph, hurdles, and yes, at times, disappointment. But throughout it all, I’ve had a supportive team around me. While not everyone may have a “dream team” when starting out, I believe you get out of teamwork what you put in. Whether a man or woman in any role within any industry, if you bring a level of energy and conviction of belief to The Women in Industry awards help women acknowledge their small wins.
manmonthly.com.au
your career journey, the hard work will pay off and successful results will follow. Even better is when you have worked with a team for a period and have developed great synergies – this builds a solid foundation for success. Together you build excitement, engagement and a dynamic that people want to be a part of. Departments can see the rewards of their participation with you when they see the outcomes of the material you produce because of their contribution towards the end goal. As long as you are passionate, believe in yourself and strive for your best possible outcomes, you will be assured of career success and job satisfaction. It may not be easy and will possibly be a bumpy road along the way but remember to celebrate the small victories. It is easy to overlook all these important milestones when you are busy working hard for the career highs. Luckily, Women in Industry is here to help you acknowledge these small wins. We are the supportive team you can count on to be cheering for your success, the network of like-minded women here to help build the excitement and engagement that will see you ooze confidence and work towards those big overarching career highlights. Ultimately the foundation of success of women in any industry is the innate desire to achieve results and strive for success in your chosen field. Being able to participate, network and apply your own understanding of people and what drives them will build a strong supportive team to help both individuals and businesses succeed. One day, your team might even nominate you for a Women in Industry award. Until then – nominate yourself. We’ll be here, ready to support you. Manufacturers’ Monthly JUNE 2021 33
Compressor Maintenance Peace of mind with oil-free and why best practice is the smarter choice There is a growing need for standards around food safety in Australia and Sullair recommends the use of oil-injected compressors in food and beverage production.
F
OOD and beverage manufacturing is without question taken for granted in everyday life – that is until the COVID-19 pandemic. How our food was produced and distributed was brought to the forefront in 2020 and the scenes of empty supermarket shelves are still etched in our memories. The impact of the pandemic on these companies behind the scenes was enormous and as a result, many are re-evaluating everything about how they do business. This will be even more necessary where the transit of goods across international borders is concerned, in the post-pandemic marketplace of the future. Product safety has become more of a priority than ever. Regulations are expected to tighten in the marketplace to match international standards. These standards are determined by both the Therapeutic Goods Administration (TGA) and Food Standards Australian New Zealand (FSANZ). For those in food and beverage production, there’s a sense of inevitably that changes will come around the use of oil-injected compressors in food and beverage production. It has been a point of growing contention for some (especially for those exporting to heavily regulated overseas markets) and ambivalence for others, that the Australian food industry has no mandated standards around oil free equipment in food and beverage manufacturing. Internationally, this is not the case – ingestible products are produced under strict regulations and must be manufactured using oil-free machines. ISO 8573-1:2010 specifies “purity classes of compressed air with respect to particles, water and oil independent of the location in the compressed air system at which the air is specified or measured”. In fact, this standard
34 JUNE 2021 Manufacturers’ Monthly
Food and beverage manufacturers must take it upon themselves to follow best practice production processes.
specifically “provides a classification system for the main contaminants of a compressed air system”. In many countries, standards around oil-free status are strictly enforced. Companies uniformly must provide evidence of being certified to this standard for their products to be legally allowed on the market, to cross borders from one country to another, and to be protected for the purposes of insurance, to name a few examples. This kind of tight regulation protects manufacturers as much as consumers. Food contamination of any kind is not just a health and safety issue for consumers – the negative impact on a company’s reputation and its brand would be significant if consumers were alerted to the level of contaminant risk in their product. Australia currently lacks overarching standards around the use of oil-injected compressors within the food and beverage industry, and as a result the details embedded within existing standards differ from seafood to dairy, poultry to seeds and so on. The concept behind standards and regulations is to minimise risk as much as possible. However most risks can never be completely eliminated, so can be managed (and ideally mitigated)
through comprehensive standards and regulations to ensure public safety. Given the lack of Australian standards on the topic, many food and beverage manufacturers currently operate in a grey zone of safety and contamination levels. Some manufacturers argue that the air is not always in contact with the food, so the risk is removed. Others continue to use oil-injected equipment but with filters to minimise (not eliminate) contamination. The use of well-filtered oil-injected equipment still comes with the risk of contamination, as filters saturate over time and aren’t always replaced on time. However, in the majority of food production, compressed air must come into contact with food – think air being blown into bags for food to be inserted, or liquids being injected into cartons, filling deposited into cakes and pies – so the risk of oil contamination exists. Sullair aims to always take on an advisory role on this subject. Supporting the customer with insights into best practice, whilst assisting them to make choices around the best equipment for their needs is paramount. New food and beverage clients are advised to choose oil-
free, for reasons outlined, while existing customers are supported to upgrade if and when they feel the need arise. Some food and beverage manufacturers are already taking the initiative to switch to oil-free, even though regulations don’t yet demand it of them. This may seem overly cautious to some, but there is a sense that proactively making the change to oil free, will build in high levels of trust from their consumers and reduce everyone’s risk by design. Until national and mandatory regulations around compressed air quality in food manufacturing in Australia are implemented, food and beverage producers must take it upon themselves to follow best practice production processes by using oil-free compressors. After all, the easiest way to avoid oil contamination risk is to remove oil entirely. The risk of contamination in the production line exists all the time.
manmonthly.com.au
Bulk Handling Staying resilient, the Walsh & Ford way Owner of bulk handling company Walsh & Ford, Peter Walsh, speaks about how the business has been able to continue catering for a variety of demand over the decades.
W
HEN asked to share his views on what has changed in the world of bulk material handling for Australian farmers over the past decades, Peter Walsh is quick to respond with “sizes, volumes and capacities”. “The machines that we produced in the 50s, which would have serviced the requirements of farmers quite adequately, are now considered nothing but toys,” says Walsh, the owner of Walsh & Ford company based in Dalby – which has been meeting the requirements of Australian farmers for over seven decades. “Everything has gotten bigger, tougher, faster. A bulk bin in the late 60s or early 70s might have had about 8-10 tonnes of capacity. That’s now being superseded by bins 36 tonnes or bigger. The farmers want to move massive payloads, efficiently and with minimal labour.” Established in 1949 by Walsh’s father, Eric Walsh, and his business partner Percy Ford, the Walsh & Ford business began by producing different items to meet the requirements of local farms. These covered anything from bagging hooks to saleyard gates, hinges to steel shed frames. But the advent of bulk handling in the 1960s propelled Walsh & Ford onto another level, according to Walsh. “Starting around the 60s, the farmers began mechanising their bulk handling processes. By this time, we were producing as many as 100 units of augers or bulk bins per season. In those times in rural Australia, this was a major feat. Today, while we predominantly specialise in grain handling equipment, we also help with bulk movement of liquids, such as molasses, and even ducting air for cotton gins,” says Walsh. Today, Walsh & Ford has diversified its engineering services to manufacture custom-designed grain augers, barrel belt conveyors, grain buggies, grain haul and bins, and manure spreaders. Since joining the family business in 1992, Walsh
manmonthly.com.au
Walsh & Ford has been able to weather the ups and downs in market demand through diversifying their product range.
has also expanded the company’s clientele to include not only farmers Australia-wide, but also commercial customers such as cotton gins, stock feed producers and even oil and gas companies. It is through this diversification that Walsh says Walsh & Ford has been able to weather the ups and downs in market demand. “We know demand ebbs and flows across our great country and we’d prefer to have a quiver full of different arrows that can address any particular need rural Australia has. One of the most satisfying things for us is when a customer who has purchased one particular product from us comes back in a few months with a requirement for a completely different product. This tells us that our customers don’t regard us as a one trick pony,” says Walsh. Innovation in design and the capability to customise products is something that Walsh says Walsh & Ford prides itself on. “One of our biggest strengths is in taking standard products and enhancing their design so that they become more user-friendly. An example is our versatile manure spreaders. We have designed them so that you can take the top off and put a chaser bin on the same trailer frame. We initially designed the manure spreaders with removable tops for ease of servicing but as soon as we did that, it became a very popular option for farmers,” says Walsh. Backed by the skills of its long-term
employees, Walsh & Ford also helps its clients rebuild or enhance their existing equipment, some of which are 20 to 30 years old. In all of its design, manufacture and rebuild works, Walsh says Walsh & Ford always uses parts and components that have proven to provide a high performance. That is why Walsh says his choice of bearings has always been the NTN bearings. “Over the past decades, we’ve consistently enhanced our designs to cater to the higher capacities and efficiencies required by our customer. We use NTN bearings across all our products, whether it be conveyors, manure spreaders, chaser bins, or augers and we have never had any issues or failures,” says Walsh. For many decades, the CBC branch in Eagle Farm of Brisbane has been the go-to supplier for Walsh & Ford for all of their industrial requirements, not just bearings but also power transmission equipment and specialty seals. Warren Beale, who initially joined CBC in 1968 and is currently the Original Equipment Manufacturing Manager at the CBC Eagle Farm branch, has known Walsh since Walsh was a kid, visiting the CBC store with his father. “Peter is very much a relationshiporiented person, so whenever he visits Brisbane, he makes sure to visit our branch and he always meets everybody in the branch. We also regularly visit him in Dalby to help him with any supply requirements he may be having or any specific parts he may
be looking for.” Walsh says the close relationship he shares with CBC as his supplier has helped him in more ways than one. “CBC is more than just a supplier for us. I’ve known Warren Beale since the time of my father. Keeping faceto-face relationships is very important to me and CBC is very good that way. They are the type of people that I can ring up, talk about certain things and they can solve issues for me or aid my manufacturing. These might be things like sourcing taconite seals for my manure spreaders or finding parts for old equipment we are refurbishing.” Moreover, Walsh says having a reliable supplier like CBC is critical for his business to meet its commitments to customers. “We have just-in-time policies that need to be spot on. That’s especially important for us during the busier seasons. For example, last year’s grain harvest was our largest season yet, and with the pressures on supply chain because of COVID-19, I was regularly talking to CBC about the supply situation. They would let me know if something was going to be in short supply as I didn’t want to strain the market with my orders. That’s the sort of trust-based relationship that I share with CBC,” says Walsh. Despite the hit backs from droughts in the east coast, Walsh is optimistic about the region’s agricultural recovery. “The future is bright. There have obviously been issues for farmers as droughts have affected the east coast, but with the foreign trade deals the country has recently secured and our domestic capabilities around food product manufacturing, I believe agricultural trade is going to pick up soon. And if we have learned anything from working in this sector is that nothing stays the same. The weather systems will change and the farmers and cotton gins will be looking at enhancing their existing equipment. When they do, Walsh & Ford is always ready to help them.” Manufacturers’ Monthly JUNE 2021 35
Welding Giving Australian farmers the most efficient grouper bins Clear Ridge Fabrication’s SUPA Bin eliminates the need to tip multiple trailers, making for a safer and more efficient workplace.
S
WITCHING between seed, fertiliser and urea without contaminating one with the other is the ultimate goal when using a grouper bin – and Clear Ridge Fabrication (CRF) have found a way to make it possible. The company’s SUPA Bin is a multipurpose unit that can be utilised in many farming operations including sowing, spreading, filling sheep feeders, filling silo bag machines at harvest time and carting bulk grain. With an unloading rate of up to four tonnes per minute, CRF’s SUPA Bin is an efficient grain transfer option for bulk storage. Brothers Kaidan and Dallas Boyd, both qualified welders, began developing their SUPA Bin design after they leased their family farm nearly three years ago. Traditionally, the Boyd family cropped 3441 hectares of wheat, barley, and canola north of West Wyalong in New South Wales. When the drought took hold, the family made the decision to lease out their farm and the two brothers combined their talents as qualified welders to launch CRF. “On the farm, we always dreamed of a bin like this. We had created the design in our heads so when we leased out the farm, we jumped straight into manufacturing,” says Kaidan. To manufacture and mount the SUPA Bins, the CRF team puts in many hours of welding. Kaidan says each unit roughly needs 80 to 100 metres of welding, with the team delivering as many as 30 units per year. In search on quality welding equipment, they needed to look no further than the local BSC branch in Wagga Wagga. “Welding is a major part of what we do. Achieving clean welds is 36 JUNE 2021 Manufacturers’ Monthly
critical to both the quality and the aesthetical design of our products,” says Kaidan. In collaboration with Welding Industries of Australia (WIA), the BSC branch delivered four WIA Weldmatic 270 single-phase welders to CRF, which the team has been successfully using to manufacture their products. According to Kaidan, WIA was a brand of choice for CRF from past experience. “When Dallas and I were apprentices, we worked with a few different welding machines, but the best welders in the shed were always WIA. Knowing that, we contacted Mitch Chaffer, sales representative at BSC Wagga, looking for our WIA welder machines.” Willem Corbett, WIA’s Development Engineer for Equipment, says the WIA Weldmatic 270 is often used for light fabrications in rural and semi-rural areas where three phase power is not very common. “The Weldmatic 270 machine runs on a single phase 240V power supply. If operated below 200 Amps (amperes), then the machine can comfortably run from a 15A single phase 240V supply. If full 270 Amp performance is required, then a larger supply – typically 32 Amp – is required. This single-phase convenience will suit many light fabrication businesses,” says Willem. Kaidan says he is pleased with the service they receive from BSC. “Everything is just easy with BSC. BSC Wagga Wagga supplies us with everything from bearings to consumable products for our workshop. The transaction is always very smooth and problem free,” he says. Within just three years, the SUPA Bin has reached farmers in almost
every state in Australia. The CRF team has also expanded to include three new tradesmen in addition to Kaidan and Dallas. Kaidan says CRF has already filled out its order slots until January next year, with orders still flowing in. Kaidan says customers had been looking for a bin to take the place of multiple trucks and cut down on fillup time of an air seeder. The SUPA Bin design has addressed both issues with the added bonus of eliminating tipping trucks in the paddock, resulting in a safer operation. “When you use tipping trucks on wet paddocks, you run the risk of the equipment turning over or getting stuck in the land. We saw a gap in the market for non-tipping trailers that would eliminate those safety risks. SUPA Bins can be mounted on any existing equipment such as skel trailers or any other equipment as per CFA customers’ requirements,” says Kaiden. “Moreover, a lot of growers use their existing augers on the side of the air seeder, which poses risk of cross contamination if the augers are not cleaned properly. We have introduced the SUPA Tube to replace belts where augers were traditionally used. The SUPA Tube ensures there’s no contamination between the seed and the fertiliser,” he adds. As the CRF business grows, Kaidan says the company is set
to move to a bigger workshop to increase production rates, as well as to develop new products for its customer base. The team is also looking to purchase more WIA welder machines. “We are happy with the performance of our four existing WIA welding machines. The next step for us is to buy a three-phase welding machine from WIA. When we are ready, we will get in touch with Mitch Chaffer from BSC to work out the best product for our workshop,” he says.
Welding Tips To choose the best welding machine for your workshop, you need a clear understanding of the anticipated current and duty cycles. If your workshop is limited to single phase supply, you need to take into account the machine temperature rise and the power supply capability. To better understand the duty cycle, consider the below example: The WIA Weldmatic 270 duty cycle is rated as: • 270 A, 27.5 V, 20 per cent duty cycle on 25Amp supply • 200 A, 24 V, 22 per cent duty cycle on 15Amp supply Duty cycle is interpreted as the weld percentage time over 10 minutes. So, a duty cycle of 20 per cent means two minutes of weld at 270 amps, followed by eight minutes of no weld. If the output current is less, then the duty cycle can increase.
The SUPA Bin has reached farmers in almost every state in Australia.
manmonthly.com.au
Compressors CAPS compressor instrumental to University of Melbourne research The high-pressure Sauer compressor from CAPS Australia is helping researchers at the University of Melbourne develop accurate testing processes.
The researchers were trying to create an accurate theoretical model of hydrogen oxidation and the use of highpressure compressed air to dilute the gases was required – which was where CAPS compressors came in.
W
HEN University of Melbourne PhD researcher Junqiu Jiang walks into the Mechanical Engineering laboratory to conduct tests on hydrogen gas with a Plug Flow Reactor, one of the first things he does is to turn on the highpressure Sauer compressor unit the lab has received from CAPS Australia. The unit, which CAPS Australia’s Melbourne division helped design and deliver, can compress air at a maximum pressure of 80 bars, at a 30 grams-per-second flow rate. The Sauer high pressure unit also features high-pressure BEKO air dryer system to remove moisture and oil from the air – something that’s critical to Jiang’s test processes. Jiang’s research aims to create an accurate theoretical model for hydrogen oxidation by simulating a high flow reactor. As such, his study relies on high-pressure compressed air to dilute the gases he experiments with. “When you need to design something, you want to be able to simulate it first instead of building a prototype every time. That’s what I’m doing. I’m trying to make an accurate hydrogen combustion model,” says Jiang. CAPS’ product manager for gas and special products, William Chan,
manmonthly.com.au
says the unit was designed by CAPS with the specific requirements of the research in mind. “We followed the process we usually follow for any of CAPS customers, which is to gather information about the flow rate, the pressure, the type of gas and the air quality required. Based on those parameters, we recommended the Sauer high-pressure compressor and the BEKO air drier as they provided the best combination for the laboratory’s application,” says Chan. Once CAPS engineers defined the parameters, the unit was manufactured by Sauer and shipped to Australia via sea. The overall time from order to delivery was less than 20 weeks. CAPS’ local service team in Melbourne then helped the university with the final commissioning. The University of Melbourne is not the only higher education institute where CAPS’ compressors are helping research. William says CAPS’ oil-free and high-pressure compressors are installed in multiple universities in Western Australia, Victoria, Queensland and ACT. CAPS Australia territory manager, Martin Wahl, says being the largest independent compressed power generation provider in Australia enables CAPS to custom design compressor
units in collaboration with leading global manufacturers – without being limited to any one company’s products. “CAPS works with a number of local companies to assist with the pipework and installation. In this case, the University of Melbourne undertook the installation themselves, but our engineers conducted the pre-commissioning checks to make sure everything was installed correctly,” says Wahl. “CAPS is the exclusive distributor of the Sauer industrial range in Australia. We are also the biggest local distributor of BEKO dryer systems. Both companies are known as high-end brands in their respective fields. At CAPS, we are never limited to off-the-shelf products. That enables us to provide fit-for-purpose compressors to our customers.” Headquartered in Perth, CAPS Australia has over 200 employees across nine branches nationwide. That is another reason Wahl says the University of Melbourne chose CAPS. “When the University of Melbourne decided to buy a compressor unit, CAPS was the only compressor company with a local presence in Victoria that could provide the service they were looking for. With a team comprising
of engineers, support staff and an aftermarket service team, we were able to meet and exceed the university’s expectations.” Since installing the unit nearly two years ago, the CAPS service team has conducted one annual routine maintenance and assisted the lab with after-sale support, as Jiang explains. “CAPS has been very helpful in providing us with after-sales services. Last year, when we had some concerns regarding the heat generated from within the room, CAPS’ service team was quick to respond with a solution with extended intake from outside of the room and advised on installing powerful ventilator fans to solve the heat issue,” Jiang says. Though the Sauer compressor unit can provide up to 80 bars of pressure, Jiang is currently using about half of that pressure for his study. But the pressure can easily be regulated to higher levels for any future research program conducted in the lab. “The compressor has been a great addition to our laboratory. We had never had any compressor of such scale in the Department of Mechanical Engineering. I’m sure the compressor unit will work for many years and researchers after me will continue to see its benefits.” Manufacturers’ Monthly JUNE 2021 37
Sustainability in Fabrication PMI commits to achieving carbon peak and carbon neutral With global warming being an issue, manufacturers need greater awareness in their production chain, and sustainability in its aluminium production is something that PMI takes seriously.
C
LIMATE change is a global problem that the world is facing at the moment. In order to target the global warming threat, the United Nations has stated a framework convention on Climate Change under Paris Agreement since September 2020 with China planning to draw up an action plan to control peak carbon emissions by the year 2030, which will then be followed by going carbon neutral before the year 2060. Industrial aluminium is a fundamental alloy that is used in developing and raising living and economic standards. The carbon emission take count in the aluminium production process starts from ore, smelting, fabrication until the final product and eventually to when it is recycled. The research into the reduction in emissions in the aluminium industry has resulted in significant action to achieve carbon peak emissions and carbon neutrality in China and other countries.
Recycling aluminium is a critical condition for carbon neutral Compared to other metals, aluminium’s special characteristics makes it the ideal, highly efficient limitless recyclable “green alloy”. This is because it has relatively high yield returns and good economy in recycle recovery and feasibility. In an aluminium product’s manufacturing chain, the ore is refined as aluminium oxide, and then smelted into aluminium ingots. There is huge energy consumption and large amount of greenhouse gas released within the upstream energy chain. The fabrication chain uses relatively less energy when it comes to a product’s shape transformation and property 38 JUNE 2021 Manufacturers’ Monthly
formation as compared to the downstream energy chain. Recycled aluminium is the product form of one cycle of the up and downstream energy chain, then limitless recycling at downstream portion – this avoids the repeat occurrence of upstream high energy consumption during further recycling. This shows that a carbon neutral task is not limited to an over singular part of one product manufacturing chain, worked through the entire supply chain. According to a research, it is stated that in contrast with the primary ingot output which produces one tonne of recycle aluminium – that would save approximately 3.4 tce, 14 cubic metres of water, 20 tonnes less solid scrap. For one tce which is equivalent to three tonnes of CO2, one ton of recycled aluminium could save approximately 10.2 tonnes of CO2 produced – this is a huge improvement on energy efficiency. As aluminium possesses good plasticity and balanced unit strength, the aluminium product manufacturing process can be shorter, theoretically, in contrast to other metals. The product and production design has many available options, which can reduce the carbon footprint in its fabrication process dramatically. Aluminium which has a relatively lower melting point makes the fuel consumption with heat treatment process such as melting, heat-treat strengthening process a lot less. So, it can have a lot more flexibility in terms of clean-energy options possible, having an advantage on carbon emissions. China’s recycled aluminium output over total aluminium output found lower than Global average, which is a contrast to other developed country & obvious the recycle aluminium potential in carbon neutral activity.
PMI has actively been promoting leading projects such as Green Supply Chain within the industry.
Carbon-neutral target and PMI in action PMI works endlessly in an effort to promote a “Clean Production” model since its establishment and has been deploying multiple eco-friendly projects in its production garden, such as solar-power auxiliary source, clean energy, eco-friendly production etc. since year 1993. PMI’s subsidiary in Malaysia, PMA, has launched “Recycle Aluminium Production”, where it contributes 90 per cent of its product manufacturing and is recognised by its customers on its stable quality. For its long-term operation development plan, PMI is mutually recognised as a partner with multiple global customers in the “Global Strategy on Sustainability Development”, in which recycled aluminium application is one of the main goals. PMI Light Metal R&D Institute has a R&D experiment running on recycled aluminium application optimisation while fulfilling customer quality requirements, which has been verified and started to small batch delivery (SBD). After the technical development, with PMI business structure and technical transfer, the application will be planned for
further expansion under the theme of “Sustainability Development”. Instead of in-house activity, PMI has actively been promoting leading projects such as Green Supply Chain via third party organisations in the industry. When it comes to promoting carbon neutral targets and planning the implementation of supply chain R&D, PMI leads the way in sharing these values about standardisation in these areas. To have a balance with product quality and the concept of sustainability, the team at PMI will keep pushing forward with customers and suppliers alike.
Aluminium has a relatively lower melting point as compared to other metal alloys.
manmonthly.com.au
Sensors From simple to complex With new pressure sensors and level switches, VEGA becomes a full-range supplier for level and pressure in pharmaceutical applications.
T
HE special challenges faced by the pharmaceutical industry result from the diversity of its processes. Success depends on the consistency and continuity of the production processes – whether it be mixing, filling, autoclaving or CIP and SIP cleaning. This makes it all the more important for operators to be able to rely fully on the measurement technology deployed on the plant. Level and pressure sensors from VEGA have made a name for themselves over many decades for their reliability and longevity. Robust, versatile and easy to use – even under extreme conditions or strict regulations – they provide important impulses for greater plant safety and efficiency.
Complete supplier for level and pressure
any direction. This illuminated ring, which can be customised from a choice of 256 different colours, remains clearly visible, even in daylight. At a glance, the user can see if the measuring process is running, if the sensor is switching or if any sensor management required.
Intelligence with IO-Link There is a lot of sensor intelligence built into the new compact series: the standard IO-Link protocol ensures both universal and simple communication. This means that, via the standardised communication platform, this enables seamless data transfer and simple system integration.
Everything’s easier with wireless operation VEGA has also integrated wireless communication into its new
VEGABAR and VEGAPOINT measuring instrument series. The sensors can connect via smartphone or tablet. Especially useful in environments such as clean rooms, where physical access involves a lot of effort, it means setup and operation become easier. The new VEGABAR pressure switches/sensors and VEGAPOINT level switches represent an important milestone for VEGA, combining key elements of reliability, flexibility and accuracy for pharmaceutical processes.
The universal, flexible hygienic adapter system of the new instrument series reduces not only the amount of work involved, but also the spare parts inventory. Now, users not only get an entire range of level and pressure measurement technology from a single source, but also hygieneoptimised instrument designs that are extremely easy to install and use.
VEGA now completes its measurement portfolio for pharmaceuticals production with two new compact instrument series comprising of pressure sensors/ switches and point level switches. The product families VEGABAR and VEGAPOINT prove that automation can be quite simple and highly efficient at the same time, without compromising on reliability, hygiene or accuracy. The new measuring instruments are tailored to standard applications that nevertheless require high quality. Their standardised hygienic adapter system provides the flexibility needed to keep installation effort and parts inventory to the minimum. The process fittings can be interchanged and adapted to local requirements.
At a glance: 360° switching status display With the all-round status display, all sensor states can be seen from manmonthly.com.au
The new VEGABAR compact pressure sensors with switching function and VEGAPOINT capacitive level switches are tailored to standard applications. Manufacturers’ Monthly JUNE 2021 39
MANUFACTURERS’ MONTHLY
Brought to you by
SUPPORTS THE INSIDE WASTE INDUSTRY REPORT 2021 If you work in or provide a product or service to the manufacturing industry, we want to hear from you!
To better understand the markets for recovered materials, Manufacturers’ Monthly is conducting a survey on the appetite, barriers and opportunities for boosting the use of recycled content material in manufacturing. Scan the code below and help us map out the demand for recycled materials by taking this 4 min anonymous survey.
To find out more about the magazines that cater to the waste and recovery industry, get in touch with Chelsea Daniel-Young by email on Chelsea.daniel@primecreative.com.au or call +61 (0)425 699 878
THIS MESSAGE IS BROUGHT TO YOU BY PRIME CREATIVE MEDIA. Registered Address: Prime Creative Media, 11-15 Buckhurst St, South Melbourne VIC 3205, Australia. Ph: (03) 9690 8766 ©2021 Prime Creative Media
What’sNew Abrasion resistant acrylic sheet - DONCHAMP SurfaceGuard – Ideal for the framing industry Allplastics Engineering has responded to numerous requests from a wide range of industries such as picture framers; exhibition designers; retailers; glazing projects and many others for an acrylic that has an abrasion resistant surface. As most users are aware while acrylic has a wonderful range of applications and advantages, it can be susceptible to scratching in heavy traffic situations or due to constant cleaning/rubbing. With stocks available in 3mm and 4.5mm thick – DONCHAMP SurfaceGuard S1 hard coated sheets have coating on only one side which allows screen or digital printing on the other side. This also allows fabricated displays to be glued to surfaces making it exceptionally convenient for advertisement and other display purposes. The combination of functionality and visual attraction makes DONCHAMP SurfaceGuard panels an excellent choice for high traffic glazing and signage applications. The transparency of the panels, coupled with the high surface hardness, increased chemical resistance, plus reducing paint adhesion, enables DONCHAMP SurfaceGuard to be used in numerous applications. DONCHAMP SurfaceGuard has approximately 11 times the break resistance of glass and weighs considerably less than glass, making transportation easier and safer. The panels are easy to clean with a high resistance to commercial cleaning solutions.
• f urniture industry – back painted/protection layer enabling gloss appearance; •w hite goods – refrigeration parts; • s ignage – way-finding interior signage/directory displays; •m ap protection; • ATM surrounds; • machine guards; • double glazing; •p ermanent sneeze screens/anti jump counter screens; • balustrades; and •m useums and galleries display.
Advantages: • f ive-year manufacturer’s limited UV warranty; •e xcellent abrasion/mar resistance (pencil hardness 6H); • i ncreased chemical and paint resistance on coated surfaces; • strength/mechanical properties; •e asy to clean and maintain; • s uperior optical properties; •h igh rigidity; • good UV stability; • l ight weight; and •g luing possible on an uncoated surface.
Company: AllPlastics Phone: (02) 8038 2000 Web: www.allplastics.com.au
Available sizes •2 440mm x 1220mm; and •O ther sizes available on request. Thickness •3 mm and 4.5mm; and •o ther thicknesses available upon request.
Applications •p icture framing; • electronic components (displays); • poker machine/gaming displays;
Stamped contacts – a convenient alternative from Treotham The new ilme SI 5 A gold plated stamped crimp contacts from Treotham are the right solution for signal and data applications, particularly required in the automation and robotics sectors and on installations on electrical panels. The new series offer an outstanding price-quality ratio and time optimisation for high volume automatic processes. They are also compatible with the main data connectors and standard or modular inserts used in the automation sector. With its open-barrel crimping structure compliant with EN/IEC 60352-2:2006, the contacts are available in several variants, suitable to any type of installation requirement.
• t hree packaging options – loose parts (200 pcs), coil (500 pcs) or reel package (10.000 pcs). Furthermore, the dedicated easy handling manual crimping tools are available for loose contacts (part number SIPZ W) or for coil packaging (part number SIPZC W). Company: Treotham Automation Pty Ltd Phone: 1300 65 75 64 Web: www.treotham.com.au
These include: • t wo different sizes – 0.2 for 0,08-0,21 mm2 wire cross section / AWG 28-24 or 0.5 for 0,21-0,52 mm2 wire cross section / AWG 24-20. • t hree types of gold plating thickness – 1D for 500 mating cycles, 2D for 250 mating cycles or 3D for 50 mating cycles. manmonthly.com.au
Manufacturers’ Monthly MAY 2021 41
Brought to you by
ICP DAS’s tDS-718i-T Tiny (1x Isolated RS-232/422/485) ICP Australia is proud to introduce ICP DAS’s tDS-718i-T is a Serial-to-Ethernet device server that is designed to add Ethernet and Internet connectivity to any RS-232 and RS-422/485 device, and to eliminate the cable length limitation of legacy serial communication. By using the VxComm Driver/Utility, the built-in COM port of the tDS-700 series can be virtualized to a standard PC COM port in Windows. Therefore, users can transparently access or monitor serial devices over the Internet/Ethernet without software modification. The tDS-700 series device servers can be used to create a pair-connection application (as well as serial-bridge or serial-tunnel), and can then route data over TCP/IP between two serial devices, which is useful when connecting mainframe computers, servers, or other serial devices that do not themselves have Ethernet capability. By its protocol independence and flexibility, the tDS-700 meets the demands of virtually any network-enabled application. The tDS-700 series is designed for ultra-low power consumption, reducing hidden costs from increasing fuel and electricity prices, especially when you have a huge amount of device servers installed. Reducing the amount of electricity consumed by choosing energy-efficient equipment can have a positive impact on maintaining a green environment.
• supports UDP responder for device discovery (UDP Search); • static IP or DHCP network configuration; • easy firmware update via the Ethernet (BOOTP, TFTP); • tiny web server for Configuration (HTTP); • contains a 32-bit MCU that efficiently handles network traffic; •1 0/100 Base-TX Ethernet, RJ-45 x 1 (auto-negotiating, auto MDI/MDIX, LED indicators); • power input: DC terminal block; • allows automatic RS-485 direction control; • 3000 VDC isolation and +/-4 kV ESD protection for i versions; • terminal block connector for easy wiring; • tiny form-factor and low power consumption; • RoHS compliant and no halogen; and • cost-effective device servers. Company: ICP Electronics Australia Phone: (02) 9457 6011 Web: www.icp-australia.com.au
Key features: • incorporates any RS-232/422/485 serial device in Ethernet; • data transmission via virtual COM or raw TCP connection; • VxComm driver for 32- and 64-bit Windows 7 SP1/10/2012/2016; • max. connections: 1 Socket per serial port is suggested; • supports pair-connection (serial-bridge, serial-tunnel) applications; • supports TCP client-mode and TCP server-mode operations;
Analog Devices Inc LTC2672 16-bit digital-to-analog converter Analog Devices Inc. LTC2672 16-bit digital-to-analog converter is a five-channel, current-source output DAC, with selectable output ranges, precision reference, and a multiplexer for surveying the channel output voltages and currents. The eight current ranges are programmable per channel with full-scale outputs of up to 300mA. The channels can be paralleled to allow either ultrafine adjustments of large currents or combined outputs of up to 1.5A. A dedicated supply pin is provided for each output channel. Each channel can be operated from 2.1V to VCC, and internal switches allow any output to be pulled to the optional negative supply. The LTC2672 includes a precision integrated 1.25V reference (10 ppm/°C maximum), with the option to use an external reference. The Serial Peripheral Interface (SPI) compatible, 3-wire serial interface operates on logic levels as low as 1.71V and at clock rates as high as 50MHz. The Analog Devices Inc. LTC2672 ADC is offered in a 5mm x 5mm Lead Frame Chip Scale Package (LFCSP) with an exposed pad for enhanced thermal performance. Its applications include tuneable lasers, semiconductor optical amplifier biasing, resistive heaters and current mode biasing.
• internal switches to an optional negative supply; • precision internal reference (10ppm/°C maximum VREF temperature coefficient) or external reference; • full 16-bit resolution at all ranges; • analogue multiplexer monitors voltages and currents; • A/B toggle via SPI or dedicated pin; • 1.71V to VCC digital I/O supply; • operating temperature range; and - LTC2672CUH: 0°C to +70°C - LTC2672IUH: -40°C to +85°C - LTC2672HUH: -40°C to +125°C • 5mm x 5mm LFCSP32 package. Company: Mouser Electronics Phone: +852 3756-4700 Web: au.mouser.com
Features: •p er-channel programmable output current ranges: 300mA, 200mA, 100mA, 0mA; 25mA, 12.5mA, 6.25mA, and 3.125mA; • flexible 2.1V to VCC output supply voltages; • flexible single- or dual-supply operation; • 0.6V maximum dropout voltage guaranteed; • separate voltage supply per output channel;
42 MAY 2021 Manufacturers’ Monthly
manmonthly.com.au
What’sNew
WOMEN IN INDUSTRY AWARDS N O M I N AT I O N S ARE NOW OPEN
WOMEN IN INDUSTRY.COM.AU
S I M O N . C O B U R N @ P R I M E C R E AT I V E . C O M . A U
P R O U D LY P R E S E N T E D B Y
MHD Supply Chain Solutions
P LATIN UM SPONSOR
AW A R D S SPONSORS
The Last Word
INNES WILLOX – Chief Executive, Ai Group
Our buoyant manufacturing sector can’t grow without major change to the skills landscape
A
I Group is continuing to witness a reinvigoration of the manufacturing sector in 2021. Our Australian Performance of Manufacturing Index (Australian PMI) increased by a further 1.8 points to 61.7 in April, indicating a seventh consecutive month of recovery from the severe disruptions of COVID-19 in Q2 of 2020. The sector’s resilience has led to all six manufacturing sectors in the Australian PMI expanding in April 2021. The capacity utilisation index hit a record high, suggesting employment and/or investment may need to step up in order to facilitate further growth from here. However, this growth cannot be realised unless manufacturers have the right skills, for skills underpin all work. Concerningly, Ai Group is seeing strains on companies caused by re-emerging skills gaps and shortages. Industry had lived with skills shortages for a few years, most acutely for trades workers and technicians. After a short hiatus last year, skills shortages have quickly started to reappear as one of the main concerns for our members. Ai Group believes Australia’s skills landscape is facing much change and in need of urgent attention. A number of factors are converging to create an urgency to skills formation and development. We are at a juncture where the pace of change is colliding with the development of skills. New technologies are reshaping existing industries and creating new ones. Workplace cultures are shifting. Higher productivity is being achieved through remote-work arrangements and multiple, rapid meetings. Data science and interpretation are becoming larger parts of many roles. Circular and sustainable planning and processes loop in new capability needs. Corporate social responsibility endeavours are colliding with skills as companies consider diverse cohorts disadvantaged through COVID-19 when re-building capabilities. COVID-19 has led to a forced and more rapid switch to digitisation
44 JUNE 2021 Manufacturers’ Monthly
for many. Global McKinsey data show that in a matter of months many companies accelerated the digitisation of their customer and supply chain interactions and internal operations by three to four years. While many companies did pivot, Ai Group is seeing signs that the switch to digitisation has not always been as deep as it needs to be and that some companies are still requiring basic digital skills before they move to more sophisticated technologies. Late in 2020 we undertook a survey that focused specifically on the skill needs and workforce development plans of businesses as they ramped up their activity. Ai Group surveyed CEOs nationally, receiving 115 responses from companies employing a total of 39,447 people. Responses came from a mix of industry sectors: Manufacturing (58 per cent), Construction (9 per cent), Services (13 per cent), Mining (3.5 per cent) and other sectors (16 per cent). Respondents represented all company sizes: 31 per cent smallsized, 45 per cent medium-sized, and 24 per cent large-sized businesses. Findings from the survey show technicians and trades workers re-emerging as the most difficult roles to fill, followed by managers, professionals and sales workers. The digital skills employers most need to increase are basic digital skills, cyber security and data analytics. Fewer said they required cloud computing, AI, augmented or virtual reality or blockchain. This suggests many are yet to reach the stage of harnessing technologies together in an integrated and digitalised approach that captures wideranging digitalised capability needs: production technologies; ‘design to operate’ process flows; sourcing and procurement; asset management; finance; HR and payroll. Increasingly, this will become an issue as the forced switch to digital operations will require deeper digital strategies and the capacity to adopt, and have employees engage with more
advanced technologies. Other findings include: - an increased demand for soft skills across all occupational categories - an increased commitment to taking on apprentices - the most important entry level recruiting factors are a positive attitude and soft skills - wage subsidies would allow many employers to take on displaced workers and young people - employers would take on more university or TAFE students as higher apprentices, cadets or interns to increase their skill levels as their business needs change. Major disruption in industry through digitalisation should be seen as a natural trigger for major disruption in education and training. Under current education and training models, development is often not quick enough to recalibrate the skills required for entry level employees. Companies are struggling to find timely, relevant short programs to re-skill existing workers at pace. Learning models are under pressure. Educators are exploring how to prioritise and integrate the humancentred skills increasingly flagged as dominant skills for the future. Skilled migration has plummeted creating opportunities to improve the system during the pause in student arrivals. Adding to the major disruption in the skills landscape, research on the changing workplace is showing there is an evolution to the nature of work. It speculates that the way people work is changing in an unprecedented way, suggesting skills development needs a different approach moving forward: where learning is not separate from doing; where we immerse learning in work environments. Skills urgency is pointing to the need for new responses, new support and upscaled collaborations across Australia’s broad skill ecosystem. More intensified action must help to establish: - new templates for partnerships across the skill eco-system;
Ai Group’s chief executive, Innes Willox. - broad digital skills development integrating human capabilities; - a re-imagined apprenticeship system - work-based learning as a core; principle in qualifications; and - flexible qualifications allowing short form training. Ai Group has established a new Centre for Education and Training to explore new ways of building skills and capabilities for companies and individuals for success now and into the future. The Centre’s proactive research, policy and advocacy agenda will strive to ensure Australia’s skills development outcomes are in line with current and emerging economic needs. It aims to link the real needs of industry with the training, education and career aspirations of individuals. The Centre’s first report, Skills Urgency – Transforming Australia’s Workplaces, is a thought starter for encouraging bigger change around skills in Australia. The Centre welcomes approaches from likeminded agencies and individuals across the broad skill ecosystem – companies and industry, education and training providers and systems, governments and the community. manmonthly.com.au