Manufacturers’ Monthly December 2023 by Prime Creative Media

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

DECEMBER 2023

Is Australia ready to

EMBRACE ADDITIVE

MANUFACTURING?

Official Industry Partners

INSIDE >> 24

Capral supplies trailer aluminium

Endeavour Awards finalists

Next-generation battery technology

220.10 076.23

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Manufacturers’ Monthly Contents 4 Editor’s Note

32 Innovation in manufacturing

16 Weld Comment

34 Hydrogen manufacturing

8 News

36 SEMMA update

20 Manufacturer Focus

38 Endeavour Awards

24 Trailer aluminium

42 Temperature Sensors

26 Lifting equipment

44 Engineering Focus

28 Welding gas

48 What’s New

30 Fastener solutions

50 Last Word

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 of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on 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, 2023 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. Head Office 379 Docklands Drive

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Behind the cover

MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

AIR LIQUIDE EXELTOP™ Trust in performance

DECEMBER 2023

Is Australia ready to

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Since pre-COVID times, Australian manufacturing has taken bigger steps to adopting additive manufacturing techniques, enabling those who use it to reduce lead times and increase overall productivity in their processes. The Manufacturer Focus for December looks at Australian manufacturer Additive Assurance who is looking to improve the

quality control of additive printing systems globally. The feature will delve into the challenges of 3D printing and how this system could change the game and truly unlock the potential of additive manufacturing. Further in the magazine we look at welding gasses provided by Air Liquide, lifting equipment from Kito PWB and fasteners from United Fasteners. Discover How.

Air Liquide’s new patented cylinder top will help you work safely, gain greater performance and save you time and money.

ESSENTIAL SMALL MOLECULES FOR MATTER

MANUFACTURING?

Official Industry Partners

INSIDE >> 24

Capral supplies trailer aluminium

Endeavour Awards finalists

Next-generation battery technology

Manufacturers’ Monthly DECEMBER 2023 3

Editor’s Note

JOSH FARRELL – Editor, Manufacturers’ Monthly

Victoria supporting manufacturing

ELCOME to the final edition of Manufacturers’ Monthly for 2023, it has been a positive year for manufacturing and we look forward what 2024 may hold. This period as we approach Christmas, we will be taking the opportunity to reflect on the year that was and there’s no better opportunity than at this year’s Endeavour Awards. The Awards celebrate the successes in manufacturing for 2023, with all nominees deserving of the spotlight and I am personally looking forward to chatting with some of these illustrious industry members this November. 2023 was jam packed with government announcements aimed at better supporting manufacturing – something that has provided excitement to the industry and has further cemented the notion that Australia can become a powerhouse in the manufacturing space. To get an idea of which state government has been supporting manufacturing best, Manufacturers’ Monthly

4 DECEMBER 2023 Manufacturers’ Monthly

set up a poll on Linkedin with four states – Queensland, Victoria, South Australia and, New South Wales to see who our audience thought was best. The overwhelming winner was Victoria (my home state – so proud!) with 53 per cent of the vote. The Victorian Government has been prioritising manufacturing recently, and is setting a strong example for other states to follow. The state recently showed of its next generation trains and trams, both made by Alstom, which will be rolling out in the coming years across the state. The government funding for manufacturing has been impressive during recent times. In early November, the state government announced that round two is open for the Made In Victoria manufacturing growth plan. The Victorian government will be providing grants of up to $250,000 to help businesses introduce new technology, improve productivity and competitiveness, upskill workers and,

create new jobs. The new Minister for industry and Jobs Natalie Hutchins explained that the government is investing in manufacturing to “grow our economy and improve productivity.” Recipients of Round one of the program were announced in October, with 14 Victorian manufacturers supported and 138 new jobs created.The state government has also announced it is striving to bring more women into manufacturing to help meet the skills shortage the industry is facing. Minister Hutchins announced an investment of $840,000 to deliver targeted initiatives to help students ‘try a trade’, provide mentoring for women employed in these industries and help them progress to senior positions. The funding is the first tranche of a $2.7 million fund to support the energy and manufacturing sectors to attract, recruit and retain women and remove barriers in these historically maledominated workforces – a key part of the

government’s response to the Inquiry into Economic Equity for Victorian Women. While many states such as Queensland are doing comparable work, Victoria continues to be forward thinking and reacting to industry needs well, I encourage all governments to continue finding ways to support our great industry. It has been a pleasure putting together the final edition of Manufacturers’ Monthly for 2023 with some truly interesting stories. The Manufacturer Focus feature looks at Additive Assurance, a manufacturer taking 3D printing to the next level. while ourEngineering Focus story looks at some exciting disruptive developments in the battery space, which manufacturers should read closely. Look forward to a comprehensive preview of this years Endeavour Awards as well with all the nominees ahead of what promises to be a big night. The team at Manufacturers’ Monthly would like to wish all our readers happy holidays and see you next year!

manmonthly.com.au

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Welding is a key to the industrial process required to support the achievement of the Government’s priorities.

Melding skills with strategy: Weld Australia’s blueprint for a working future

N late September, the Federal Government released its employment white paper, Working Future – a roadmap to ensure more Australians can make the most of the big shifts underway in the economy and our society over the coming decades. According to the Government, Working Future presents a vision for a dynamic and inclusive labour market in which everyone has the opportunity for secure, fairly paid work and people, businesses and communities can be beneficiaries of change and thrive. The Government’s vision is underpinned by five ambitious objectives: delivering sustained and inclusive full employment; promoting job security and strong, sustainable wage growth; reigniting productivity

6 DECEMBER 2023 Manufacturers’ Monthly

growth; filling skills needs and building our future workforce; and overcoming barriers to employment and broadening opportunity. Fostering an inclusive, flexible and productive labour market is critical to achieving the Government’s priorities, including the net zero transformation, the implementation of the Defence Strategic Review 2023, the AUKUS agreement, and supporting workers with expanded use of digital and advanced technologies. Welding is a key component of the industrial processes required to support the achievement of the Government’s priorities outlined in Working Future. As such, Weld Australia estimates that an additional 70,000 welders will be required over the next decade.

Weld Australia and its members already operate a range of programs designed to increase the capacity, quality and skill of the Australian welding sector to not only meet these challenges, but support Australian industry to thrive. However, there are several opportunities to partner with governments at all levels to grow Australia’s local welding industry to meet the objectives outlined in Working Future.

Objective 1: Delivering sustained and inclusive full employment Sustained full employment is about minimising volatility in economic cycles and keeping employment as close as possible to the current maximum level consistent with low and stable inflation.

Inclusive full employment is about broadening opportunities, lowering barriers to work, and reducing under employment.

Establishing a First Nations Welder Training Academy Weld Australia is partnering with a major essential services provider to establish a First Nations Welder Training Academy in Port Headland, Western Australia. The first of its kind, the Academy will provide a culturally-safe program facilitated by First Nations instructors. It will deliver international-standard welder training to up to 100 First Nations people in the first two years. This initiative will provide a pathway for First Nations people into inclusive employment. Weld Australia is seeking government funding for manmonthly.com.au

Academy, and looking to work with government employment services providers to establish a long-term pipeline of candidates.

Objective 2: Promoting job security and strong, sustainable wage growth Real wage growth is a key element of increasing living standards but not all workers are fairly paid. The gender pay gap remains an ongoing challenge, and some groups are more susceptible to exploitation.

Increasing the Workforce Participation of Women Welders Encouraging the participation of women in male-dominated industries is critical to ending employment disparity and the gender pay gap. Weld Australia facilitates the Women in Welding discussion group, and undertakes other activities to promote greater female participation. In conjunction with Corrections Victoria, Weld Australia is also in the process of establishing an Advanced Welder Training Centre at the Tarrengower Prison in Victoria, to provide a pathway to employment for women prisoners reintegrating into the community. However, Weld Australia and its members cannot tackle this problem alone. Support is needed from governments of all levels to: set measurable targets to improve the gender balance across the welding industry; implement marketing and engagement campaigns that attract women into welding; and create streamlined training and employment pathways.

welders spend approximately two hours on-arc time per shift, which is below international benchmarks (four hours per shift in the US and Japan). The remainder of their time is spent completing manual labour, such as materials handling. By reducing the manual labour load, there is an opportunity to increase welder productivity and improve the capacity of the domestic welding industry to achieve the government’s priorities. Weld Australia is currently partnering with TAFEs to train welding apprentices to program cobots, which can reduce the manual labour burden on welders. This program, at scale, has the capacity to double the on-arc time of Australian welders. To broaden this program, two things are needed: the introduction of a dedicated cobot programming module as part of the Certificate III and IV in Metal Fabrication; and additional government funding to supply TAFEs nationally with cobots and qualified instructors.

Increasing Welder productivity through Trades Assistants The manual labour burden on welders could be also be reduced by employing trades assistants to complete materials handling and griding work. Weld Australia will execute a research project in 2024 with a view to benchmarking current productivity levels and developing a business case to bring welder productivity in Australia in line with international best practice. A ratio of 2:1 Certificate II-qualified trades assistants represents industry best

practice, and requires funding support from the Australian Government in order to achieve its policy objectives, including the net zero transmission.

Objective 5: Overcoming barriers to employment and broadening opportunity

Some rapidly growing industries are facing acute skills shortages and will require tailored workforce solutions. This requires investments in domestic skills and training, complemented by targeted migration pathways.

Disadvantage reduces the employment prospects of many people and can lead to intergenerational cycles of joblessness. Compounding local factors, complex personal circumstances and discrimination can make engagement in work challenging for families and communities, including to break out of cycles of disadvantage. Many people face multiple, interconnected barriers to employment.

Expanding advanced welder training centres into schools

Expansion of advanced welder training centres in prisons

Weld Australia has 180 advanced welder training simulators across 90 schools in New South Wales, and is working with industry partners to create a pathway to employment for school leavers into the clean energy industry. The Australian welding industry needs a governmentsupported national plan and marketing campaign to promote skills training in schools, linked with clear pathways to employment and future career opportunities.

Weld Australia currently supports five Advanced Welder Training Centres in Victorian prisons, including both men’s and women’s facilities. Weld Australia would welcome additional opportunities to partner with the federal, state and territory governments to establish Centres across correctional jurisdictions. Welding is a key component of the industrial processes required to support the achievement of the priorities outlined in the Working Future white paper. The initiatives outlined above represent a promising start to addressing the critical skills gap and securing the additional 70,000 welders required to deliver on the Australian Government’s commitments. There is a real opportunity for the Australian Government to lead the way forward in partnership with Weld Australia and its members, for the benefit of Australian industry, communities and the economy.

Objective 4: Filling skills needs and building our future workforce

Supporting older welders to transition into teaching Weld Australia is partnering with TAFE to design and implement a bridging course for older welders to fast-track skilled professionals into teaching. This will help improve workforce participation and address demand in the TAFE sector. Weld Australia urges governments to support this program.

Weld Australia will be executing a research project in 2024 to benchmark existing productivity and develop a business case for best practices.

Objective 3: Reigniting productivity growth Productivity growth is the key driver of real wage growth and rising living standards over the long term, but it has been slowing around the world. In the decade to 2020, productivity growth in Australia was the slowest in 60 years. Raising productivity is becoming increasingly important.

Increasing welder productivity through cobots Currently, Australia’s 70,000 manmonthly.com.au

Manufacturers’ Monthly DECEMBER 2023 7

News @MM $122 million for SA economy announced The South Australian Government is investing in businesses located in the state to help them grow. The first round of the $122 million Economic Recovery Fund (ERF) opens today, with a focus on Manufacturing Innovation and Regional Tourism Infrastructure Development. A total of $20 million will be available to co-invest with successful businesses and organisations in the form of grants or concessional loans. Successful businesses will need to demonstrate the project will have a wider economic benefit, such as creating ongoing jobs, upskilling an existing workforce, improved productivity, access to new markets or the introduction of new products, services and technologies. Manufacturing Innovation applicants must also show: • Current advanced manufacturing knowledge, capabilities, processes and business models or the potential to become an advanced manufacturer with the proposed project; • Competitive neutrality – that is, the project will not be to the economic detriment of another South Australian based advanced manufacturer; and • A level of innovation and uniqueness of the project, for example being new to South Australia. Manufacturing is the state’s largest sector, with more than 6,700 businesses contributing an estimated 17 per cent of SA’s annual output, 25 per cent of business research and development and 20 per cent of exports. The Regional Tourism funding stream is dedicated to eligible infrastructure projects, examples include: • New accommodation or expansion builds; • Infrastructure to enhance visitor engagement, including cellar doors; and • Infrastructure required to develop a new tour offering utilising existing products and experiences. The 11 regions are: • Adelaide Hills • Barossa • Clare Valley • Eyre Peninsula • Fleurieu Peninsula • Flinders Ranges and Outback 8 DECEMBER 2023 Manufacturers’ Monthly

The ERF is in addition to the SA government’s Major Events Fund and Tourism Industry Development Fund.

Kangaroo Island Limestone Coast Murray River, Lakes and Coorong Riverland Yorke Peninsula Tourism is a key growth sector in South Australia. The tourism industry employs around 40,000 South Australians. The sector is worth a record $9.9 billion to the State and is well on track to hit its 2030 target of $12.8 billion. The ERF is in addition to the government’s Major Events Fund and Tourism Industry Development Fund, and major drawcards such as LIV Golf, AFL Gather Round and the Adelaide 500. This is the first of several targeted rounds specifically calibrated to assist

• • • • •

business and industry grow jobs, improve productivity and introduce innovative technologies, products or services in South Australia. The focus of future ERF rounds will be announced as they are opened. The ERF was established in the 202223 Budget. It’s being deployed now to ensure the government is supporting businesses to grow as national and global economic conditions soften. With the establishment of the new grants program the State Government will allocate the remaining $5 million of the $10 million Manufacturing Innovation Grants Program from the ERF. The other $5 million of the Manufacturing Innovation Grants Program saw $4 million allocated towards Flinders University Factory

of the Future project and $1 million for Belgravia Apparel to expand its manufacturing operations. Applications for the first round close on 15 December 2023. Coinciding with the first round of the ERF, the South Australian Government will release the South Australia’s Advanced Manufacturing Strategy – the state’s plan to drive greater economic productivity and complexity by exporting higher valueadded goods and services. The 10-year strategy aims to harness South Australia’s competitive advantages to support multi-generational opportunities in defence, the state’s transition to a low-carbon industrial future, and to increase innovation and skilled jobs. manmonthly.com.au

News @MM NIOA begins boxer ammunition production NIOA in conjunction with Rheinmetall NIOA Munitions has begun ammunition production for the Army’s next-generation armoured Boxer vehicle, marking a significant milestone for munitions manufacturing in Australia. The company will produce 40,000 rounds of medium calibre training ammunition at the Commonwealth Government-owned NIOA-operated plant in Benalla, Victoria for the Boxer Combat Reconnaissance Vehicle (CRV) which is being made in Queensland by Rheinmetall. It comes as the Minister for Defence Industry, Pat Conroy announced a $220 million investment in munitions production at Benalla and another government-owned contractor-operated (GOCO) factory at Mulwala in regional New South Wales. Minister Conroy and Guided Weapons and Explosive Ordnance (GWEO) enterprise chief AVM Leon Phillips OAM toured NIOA’s Benalla operation as the

manmonthly.com.au

first batch of 30mm projectiles was being prepared to roll off the line. A key recommendation of the Defence Strategic Review was to replenish GWEO stocks and to establish sovereign missile and munition manufacturing facilities in Australia. “Improving Australia’s ability to manufacture the munitions our defence force needs is not only critical to meeting the strategic challenges we face as a nation, it will also support local industry and wellpaid, skilled local jobs,” Conroy said. “The Mulwala and Benalla munition factories underpin Australia’s ability to develop critical propellants, explosives and munitions for the Australian Defence Force. NIOA Australia and New Zealand CEO Ben James welcomed the Government’s investment in domestic munitions production. “This will further support Australia’s growing defence industrial base and comes at an exciting time as we ramp up

NIOA will produce 40,000 rounds of mediumcalibre training ammunition at the plant in Benalla, Victoria for the Boxer CRV.

production of the Boxer ammunition at Benalla,” he said. “NIOA’s $12m investment at Benalla reflects our commitment to work with Government and Defence in delivering sovereign capability and local jobs. “We have a highly-qualified and professional team at Benalla who have worked exceptionally hard to reach this key milestone in sovereign munitions manufacture,” James said. The NIOA tenancy at Benalla maintains

the Commonwealth’s capabilities for the manufacture of primary energetics, pyrotechnics, medium calibre, mortar and tank ammunition, hand grenades, fuzes, primers, along with various laboratory test facilities. The medium calibre line is a joint investment with Rheinmetall NIOA Munitions. NIOA recently completed work at Benalla recapitalising 120mm tank ammunition for the Australian Army’s M1A1 Abrams tank fleet.

Manufacturers’ Monthly DECEMBER 2023 9

News @MM Car part manufacturer set to expand

PWR supplies its cooling technology to various industries besides motorsports – including defence and aerospace. A Queensland company that supplies cooling technology for V8 Supercars, Formula 1 and NASCAR is expanding its operations and creating another 488 jobs with an investment from Queensland Treasury. Gold Coast company PWR Advanced Cooling Technologies will invest $21.9 million in facility upgrades and new equipment over three years to increase production capacity by 114 per cent. Up to $8.78 million in support will be provided by the Queensland Treasury’s Invested in Queensland program. The new facility, expected to ready in 2025, will also see PWR add up to 488 new jobs over the next 10 years. This will more than double its current Australian workforce of 340 staff. Additionally, the 18-month construction phase will support about 75 jobs. 10 DECEMBER 2023 Manufacturers’ Monthly

Minister for Trade and Investment Cameron Dick spoke about the manufacturer and the support provided by the government. “PWR Advanced Cooling Technologies is already a Queensland success story, and support from our Invested in Queensland program is helping to keep their home-grown ingenuity on the Gold Coast,” he said. “With our support, PWR will expand into a larger, purpose-built facility giving them the room to grow even more. “The new facility is expected to support new innovation and technology that will enable PWR to remain at the cutting edge of cooling technologies and grow their exports and take advantage of emerging markets. “This is another great example of how we’re partnering with the private

sector and encouraging them to invest in expansions that will support the growing Queensland’s economy well into the future,” Dick said. PWR has already been a motor sport success story and is seeing rapid growth in defence and aerospace industries. The company has revolutionised the cooling technology within its many products. PWR managing director Kees Weel explained in greater detail the companies expansion plans. “It has been an extraordinary journey and PWR’s reputation is now cemented globally for quality and innovation for advanced cooling solutions,” he said. “We are proud of all our achievements and proud of every

single one of our team members. “While we have operations in the US and Europe, PWR is headquartered in Queensland and is a Queensland success story. “We are excited to be building an advanced manufacturing facility that will accelerate our growth into aerospace, defence and the renewable energy sectors from right here on the Gold Coast. “The Invested in Queensland program has provided real incentive to re-invest in Queensland and provide hundreds of new local jobs as a result.” PWR’s customers include high-end automotive brands Aston Martin, McLaren and Koenigsegg, and is a key supplier to automotive racing teams in V8 Supercars, Formula 1 and NASCAR. manmonthly.com.au

News @MM First Look At Melbourne’s Next-Gen Trams Melbourne’s locally made next generation trams are one step closer after a life-sized model of a G-class tram was unveiled for testing and evaluation for the first time ahead of production ramping up. Minister for Public and Active Transport Gabrielle Williams visited Tullamarine to unveil the first life-sized mock up of a next generation tram for testing and evaluation – set to hit the network by 2025. The Victorian Government is investing $1.85 billion in 100 new G-class trams alongside a new tram maintenance and stabling facility when

the fleet is ready. The more accessible trams will be built by Alstom in Dandenong using at least 65 per cent local content and supporting up to 1,900 local jobs through manufacturing, the supply chain and construction. They will replace some of Melbourne’s longest-serving A and Z class high-floor trams, making the public transport network more accessible for all Victorians. Minister for Public and Active Transport Gabrielle Williams spoke about the new G-class trams.

“We’re getting on with delivering modern and more accessible trams to Melbourne’s west, replacing our longest-serving high-floor trams while supporting hundreds of skilled jobs.” “This is the biggest investment in locally made trams in Australia’s history and today is an important step towards finalising the design before production gets underway in Dandenong,” she said. With greater capacity than the high floor trams, they will have space for up to 150 passengers and feature a low floor design to improve accessibility. The trams also feature on-board energy storage to

reduce power use and network costs. The first G Class trams are scheduled to begin testing on the network from 2025, before taking passengers on Routes 57, 59 and 82 in Melbourne’s west. The life-sized model allows passengers, tram drivers, technical and accessibility groups to walk through the interior layout including the drivers cab to provide feedback on the design. The Victorian Government has invested more than $9 billion in new and upgraded rolling stock and supporting infrastructure since 2015 to get people where they need to go safer and sooner.

There is more than $1.85bn invested in 100 new G-class trams in Victoria, together with a new maintenance and stabling facility.

manmonthly.com.au

Manufacturers’ Monthly DECEMBER 2023 11

News @MM South Australia’s advanced manufacturing strategy announced South Australia‘s Advanced Manufacturing Strategy has been developed to guide future industry and government collaboration, grow manufacturing, and drive the state’s economic transition towards a knowledge-based, resilient, and greener economy. Manufacturing is currently South Australia’s largest sector, accounting for around 17 per cent of total state output by revenue, 25 per cent of business research and development, 18 per cent of exports, 7 per cent of employment, and 6 per cent of industry value-add. The state’s thriving food and beverage sector is a major driver of local manufacturing, with food-

related manufacturing, machinery and equipment the largest component of South Australia’s manufacturing sector – accounting for nearly half of all manufacturing activity, or 3 per cent of the state economy. Even in ‘traditional’ sectors like food manufacturing, the adoption of industry 4.0 technologies is set to mitigate South Australia’s historical challenges of cost, scale and distance to markets by improving its ability to provide customised and high-value products to global customers. South Australia is at a turning point in its economic history, with exciting new opportunities for re-industrialisation as the state emerges from the impacts of the

COVID-19 pandemic and embraces sovereign manufacturing in a lowcarbon, clean industrial future. Its international leadership in renewable energy and investment in hydrogen production are creating new manufacturing opportunities for premium low-carbon products like green metals, minerals, and fuels that capitalise on the global green transition. Consistent with findings across Australia and most OECD nations, domestic manufacturing has contracted in South Australia over the last decade – from 9.7 per cent (2011-12) of industry growth value-added to 6.3 per cent (2021-22). The loss of local automotive manufacturing in 2017, when the Holden

plant in Elizabeth ceased operations, was a viewed as a major milestone of this decline. However, the world’s manufacturing sector has shifted significantly since then – a result of the COVID-19 pandemic, focus on decarbonisation, and other global market disruptions. Now, manufacturers are evolving to compete more on design, quality, and innovation than cost. This is an arena where South Australia has several significant competitive advantages. State Government is UIDE LIQeducation, working closely withAIR industry, ELTOP™ to EXstakeholders union and community in stadvantages, identify and exploit Tru these mance with a plan to support thefor growth of per local manufacturing currently under development.

Discover How. Air Liquide’s new patented cylinder gain top will help you work safely, you greater performance and save time and money.

ESSENTIAL SMALL MOLECULE

S FOR MATTER

The economy of South Australia is at an exciting crossroads with exciting new opportunities.

12 DECEMBER 2023 Manufacturers’ Monthly

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2023

News @MM Manufacturing to feature in an inquiry into government procurement The inquiry was established in response to concerns raised by the Minister for Domestic Manufacturing and Government Procurement Courtney Houssos about the decrease in local manufacturing, and local content under the previous Government. Minister for Domestic Manufacturing and Government Procurement, Courtney Houssos spoke about why the government has announced the inquiry. “The former Liberal-National

Government decimated the state’s manufacturing industry over more than a decade by sending major projects and the jobs they support overseas,” Houssos said. “It will take time to rebuild the sector after the previous government’s failures and the inquiry will help direct critical reforms.” “They allowed key government contracts to leave NSW, missing the opportunity to create thousands of local jobs,” she said.

A McKell Institute report from 2021 found that thousands of jobs would have been created in NSW had the previous Government contracted local train manufacturers instead of going offshore. The NSW Government spends about $37 billion on goods and services, construction and with other suppliers annually. The state Government is committed to transforming the state’s procurement framework and practices.

Doing so can promote local industries, accelerate economic growth, promote regional development, and ensure jobs remain onshore. The Minister for Domestic Manufacturing and Government Procurement encourages interested parties to make a submission to the inquiry to help inform its recommendations. The inquiry is expected to hand down its findings by July 2024.

The inquiry looks to find ways to improve the NSW’s procurement practices at a state level.

14 DECEMBER 2023 Manufacturers’ Monthly

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News @MM Construction begins on $40m robotics and advanced manufacturing centre The new Big Build $40 million Robotics and Advanced Manufacturing Centre at Eagle Farm TAFE will train and upskill Queensland’s manufacturing workforce to embrace automation and Industry 4.0, Queensland Government’s initiatives for the Fourth Industrial Revolution. Forecast for practical completion in late 2024, the Centre will improve specialised training in robotics, advanced manufacturing, process instrumentation, renewable

technologies (hydrogen and solar) and telecommunications. It showcases the Queensland Government’s commitment to providing sustainable and future-proof training facilities. “The Eagle Farm TAFE campus specialises in trade-related courses such as automation, instrumentation and control, renewables, plumbing and electrotechnology, telecommunication, and utilities,” said Minister for Training

and Skills Development, Di Farmer. “With this new investment, our future Advanced Manufacturing workforce will receive the best training in a high-tech, supportive environment and will gain the necessary skills to take on high-value jobs – in the lab, and on the production line.” The Centre is targeting a 5-Star Green Buildings rating which demonstrates Australian excellence in its design and construction. It caters for the increased demand

for Advanced Manufacturing skills and training. The Advanced Manufacturing Gateway to Industry Schools (GISP) program has grown from seven participating schools in 2017 to 46 participating schools in 2023 – achieving its target number of participating schools for 2023. In 2022, more than 2200 students participated in GISP advanced manufacturing-related activities.

Local manufacturing driving Victoria’s net zero future Minister for Jobs and Industry Natalie Hutchins today announced applications are open for the Made in Victoria – Energy Technologies Manufacturing program to support manufacturers to purchase or develop new equipment, skills, or technology enabling them to capitalise on renewable energy opportunities. “Through this grant program, we’re supporting our transition to net zero and the transformation of our manufacturing sector to develop more skills and capabilities, attract investment and create the jobs of tomorrow,” Hutchins said. Grants of between $100,000 and $750,000 are available to businesses to increase capacity to manufacture components for zero emissions and renewable energy supply chains like wind, hydrogen and solar. The program will help businesses become more competitive, increase exports, upskill staff and create highskilled jobs, while strengthening the state’s supply chain resilience – backing Victoria’s path towards achieving net zero by 2045. This initiative builds on the success of the Low Carbon Manufacturing Grants program, which has provided $1.8 million in funding to 19 businesses across the state in the past year. Victoria’s $33 billion manufacturing sector is a driving force of the state’s economy and is made up of more than 16 DECEMBER 2023 Manufacturers’ Monthly

The program will be issuing grants of $100,000 -$750,000 to participating manufacturers. 24,000 businesses, supporting around 260,000 jobs and exporting $23.9 billion worth of goods. Underpinned by the Made in Victoria

2030 – Manufacturing Statement, the Labor Government continues to drive growth and innovation in the manufacturing sector through initiatives

like the $20 million Manufacturing and Industry Sovereignty Fund and the $4.5 million Digital Jobs for Manufacturing program. manmonthly.com.au

News @MM Lockheed Martin selects Axiom and Nupress for Orion Spacecraft Program In a significant step for the Australian space industry, Axiom Precision Manufacturing (Axiom) and the Nupress Group (Nupress) have been selected as global supply chain partners by Lockheed Martin for the Orion spacecraft program, a cornerstone of NASA’s Artemis missions to the Moon. Lockheed Martin’s decision to select Axiom and Nupress to supply precision machined components for the Orion program followed a rigorous evaluation process, focusing on their substantial costsaving proposals, exceptional customer responsiveness and reduced lead times. Having previously established themselves as industry partners on the F-35 program, Axiom and Nupress were identified as potential partners for the Orion program during a roadshow led by Lockheed Martin’s Office of Australian Industrial Participation team. Since receiving their space quality

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certifications, Axiom has so far secured one contract while Nupress has already secured two contracts. The contracts were awarded under Lockheed Martin’s Global Supply Chain (GSC) Program agreement with the Commonwealth of Australia. Both companies are poised for growth as they rise to meet the future production demands of this historic endeavour. The Orion Production and Operations Contract (OPOC), an indefinitedelivery, indefinite-quantity (IDIQ) contract, encompasses up to twelve vehicles, divided into three or four different orders. Up to six additional Orion spacecraft may be ordered under the IDIQ contract, leveraging production cost data from the previous six missions to enable optimised unit prices. Warren McDonald, chief executive Lockheed Martin Australia and New

Axiom and Nupress have both received their space quality certifications. Zealand, congratulated both firms on their selection for the program. “Axiom and Nupress exemplify the vast industrial capability available in Australia. Their commitment to quality and innovation aligns perfectly with Lockheed Martin’s dedication to delivering excellence. This is an example of how the Global Supply Chain program has allowed us to partner with and provide opportunities for Australian industry to

shape the future of defence and space exploration,” McDonald said. “Axiom is proud to contribute to the Orion spacecraft program,” said Craig Maynard, general manager of Axiom. “This new partnership with Lockheed Martin exemplifies our dedication to precision, innovation and embracing complex challenges, and we look forward to our expanding role in advancing space exploration.”

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News @MM Government to assure Collins class submarines NEW full feature oil injected screw compressors 4-22kW

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The Australian Government is committed to a potent, enduring and agile submarine capability, and will use an independent assurance activity to inform the life-of-type extension of the Collins class submarine fleet. Australia’s transition to conventionally-armed, nuclear-powered submarines is underpinned by the ongoing availability of the Collins class submarine capability throughout this transition period. This will require the life of the Collins class submarines to be extended. Minister for Defence Industry, Pat Conroy said, “The Collins class submarines remain one of the most capable conventionally-powered submarines in the world.” “The life-of-type extension of the Collins class is essential to the maintenance of Australia’s submarine capability as we transition from conventional to nuclear-powered submarines.” “This independent assurance activity seeks to ensure the life-of-type extension is delivered in the most effective and efficient manner, guaranteeing Australia retains an enduring, potent and agile submarine capability,” Collins continued. This assurance activity will provide the Government with advice on Defence and industry’s current preparedness to deliver the Collins class submarine life-of-type extension. This assurance activity will not delay any of the vital work that Defence and industry are continuing to deliver to sustain and extend the life of the Collins class fleet. The independent assurance activity is being led by Gloria Valdez, a member of the Naval Shipbuilding Expert Advisory Panel. A classified report will be delivered to the Australian Government in the second quarter of 2024. manmonthly.com.au

News @MM New $7.1 million grant cutting energy use for manufacturers The Queensland Government’s new Manufacturing Energy Efficiency Grant program will help manufacturers reduce their energy usage and cut energy costs, by providing direct support to manufacturing businesses. From Thursday the 12th of October, eligible manufacturers can apply for matched grant funding of between $5,000 and $25,000 to buy equipment or introduce processes that will reduce energy consumption and carbon emissions. Premier Annastacia Palaszczuk explained the grants in greater detail. “Our government understands that energy is critical to competitiveness in manufacturing, and we recognise the importance of the industry for secure full-time jobs in our regions,” she said. “Our Queensland Energy and Jobs Plan will provide renewable and affordable power that will set up manufacturing in our regions for the next century. “These grants will provide immediate

support for Queensland’s manufacturing businesses to improve energy efficiency. “This initiative complements our governments cost of living package – delivering the largest response to global and national cost of living pressures of any government in the country,” Palaszczuk said. With the Queensland Energy and Jobs Plan, Queensland is now one of the best places for renewable energy investment and that flows all the way down the supply to chain, creating opportunities for Queensland manufacturers – particularly those who are already on the path to decarbonisation. Australian Industry Group Queensland A/State Head Dean Deighton spoke about the importance of the grants. “Cutting energy costs often takes significant investment upfront, and the Ai Group is glad that the Queensland State Government is listening to industry and providing some financial help to businesses hard-pressed by volatile

energy prices,” he said. “We anticipate strong demand for the grants announced today, and we hope the Queensland Government will be prepared to refine and expand the program over time to help more businesses modernise their energy use, cut their bills and reduce pressures on the wider energy system.” This is another way the Palaszczuk Government is ensuring Queensland manufacturing businesses are positioned to take advantage of these new opportunities and become more nationally and internationally competitive. $7.1 million will be spread across two rounds with MEEG Round 2 being released next year. MEEG Round 1 Guidelines are now available online with applications accepted from 23 October 2023. The Round will close on 30 June 2024 or when the funding is exhausted. To be eligible, projects must be able

to demonstrate at least a 10% reduction in energy use or carbon emissions directly related to project implementation. Queensland manufacturers seeking more information about project eligibility criteria, key timeframes and assessment criteria should visit www. rdmw.qld.gov.au/MEEG. The South West Queensland regions Toowoomba office and the local manufacturing hubs in Cairns, Townsville, Mackay, Rockhampton, Gladstone and the Gold Coast, are also a point of contact for potential applicants to discuss their projects and application eligibility. Eligible projects could include: • Converting gas or fuel process to electric; • Replacing existing dryers with heat pump dryers; • Gas capture for reuse in other processes; • Replacing non-LED lights with LEDs; • Upgrades to motors; • Optimising compressed air storage.

Accelerating growth in local manufacturing Small and medium-sized Victorian manufacturers can now apply for grants under round two of the Made in Victoria - Manufacturing Growth Program.

Minister for Jobs and Industry Natalie Hutchins has announced that small and medium-sized Victorian manufacturers manmonthly.com.au

can now apply for grants under Round two of the Made in Victoria – Manufacturing Growth Program.

Grants of up to $250,000 will support businesses to introduce new technology, improve productivity and competitiveness in local and global supply chains, upskill workers and create new jobs. Minister for industry and jobs, Natalie Hutchins, said, “Manufacturing is critical to growing our economy and supporting local jobs. These grants will help more local businesses to innovate and expand, drive investment, and compete globally.” “We’re investing in Victorian manufacturers to support our growing economy and improve productivity.” Recipients of Round 1 of the

program were announced last month, with 14 Victorian manufacturers supported and 138 new jobs created. Underpinned by the Made in Victoria 2030: Manufacturing Statement, the Labor Government is supporting local manufacturers to expand operations and drive investment. These initiatives include the $2 billion Breakthrough Victoria Fund, the $20 million Manufacturing and Industry Sovereignty Fund, the $15 million Industry R&D Infrastructure Fund, the Energy Technologies Manufacturing Program and the $4.5 million Digital Jobs for Manufacturing Program. Victoria’s $33 billion manufacturing industry is a driving force of the state’s economy, made up of over 24,000 businesses, supporting more than 260,000 jobs and exporting goods worth $23.9 billion. Manufacturers’ Monthly DECEMBER 2023 19

Manufacturer Focus

Assured success With 3D printing beginning to finally have the impact on manufacturing that was expected some 30 years ago, manufacturers remain wary of truly capitalising on it. Additive Assurance is looking to change that.

HILE the growth of additive manufacturing is exciting for the industry, manufacturer Additive Assurance has identified a way to ensure the quality of 3D printing is up to the standards needed. Additive Assurance can trace its roots back to co-founder Marten Jurg’s time at Monash University completing his PhD and working with additive printing equipment. Frustration with an intermittent problem with one of printers in the mid 2010’s forced Jurg to consider a way of demonstrating to the supplier the fault in the system. “I was working in the Department of 20 DECEMBER 2023 Manufacturers’ Monthly

Materials Engineering and Science , and we had begun to notice major faults in what was being produced by our additive machines,” Jurg explained. “At the time, I was tasked with understanding fatigue in lattice structures for an aerospace client and this led me to looking very closely at the additive machines we used,” he said. Fatigue failures happen for two main reasons in additive manufactured parts according to Jurg. The first is due to high surface roughness of the parts, and the second is the presence of defects and voids inside the parts. “Put simply, when you are rapidly melting and solidifying several kilometres

of welds in a additively manufactured part there are lots of things that can go wrong, leading to flaws that cause parts to fail when in service,” Jurg said. “There are hundreds of sources of variation, everything from the machine, the laser system, the part design, the material you are processing and more. A small change in any of these could lead to a big problem,” Jurg explained. A deep understanding of these faults saw Jurg and his team at Monash contacting the manufacturer of the printer to rectify the fault they were finding in one of their systems. The printer had been installed six months prior and the sporadic fault

had the team scratching their heads and the supplier was reluctant to send a technician from Europe to inspect it, so it was time for Jurg to look at ways of demonstrating the faults clearly. “We needed to find a way to prove to the manufacturer that our system had an issue,” Jurg said. “I went into a neighbouring department that had high speed cameras to get some high-speed imagery of the system in action. “We ran the camera on the system and sure enough we could see a point where the laser system almost cut out completely, the output power dropped significantly just for a millisecond or two,” Jurg said. manmonthly.com.au

ManufacturerFocus The result of that power drop meant substantial defects forming in the part, creating more scope for fatigue issues. The next challenge the team faced was distributing that video file across to the supplier, as the file was enormous. “The video was only a couple of minutes long, but the file was several gigabytes, so it was almost impossible to send through an email or online channels,” Jurg said. “This problem made me think, what if we could flip the problem? I had a passion for photography, and so I thought could long exposure photography be the answer here.” “If we held the shutter down for a longer period at a high resolution and filtered the light emissions coming in, we could observe all of the phenomena we saw with the high-speed camera but the output was a far smaller file,” Jurg said. With this approach he knew he was onto a winner. “Not only could you see the fault we were looking for, but you

could see minor fluctuations in immense detail,” Jurg said.

Improving the system While Jurg and the team knew they had identified a winning formula, they knew it needed to be improved upon to create simplicity for users and provide even greater depth of information about the detected faults. The developments led them to where Additive Assurance is today. The system combines a suite of optical sensors to gather micron-level detail, and through machine learning provides rich insight into the process. Agnostic to number lasers and capable of detecting a wide range of process instabilities, the system offers more than simple process monitoring. Adjustable thresholds for tracking, notification and or intervention ensure highest machine utilisation and quality control. “From that initial imagery we have

further developed our offering to have a sensor package that the customers can interact with and interpret the data,” Jurg said. “We have also brought in machine learning analytics to identify faults without user input to ensure the system works as simply as possible for users,” he said. Being a start-up always has its challenges, but Additive Assurance prepared the product to market locally to begin the feedback process from users. “The early units needed some tweaking - as we expected - to meet the needs of the user,” Jurg said. “We developed more capabilities since then and we are continuing to roll them out regularly to improve our offering to market.” The team remains relatively small at Additive Assurance with about 16 members, the majority of which are based in the company’s Oakleigh office with a

few representatives overseas to support the international market.

The manufacturing process Additive Assurance is very much in the start-up phase of its growth, but it is an exciting period for the company as it begins to build towards greater success. “As it stands, we are doing a lot of the assembly ourselves with content from a range of suppliers, but I believe as we grow locally and globally that will begin to change,” Jurg detailed. “Over time we expect to outsource our manufacturing, there are numerous manufacturers doing excellent work in Australia, so we are spoilt for choice. “For us we need to be realistic about upscaling our manufacturing process, we are not going to be making a million of these products, its thousands to tens of thousands,” he said. For the team at Additive Assurance investing heavily in manufacturing

The Additive Assurance system works in conjunction with existing additive systems.

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Manufacturers’ Monthly DECEMBER 2023 21

Manufacturer Focus Marten Jurg has been developing the products since 2019 and is nowing going to market with them.

process internally would take away from the company’s ability to improve its research and development processes. “Our specialty is in software and data science side of our operations. Hardware and manufacturing is a speciality and if its not a core competency it is best outsourced to others,” Jurg said.

The challenges As with all businesses, cash flow is critical, but this challenge is always heightened at a start-up as Jurg explained. “We got our first investment in 2019 22 DECEMBER 2023 Manufacturers’ Monthly

with a plan to go to market at around mid 2020, but obviously that did not happen in the peak of COVID-19 lock downs,” he said. “The delay to our launch was actually beneficial, it allowed us to spend more time testing and ensuring we were creating a very robust product. “We developed a completely automated calibration system where we can install a sensor to a new machine and be fully setup in just a couple of minutes. “We got it to the point where we can calibrate the sensor package to less than a pixel of accuracy, it can do it completely automatically without human intervention,” Jurg said.

He went on to explain the complexities of getting a start-up off the ground and some of the unique challenges faced by Australian start-ups. “In Australia’s ecosystem you have multiple things against you, it has improved over the years, but it is still not the greatest place to get a start-up going. “The investors that understand the complexities of deep-tech and manufacturing industry are few and far between, which can be challenging. “Getting the right investors and advisors on board is crucial to building a successful business. The company has been well backed by a range of investors and groups who have competencies

in technology investing, providing excellent support to the team to get the product off the ground.

The AMGC Additive Assurance recently completed a project with the Advanced Manufacturing Growth Centre (AMGC) to fast track its commercialisation process. The specific outcome of the project was to take the beta version of its design and make it production ready. This will enable a significant growth in the additive manufacturing industry both in Australia and world-wide; create jobs in the manufacturing sector; manmonthly.com.au

ManufacturerFocus and strengthen Australia’s sovereign capabilities and expertise in additive manufacturing. “We had AMGC thankfully come on board last year to support our commercialisation rollout and they have been critical to our success,” Jurg said. “We worked with AMGC to design a project that would help us cross some of the key hurdles to meet industry requirements, and then execute on that plan to deliver this to the market.” Jurg detailed the challenge for many start-ups is obtaining funding through the middle stages of company development, as there is plenty of funding for the early and later growth stages. The AMGC came in and provided that critical support through the intermediate stage, which has now set the company to explode to the market.

3D printing in Australia Some of the earliest 3D printers were developed in the mid 1980’s and ever since it has been said that it will be a game-changer for manufacturing, but its success remains slightly elusive still; particularly in Australia. Jurg believes the time is right now for Australian manufacturers to truly capitalise on additive manufacturing.

“We have been global since day one basically, we are proud to be Australian made but unfortunately we feel like Australia has not fully capitalised on 3D printing, so we knew to expand we needed to go global,” he said. “I really want to encourage manufacturers in Australia to look closely at 3D printing and where it can fit in to their manufacturing processes. “It holds huge promise, I think people get nervous as it can seem new and risky, but that is simply not the case anymore with 3D printing. “Some companies can overhype their capabilities, so a degree of caution is warranted, but there are some genuinely capable systems out there and it has the potential to thrive in Australia,” Jurg said. Jurg explained Australia has lagged behind the rest of the world and while we have some of the best research facilities, there is a large gap between research and the widespread use of this technology in the country. “Additive manufacturing particularly makes a lot of sense in Australia as it can reduce long lead times that Australian manufacturers need to put up with, making the industry competitive on a global scale once more.”

Additive manufacturing makes a lot of sense in Australia because it reduces lead times in manufacturing.

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Jurg and his team have been attending numerous events to showcase the system.

Manufacturers’ Monthly DECEMBER 2023 23

Trailer Aluminium

Capral quality for sure Capral has been supplying high quality aluminium to SureWeld for its aluminium trailers and ramps. Manufacturers’ Monthly delves into SureWeld to understand what makes it so successful. “The trailers definitely live a tough life, so that’s why we have to develop a product to handle the rigours of the environment they work in,” Hansen said. “What sets us apart is that our products are Australian made with Australian materials thanks to sourcing our aluminium through Capral.”

Capral is supplying high quality aluminium to SureWeld to meet its demands.

The process

EGINNING life as a small welding shop in 1976 focusing on aluminium ramps, SureWeld has branched out to become a leader in the manufacturing of aluminium plant trailers. SureWeld began making aluminium trailers in 2008 as the machinery industry was demanding a lightweight trailer that could carry heavy plant equipment but withstand the challenges of lugging the often heavy machines in challenging areas. SureWeld sales manager Gareth Hansen turned to aluminium to drop the weight of his trailers. “We found that the machines were 24 DECEMBER 2023 Manufacturers’ Monthly

getting heavier, the Utes were getting lighter and the braked towing capacity was dropping, so we developed the aluminium trailer, which was about a third of the weight when compared to standard steel,” Hansen said. “We started with one trailer model that was for 1.7 tonne machines and over the years we have continually developed it to now include 2.5 to 4.1 tonnes.” SureWeld is distributing Australia wide from its base in Victoria. Hansen said 80 per cent of customers are through machinery resellers and a small portion of its business is direct dealings with end users. The trailers are often sold as a package with the machines themselves.

SureWeld is located in the regional Victorian town of Wangaratta. The company supports Australian industry and local Victorian industry to produce and transport the trailers Australia wide. While its trailers have become a critical component of the business, SureWeld has not forgotten how the company started. “Our aluminium ramps are a little over 50 kilograms, whereas others can be closer to 80 kilograms,” Hansen said. “We take a lot of pride in our trailers and ramps using a process we call our rolled drawbar. “Effectively we take on piece of aluminium that we heat treat and roll into the shapes we need, it adds greater stability to the trailer and improves the life expectancy.” SureWeld has cultivated a strong relationship with Capral. After previously sourcing its aluminium from other

suppliers, it needed the quality and reliability of Capral during COVID. “When the material first arrives from Capral, we rigorously test it on our hardness tester to ensure it meets the standards we set,” Hansen explained. “Capral has excellent testing procedures but by doing the testing ourselves as well, we know we are sending the best quality product to market. “Once it passes its testing, it then rolls onto the production line, where it goes through cutting, shutting, welding, and then finally cleaning.” Over the previous decade, SureWeld has begun to slowly implement automation into its production line. “We have brought in a couple of CNC water jet cutters, brake presses, guillotines and other things to improve our processes,” Hansen said. “Bringing in this automation allows us to ensure we have consistency going out to market.”

Working with Capral The extrusions used by SureWeld have developed at regular intervals over the journey. The desire for a high quality aluminium was what saw them return to the aluminium specialist. “When we came back to Capral in manmonthly.com.au

TrailerAluminium

The trailers are designed to last in some of the harshest environments in Australia.

2020, we worked closely with the team when we wanted to add hollows in some sections and thin out and beef up others,” Hansen said. “Capral has been really good at giving feedback on what they can extrude – our engineers will approach the team and they will give us an understanding of the feasibility.” While the materials received from Capral have been of the highest quality for SureWeld, the relationship between the two is also important. “Capral have been an excellent supply chain partner over the years,” Hansen explained. “The fast lead times, ease of doing business and their prompt response to all our enquiries make them an excellent supply chain partner for us. “They are priced really well and they are Australian made and produced, which is a major plus for us.”

Designing the trailers SureWeld has a team of around 30 staff all striving to deliver the highest quality aluminium trailers and ramps. The quality process all begins with the design team. “All of our design is done in house with our team of engineers,” he said. “The designs begin at inception when they are drafted, then we move on to the prototyping stage in which we test the capabilities to mass manufacture the trailers and ramps. “Those prototypes will then go into field testing where they can spend months and even years to test for fatigue issues and any potential shortcomings of the trailer.” The trailers are also inspected by infrastructure Australia to ensure they meet the organisations specifications and minimum design requirements. “Quality is one of our top priorities,”

The ramps and trailers are rigorously tested by both Capral and SureWeld to ensure they meet the necessary standards.

Hansen said. “The reality is that aluminium does wear out, but the quality of our product offers the most life expectancy out of it. “If anything goes wrong, we always ensure that we provide that backup support needed to get them back online as quickly as possible.”

Supporting customers Capral works hard to deliver the materials quickly and to the highest quality.

manmonthly.com.au

The motto for SureWeld is to keep Australia moving. That can mean either the machines or the people. “Things can go wrong, but we have backup support across the country to

support them and get them up and running,” Hansen explained. “All of our spare parts are Australian made and locally sourced to ensure we are giving the highest quality to our customers. “Customers are regularly commending us on how easy we are to do business with from the registration through to the ordering. “There does not need to be a lot of backwards and forwards trying to understand each other, all we need to do is uncover their needs from the get-go and deliver them a quality aluminium trailer.” Manufacturers’ Monthly DECEMBER 2023 25

Lifting equipment Kito Crosby Australia’s Custom Hoist Assembly Kito Crosby Australia, a leading provider of lifting equipment, has established itself as a trusted partner in delivering tailor-made hoists and associated lifting solutions. recently customised some hoists that able to travel 130m in and out of a mine shaft.

Custom solutions in Kito manual hoists

Kito Crosby Australia prides itself on offering one of the most customisable ranges in lifting equipment.

N today’s rapidly evolving manufacturing industry, organisations face unique challenges in the realm of lifting and material handling. Kito Crosby Australia (Kito PWB) has been a trusted name in material handling solutions for decades, the company is consistently pushing the boundaries of innovation to meet the unique demands of various industries. In this article, we delve into Kito Crosby Australia’s expertise in hoist customisation and their custom hoist assembly shop.

Kito hoist customised builds KITO is the world’s leading manufacturer in light lifting technology and stands for unsurpassed quality, maximum safety, and excellent service. KITO products are broad in range, from chain and wirerope hoists for lifting and lever hoists for holding to cranes for transporting. They offer a range of specialised builds designed for specific manufacturing applications. 26 DECEMBER 2023 Manufacturers’ Monthly

For instance, the RY Series Wire Rope Hoists deliver high-lifting speed for heavy-duty lifting demand and is available in 5 tonne and 10 tonne. The ER2 Series Electric Chain Hoists is an all-rounder suitable for the toughest conditions with lifting capacity up to 5t. The EQ Series Electric Chain Hoist offers a 23 per cent reduction in dead weight compared to the ER2 series and can be used for everyday tasks of all kinds, while the ED series is ideal for compact spaces or single-phase power supply requirements. The manufacturing sector encompasses a diverse range of industries, each with unique lifting requirements. Kito Crosby Australia recognises these distinct needs and offers a comprehensive tailored solutions to meet the demands of manufacturing. The tailored solutions they offer including long lift chain buckets, specialised load cells and displays, travel limits, visual and audible alarms, radio remote control systems, closed coupled trolleys, overload limiters and

additional hoisting limits. Every item leaving its workshop undergoes thorough functional load testing in accordance to AS1418, ensuring manufacturers find the perfect electric chain hoist for their unique needs.

Mining plant: Productivity booster In mining operations, electric chain hoists can be used to lift heavy equipment and materials. The KITO ER2 electric chain hoist is designed for peak performance, even on the toughest jobs in the toughest conditions. It is a preferred choice for the most demanding environments. It is classified as an ‘infinite duty cycle,’ which means the user can run it repeatedly without causing it to overheat and has infinitely variable speeds. It guarantees safe and efficient load movements of heavy mining equipment and materials, reducing manual labours and elevating manufacturing standards. They are versatile and customisable to suit each mining application. For instance, they

Manual hoists remain indispensable in manufacturing, especially when power sources are limited, or operators require more hands-on control. Kito Crosby Australia offers a range of manual hoists and trolleys that can be customised for specific applications. The KITO M3 Manual Chain Blocks offer exceptional load capacity options for various usages, engineered to withstand rigorous working conditions while ensuring precise control over lifting operations. The KITO L5 Lever Blocks provide additional options such as overload protection, shipyard hooks, load signal handle for enhanced safety, meeting specific manual lifting requirements. In manufacturing assembly lines, where speed and control are essential, KITO manual hoists come into play. They facilitate the smooth movement of materials and components, ensuring efficient production target fulfillment. These hoists can be tailored to specific assembly line configurations, reducing downtime, and enhancing workflow.

Maintenance and repair operations: Versatile tools Regular maintenance and repairs are inevitable in manufacturing facilities. KITO manual hoists are versatile tools that can be customised with features such as corrosion-resistant coatings and overload protection, making them ideal for outdoor use in industrial settings. It aids technicians in safely and efficiently lifting heavy machinery components, reducing downtime, and improving functionality. Whether lifting delicate instruments or heavy machinery parts, these custom hoists are engineered to meet specific tasks.

Special builds in ENDO Air Hoists Kito Crosby Australia also offers manmonthly.com.au

Liftingequipment

customisation in ENDO air hoists, which provide efficient pneumatic lifting solutions for manufacturing environments where compressed air is the preferred power source and safety is required within hazardous work conditions. These air-powered hoists have very fast lifting speeds and infinite duty cycle, and suitable for various industries such as food manufacturing, pharmaceuticals, paint shops, and especially mines and oil and gas companies.

Chemical plant: Safe and efficient lifting In chemical plants, safety is paramount, and hazardous materials are handled regularly. ENDO air hoists are powered by air, making them safe to use in such environments. They are ideal for attaching, detaching and moving machining work, mold work, and tool centering. The variable speed control of the ENDO air hoist allows for accurate positioning and manoeuvring of delicate loads.

Petroleum manufacturing: efficiency and safety Efficiency and safety are paramount in petroleum manufacturing. ENDO air hoists, built to handle substantial loads, are essential in assembling heavy equipment such as drilling rigs, pumps, and compressors. They guarantee the safe and efficient lifting of heavy components, even in corrosive environments, enhancing manufacturing precision and reliability. There is also a range of customisable options and special accessories available manmonthly.com.au

for every model of ENDO air hoists. Some of these extra features include an air cleaner, cleaner accessory, overload limiters, air trolleys, longer chains or cables, extended control tubes, pendant controls, and different trolleys.

Kito Crosby Australia’s custom hoist assembly shop Kito Crosby Australia’s custom hoist assembly shop is a testament to its commitment to delivering tailored lifting solutions. The shop is equipped with innovative facilities and staffed by skilled engineers and technicians specialising in hoist customisation. From consultation to assembly, the shop ensures meticulous attention to detail throughout the process.

Customisation process: From concept to reality The customisation process begins with a consultation, where the client’s unique requirements are thoroughly evaluated. Kito Crosby Australia’s experts then recommend a special build proposal, considering factors such as load capacity, environmental conditions, and safety regulations. Once approved, the assembly team swings into action. Every component is carefully selected and tested to meet Kito Crosby Australia’s stringent quality standards. Skilled technicians then assemble the hoist with precision, paying attention to every detail.

Testing and quality assurance Before a customised hoist leaves the assembly shop, it undergoes rigorous

The hoists are capable of working in some of the most senstive environments, delivering high-quality lifting solutions. testing to guarantee performance and safety. Load tests and operational checks are conducted to ensure that the hoist operates flawlessly under real-world conditions. Kito Crosby Australia’s dedication to hoist customisation and their custom hoist assembly shop positions them as

industry leaders in delivering innovative lifting solutions for the manufacturing sector. By offering customised KITO electric hoists, manual hoists, and ENDO air hoists, tailored to unique needs, Kito Crosby Australia continues to provide customers with reliable and efficient lifting equipment. Manufacturers’ Monthly DECEMBER 2023 27

Welding Gas

Thorntons new gantry, equipped with two robots, allows them to qaudruple its output.

Supplying an industry leader Thornton Engineering, a family-owned manufacturer specialising in structural steel, pressure vessels, heat exchangers, plate work and pile casings, relies on a pivotal supply of industrial gases from Air Liquide Australia.

NDREW Thornton, the company’s founder, started his journey in a small workshop on his farm Penhurst, regional Victoria and has since expanded the business into a thriving steel fabrication enterprise that is now a major player in the Australian market. Thornton’s entrepreneurial spirit began with small-scale projects, initially focusing on serving the rural industry. The workshop eventually grew to employ about 20 people, mainly in the rural sector. As the business grew, the need for expansion became evident. So, when Andrew’s son David Thornton showed a keen interest in taking the family business to the next level, it was a turning point for the company Dave Thornton - who had been studying at RMIT in Melbourne proposed that they relocate the company closer to the city. This led to a pivotal decision to move Thornton Engineering to Geelong, where they purchased two 10-acre blocks of land 28 DECEMBER 2023 Manufacturers’ Monthly

in the suburb of Corio, outside the M1.. Thornton Engineering operations manager Lucas Boogaard explained the company in greater detail to the team at Manufacturers’ Monthly. “They bought two blocks of 10 acres here in Corio, with a vision to the future and plans of building multiple shops over the years,” Boogaard said. However, the game-changer for Thornton Engineering was the implementation of a cutting-edge process integration making a slow workshop in a production line called a beamline. “Soon after building the first plate workshop, Thornton built its first beamline, and the beamline is what allows us to manufacture high quality products quickly and efficiently,” Boogaard said. The beam line revolutionised its operations, enabling them to produce structural steel with remarkable efficiency. The two extensively equipped Beamlines are designed to turn CAD drawings into fully fabricated structural steel within 48 hours. This production line encompassed a

streamlined process, starting from raw material and culminating in a painted, fabricated steel product. This innovation allowed them to become a key supplier to the mining industry, providing fast and reliable steel delivery for large-scale projects. With this newfound success, the company built a second, larger beam line to keep up with the increasing demand.

Thornton Engineering today Today, Thornton Engineering has grown to employ 220 workers, each playing a unique role in the company’s continued success. The company has since established itself as a leader in the field of steel fabrication, with 150 skilled workers on the production floor and 70 dedicated individuals in various supporting roles. “Thornton Engineering is one of the biggest steel fabricators in Australia today,” Boogaard said. “We now have three divisions including structural steel, structural plate work and pressure vessels and heat exchangers.

“This includes pedestrian bridges, road sign gantries, and even larger projects, such as railway bridges, as well as large pressure vessel tanks” said Boogaard.

Partnership with Air Liquide As Thornton Engineering’s operations continued to expand, so did its demand for reliable welding and gas, all critical to its success. “Every part of our process is important, but the majority of the work we do involves welding of steel products,” said Boogaard. “Our company is built on delivering high quality products quickly, any issues with welding equipment or gas becomes a serious problem. “We rely on Air Liquide for deliveries every Tuesday and Friday, that suits our needs particularly well, but we are beginning to consider onsite mixers in the near future, said Boogaard. The onsite mixers are being carefully considered by the management team at Thornton Engineering in conjunction manmonthly.com.au

WeldingGas with advice provided by Lau and the team at Air Liquide. Thornton Engineering currently uses an array of different gases, this includes the Air Liquide ARCAL reference line series of shielding gas products. Air Liquide welding engineer, Andy Lau explains how he ensures he meets the needs of Thornton Engineering. “Our usual biweekly delivery service for Thornton provides just-in-time service for customers and frees up working space by avoiding the need for a large storage area for gas and reducing logistics costs,” he said. “Most importantly, we have five delivery points on Thornton Engineering’s premises that that serve the individual workshops with their gas requirements.”

Air Liquide delivers high quality products for Thornton Engineering Thornton Engineering has been using ARCAL gases for several years, it is an important part of its welding process and suits the company’s needs for a high quality and robust gas. The ARCAL Speed gas is designed to increase welding speed whilst simultaneously reducing the need for wire feed and post-weld cleaning. ARCAL Prime is also used by Thornton Engineering, with its high purity it can be used universally but particularly for root shielding.

Lau also recommended that Thornton Engineering utilise ARCAL Force for fast and deep welds which has been pivotal to meeting the needs of the welders at the organisation. Air Liquide has been working diligently in recent years to improve safety for welders, and is also committed to creating a greener and safer environment. The low fume formulated product is helping to improve worker safety and reduce the exposure to harmful welding fumes relative to traditional welding gases.

Investing for the future Initially, the Kinetic plate plasma and oxy cutters were purchased by Thornton Engineering solely to support the pressure vessel shop. These were not going to be able to meet the sheer volume the company needed to be outputting in the coming years so they needed to consider alternatives to help meet the needs of the organisation. “Running two shifts a day full time, these machines demanded a significant amount of floor space and storage for the incoming plate materials,” Boogaard said. “This situation was not ideal, it made far more sense to attempt to utilise the space for fabrication as opposed to storage,” he explained. In response to this challenge, the company made a strategic decision to

install a second new Kinetic plasma cutting machine, in the dedicated plate processing shop, using a manifold supplied by Air Liquide. The specially designed manifold system promotes continuous supply and regulates the flow and the pressure of different gasses to the 2 plate cutting machines. The manifold system from Air Liquide was introduced to allow the operators to spend more time plate cutting and less time monitoring the flow and supply of gas. “By segregating our material processing from our fabrication areas, we’ve created an optimised workflow that enhances both efficiency and productivity.” The addition of a second new Kinetic plasma cutter will significantly enhance the company’s ability to process materials quickly and accurately. With the new Plate Processing Workshop, not only is Thornton Engineering increasing its production capacity but also optimising the utilisation of its floor space, thus freeing up valuable real estate for fabrication and assembly.

Enabling advanced manufacturing Thornton Engineering is already a leading player in the steel fabrication space, but it is now taking a leap into the future with its innovative use of robotics to enhance its welding capabilities.

The company, renowned for its commitment to efficiency and precision, has introduced a suite of robots that are revolutionising the welding process in its facilities. “We also have installed a robot with a plasma and oxy cutting head, in our vessel shop in which we use Air Liquide gas, this is helping us to meet high precision and efficient production timelines,” Boogaard said. The robots are strategically positioned on-site to operate within the beam lines, streamlining the welding process to maximise efficiency. In addition, Thornton has also installed a massive 15-metre-wide gantry in their newest workshop, running on a 200-metre rail track, which is the crown jewel of this new facility. The gantry boasts two robots equipped with MIG torches and twin wire capabilities. The deployment of these robots has significantly boosted the speed and precision of welding operations, allowing it to meet the growing demands of its clients more effectively Boogaard explained, and helping us to meet any skills shortages we might be facing in the coming years “These new robots have increased our output speed by almost four times what it used to be, it is a very exciting prospect.”

The pressure vessel workshop is equipped to manufacture vessels of varying shapes and sizes.

manmonthly.com.au

Manufacturers’ Monthly DECEMBER 2023 29

Fastener Solutions

United Fasteners modernises branch showrooms for enhanced customer experience United Fasteners’ is taking its commitment to customer satisfaction to the next level by updating and modernising its branch showrooms across the country.

NITED FASTENERS, a leading industrial fasteners and hardware solutions provider, is taking its commitment to customer satisfaction to the next level by updating and modernising its branch showrooms throughout Australia. These revamped showrooms showcase a wide range of products in an aesthetically pleasing and organised setting, simplifying the purchasing

process for manufacturers. The upgraded showrooms feature interactive product displays, live demonstrations, knowledge-able staff, and intuitive layouts. United Fasteners’ dedication to creating an exceptional customer experience is evident in these improvements, reaffirming the company’s customercentric approach. Sam Mitchelhill, Executive

Director at United Fasteners further explained why the company has show such a commitment to improving its processes. “Our customers are at the core of everything we do. These revamped showrooms reflect our commitment to providing a pleasant, efficient, and informative experience for our valued customers.” These enhancements align with United Fasteners’ commitment

to ongoing improvement and their continual care and focus to improve their customer’s business, making them a standout leader in the fastener industry, dedicated to delivering exceptional customer experiences, innovative solutions and building lasting customer relationships. Customers are invited to experience the new showrooms and see the difference for themselves.

The new showrooms are designed to better serve the United Fasteners’ clients.

30 DECEMBER 2023 Manufacturers’ Monthly

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InnovationIn Manufacturing

Breathing underwater made cheaper and more accessible The Australian brand SCORKL has launched SCORKL 2.0 – Electric, its new and improved underwater breathing device – built upon the previous SCORKL design – providing even more accessibility, affordability, and fun to divers and water lovers.

CORKL creator and founder, David Hallamore, was inspired by movies like James Bond and his love of the ocean to produce portable and fun underwater breathing devices that are accessible for everyone. It has been six years since Hallamore brought his dream to fruition with the launch of the first iteration of the SCORKL device – he has set his sights on improving that dream. 32 DECEMBER 2023 Manufacturers’ Monthly

“I grew up around the water, and in the water,” he said. “I’m a swimmer, a boatie, a SCUBA diver, a free diver, a rower, a water polo player, and a sailor. I love the water, and the feeling of breathing underwater is truly incredible. “My dream is to give everybody else the opportunity to experience that. SCORKL makes it possible— regardless

of age or experience, anyone can now feel that indescribable freedom,” Hallamore said.

SCORKL 2.0 After two years of research and development, the SCORKL brand is launching ‘SCORKL 2.0 – Electric’ which now features an all-new 10kg SCORKL Electric Compressor and SCORKL

Battery Pack. The SCORKL 2.0 enables automatic refills of the brand’s portable underwater breathing device at the touch of a button. While still maintaining the portability and ease-of-access aspects from the first SCORKL, the SCORKL 2.0 can now be effortlessly refilled anywhere. “I’ve always believed that every boat needs a SCORKL for things like unfouling manmonthly.com.au

ScubaManufacturing “The hand pump still provides value in certain situations, but now we’ve overcome the effort required to use these devices. Traditional SCUBA air compressors are prohibitively heavy and expensive, meaning they can only be stored and operated in dive stores or in a garage. “The SCORKL Electric Compressor, in stark contrast, is lightweight, inexpensive, and portable. Not only can you plug it into the wall, but you can power it from a boat or car battery as well,” he said. The new SCORKL 2.0 can be used underwater for up to 10 minutes, and at depths of six metres. Once air is depleted, it will take users around 10 minutes to refill the SCORKL 2.0 using the new electric compressor. If necessary, customers can still also refill the SCORKL 2.0 using the SCORKL handpump or from a larger scuba tank or compressor.

Cost matters

The future

In the first 48 hours of the launch of the SCORKL 2.0, SCORKL received $250,000 worth of pre-orders. By the end of the launch period, twenty days later, they had received over half a million dollars worth. The SCORKL 2.0 of course makes underwater breathing more accessible, but Hallamore says that it also it makes it more affordable. “It’s basically a bargain, it costs around a tenth of a traditional scuba system.” Since launching the SCORKL brand in 2019, SCORKL now sells and ships to 65 countries worldwide. The brand has received over AUD $4 million worth of sales so far.

While the SCORKL breathing devices are a certain source of success for the brand, Hallamore said that there are plans to expand the SCORKL diving and boating range. You can expect to see SCORKL brand flippers, masks, weight belts, dive lines, wetsuits, and eventually even storage and access units for boats. “The reason why boaties and sailors love SCORKL, is because it’s the perfect thing to use to clean your boat, or getting an anchor freed from a rock. It’s a game changer for utilities on boats.”

Who can use the SCORKL?

‘SCORKL 2.0 - Electric’ features a new electric compressor and SCORKL Battery Pack.

a propellor, cleaning under the hull, moving an anchor, and – of course – incredible underwater experiences,” Hallamore said. “And now, every boat needs a SCORKL Electric Compressor for effortless, unlimited refills.”

Challenges The first iteration of SCORKL remains a leading device in providing consumers with a portable and accessible alternative to traditional SCUBA systems. However, once the SCORKL was depleted of air, the device needed to be refilled using the SCORKL handpump or from a larger scuba tank or heavy dive compressor. “The handpump was an innovative offering, but the effort required was more than some people were willing to commit,” Hallamore said. manmonthly.com.au

The SCORKL 2.0 is available for almost anyone to use regardless of experience, but educational content is available for customers that are not confident. “It’s not a toy,” Hallamore said. “It’s an adventure sport, but the product has been performance and quality tested to the highest international scuba standards.” Upon purchasing the SCORKL 2.0, customers will receive user manuals and instructional videos, and links to the SCORKL school where online learning resources are always available. Hallamore said customer feedback has been positive, stating that “everybody is super excited about the SCORKL 2.0, because it’s the final link in the product we’re offering that people have been looking for.”

The new battery pack SCORKL are also launching a brand new SCORKL battery pack for any customers looking to go completely off-grid. The new battery pack features a streamlined design and marine-grade fittings, and it can also utilise everyday 18V power tool batteries to power the SCORKL Electric Compressor. The battery pack is compatible with many common power tool battery brands. The new SCORKL Battery Pack also features several utilities, such as an LED light and USB Ports to charge mobile devices.

The new SCORKL 2.0 will allow divers to remain underwater for up to 10 mintues, at depths of six metres.

Manufacturers’ Monthly DECEMBER 2023 33

Hydrogen Manufacturing Hydrogen manufacturing getting underway Energys Australia is leading the way in hydrogen fuel cell generators with some of the first rolling off the production line in Victoria to some major clients and to support regions particularly vulnerable to power outages. Lily D’Ambrosio toured the Energys facility .

NERGYS has proudly unveiled the first of five cutting-edge Hydrogen Fuel Cell Generators being manufactured for Telstra as part of an alternative energy backup pilot program. The Hon. Lily D’Ambrosio, whose portfolios include Minister for Climate Action and Minister for Energy and Resources, was on hand to watch a demonstration of the unit in action. The Hon. Lee Tarlamis MP, Member for South-eastern Melbourne, was also in attendance. The Hydrogen Fuel Cell Generators are designed as a drop-in zero emissions replacement for traditional diesel electric generators, which will inevitably be phased out as the world strives to meet emissions targets. As part of a co-funded pilot project with Victorian State Government, Telstra will install the units at five sites in outerregional Victoria with a history of storm-

34 DECEMBER 2023 Manufacturers’ Monthly

related power blackouts to provide ondemand zero emissions backup power. Lily D’Ambrosio explained the government’s role in helping to fund the project. “We’re supporting the state’s emerging renewable hydrogen sector to play a key part our transition to 95 per cent renewable energy by 2035.” said D’Ambrosio. “This innovative project uses renewable energy to keep the power running during an emergency, helping to maintain vital telecommunications, which is critical as we encounter more frequent extreme weather events.” The Fuel Cell Generator delivers 10 kilowatts of AC power using hydrogen gas as a fuel source. The hydrogen is passed through the fuel cell, which undergoes an electrochemical reaction, producing electricity. The only by-product of this reaction is pure water vapour,

which can be released harmlessly into the environment. Whilst hydrogen fuel cells have been used in niche applications since the mid 20th century, the abundance of fossil fuels limited their wider commercial adoption. With rising fuel prices and the need to cut emissions, many forward-thinking companies are working to include hydrogen in their future energy roadmap. Telstra’s purchase of an initial five units is a testament to its ongoing commitment to innovation and sustainability. The Hydrogen Fuel Cell Generator is part of a range of zero-emissions power products designed and manufactured in Victoria, Australia. It is the result of seven years of research and development. What makes this third-generation product a game changer is that it has been designed specifically for large-scale manufacture using Energys’ proprietary engine design. This makes the Energys

Hydrogen Fuel Cell Generator arguably the world’s leading mass-producible hydrogen gen-set that is available for purchase by customers now. Dr Roger Knight, Energys Managing Director spoke about the system. “We think this is the best fuel cell generator in the world. It took a lot of vision, innovation and hard work to get us to this point,” said Knight. “It’s not just about having the world’s best product, though. “You also need a very strong supply chain to deliver it in volume, we have that, and much of it is local. That puts us in a position not just to service Telstra, but other adopters as worldwide demand grows,” he said. Dr Knight went on to highlight the enormous demand for power products globally. “The diesel generator market is over US$20 billion per annum,” said Knight. manmonthly.com.au

HydrogenManufacturing “That’s an enormous demand for fossil-fuel-based generators that must be phased out. We look forward to engaging with companies eager to meet their emissions targets with reliable, commercially viable zero emissions products like this one,” he said. The Energys range of Hydrogen Fuel Cell Generators is now rolling off its production line in Mulgrave, Victoria. The facility is set for further growth in line with market demand and will deliver around 50 megawatts of fuel cell products annually as part of its phase one expansion.

Green hydrogen supply Telstra will power the Fuel Cell Generators from Green Hydrogen sources, including Energy’s hydrogen production facility, which is already under construction. The location and details of this facility will be announced in the coming weeks.

Victorian government funding As part of Victoria’s Renewable Hydrogen Industry Development Plan, the Renewable Hydrogen Commercialisation Pathways Fund provided grant funding for capital works projects that support the building of hydrogen pilots, trials, and demonstrations to kick start Victoria’s renewable hydrogen sector, unlock co-

Some of Energys’ first systems will be going to Telstra to support its network.

The work done by Energys shows the capabilities for renewable manufacturing in Australia.

manmonthly.com.au

investment and lead the way to commercialisation. The Victorian government provided a Renewable Hydrogen Commercialisation Pathways Fund grant of $1,115,185 to Telstra for the Telstra Renewable Hydrogen Fuel Cell Generator Pilot at Mobile Sites project. This project will deploy a renewable hydrogen fuel cell generator at regional mobile communication sites. It will remove the reliance on fossil fuel generators and enable renewable hydrogen to support the electricity system and reliability for telecom services in times of high demand. Energys Australia is also developing a renewable hydrogen production facility that will produce renewable hydrogen via electrolysis. The project will facilitate the uptake of renewable hydrogen, not only for use in the transportation sector but also as an alternative for other ways diesel is currently utilised. ($1m grant for $4m project cost, Energys renewable hydrogen production facility). Manufacturers’ Monthly DECEMBER 2023 35

SEMMA Update The next 12 months are favourable for manufacturing CEO of the South East Melbourne Manufacturers Alliance Honi Walker looks towards 2024 and what it will hold for manufacturing in Melbourne’s south east but also manufacturing more broadly.

Honi Walker is excited for what 2024 may hold for the southeast of Melbourne.

HE Southeast of Victoria is now considered to be the manufacturing hub of Australia, according to Bernard Salt, Australia’s most well-known demographer. “Four of the largest manufacturing regions are located in the South East of Melbourne – employing a total of 29,900 people and Melbourne is forecast to be Australia’s largest city at 7 million by 2040,” he said. Finding the right people, investment, growth, cutting red-tape and taxes, the narrative is enough to keep any CEO or 36 DECEMBER 2023 Manufacturers’ Monthly

SME business owner awake at night. But what are the things we can look forward to in 2024? Recent figures from the Victorian State Government affirm that Victoria’s $33billion manufacturing industry is a driving force of the state’s economy, made up of over 24,000 businesses, supporting 260,000 jobs and exporting goods worth $23.9billion#. Indeed, it is refreshing to see the Victorian and Federal Government working together. The recent

announcement of the National Skills Agreement (NSA) which will take effect from January 2024 hopefully means a coordinated effort to not just fill these skills gaps now but ensure we have a pipeline of skilled people for the foreseeable future. Never has this been more important as we continue to stress the need for our sovereign capabilities to be recognised and protected – we believe our rail industry needs to be part of this consideration, and SEMMA will take up

this conversation at AUSRAIL in Sydney this November. SEMMA is doing what it can to help develop a pipeline of skilled people. Earlier this year we launched our SMART SECURE SUSTAINABLE – Manufacturing has Evolved – So have our Careers campaign promoting the range of new careers emerging from advanced manufacturing while encouraging secondary students to consider the benefits of apprenticeships, traineeships and VCAL programs through the TAFE sector. manmonthly.com.au

SEMMAUpdate We are working closely with one of our founding members – Chisholm TAFE to bring a new generation of people into manufacturing. We have a Meet the Graduate event at Chisholm on Thursday 23 November, linking employers and recent engineering/ fabrication graduates seeking a role in manufacturing. We are also working closely with Monash University to engage their interns within our industry, and we have joined with Federation University’s Industry Co-Op model to ensure work experience and skills align. New partnerships are in discussion – so I urge you to do your part and talk to any young people you know about considering a career in manufacturing, the roles are vast and I firmly believe the opportunities unlimited. Victoria is the powerhouse of Australia’s manufacturing, but what is keeping SEMMA members awake at night? The recent increases to Workcover premiums have been a nasty surprise for most of our members. Some of our members say their premium has increased by 67 per cent and up to 83 per

cent. These increases are unsustainable, especially when members have not made any claims for many years. This is an area SEMMA will continue to press the Government on as we move into 2024 and while having it rewound is unlikely, we can look for other ways to assist our members by reducing red tape. According to the ABS Manufacturing industry earnings grew $7.6b (17.8%) in 21-22*. How’s ‘23 looking so far? According to our members, despite rate rises, the housing crisis and inflation, it’s steady as she goes. So, the pulse is strong for manufacturing – what are the growth areas and what are those issues that threaten manufacturing? What can we do, as an industry association to help our members grow?

come online (see SUSTAINABLE below). Industry input into university and TAFE courses will shore-up our talent pipeline. Partnering with organisations like Australian National Nanofabrication Facility (ANFF) and Swinburne University Smart Hub means our members can be at the forefront of testing their technological capabilities.

Secure Transport: Some sectors within manufacturing seem to be softening while others are ramping up – Alstom are gearing up for major production of the new train and tram fleet out of their Dandenong and Ballarat sites. Specialty Additives: This sector is continuing to grow, and with the increasing need to supply to Defence, this sector will continue to perform well.

Smart

Sustainable

Ai, Robotics and the renewables sector will continue to see business investment and jobs growth and as we look to opening up the regions and new projects

The growth corridor of Officer South/ Thompsons Rd will be essential if Victoria is to maintain our position as the hub of manufacturing in Australia.

This region needs the road upgrade to open the vast amount of land for commercial, industrial and residential use. Port of Hastings and the Sale New Energy Hub are in planning and offer a multitude of opportunities and SEMMA will be there connecting our members to the next wave. I encourage you to become a SEMMA member – if not already as we continue to look for those collaborative opportunities. We will continue to advocate on behalf of members and develop key partnerships as we strive for our vision that SEMMA is the leading representative body for manufacturing across Melbourne’s southeast region, recognised for its influence and collaboration. www.semma.com.au @ Source, Bernard Salt, The Demographics Group, SEBC presentation September 2023. # Source, Jacinta Allan Media Release 31 October, 2023 *Source, ABS Australian Industry, 2021-22 financial year | Australian Bureau of Statistics (abs.gov.au).

SEMMA advocates for manufacturing,

retaining local content, local capability and Australian-made. Manufacturing isn’t dying, it’s evolving. Peter Angelico | Founder and Managing Director ABECK Group, Dandenong South VIC SEMMA President since 2019

View the video on LinkedIn https://au.linkedin.com/company/semma-au

WWW.SEMMA.COM.AU WE SUPPORT, ADVOCATE AND CONNECT MODERN MANUFACTURING: SMART, SECURE, SUSTAINABLE

manmonthly.com.au

Manufacturers’ Monthly DECEMBER 2023 37

Endeavour Awards

2023 Endeavour Awards preview The Endeavour Awards is recognised as the premier Awards program within the manufacturing industry – the evening is a chance for all involved in manufacturing across Australia to celebrate the many successes within the industry, to help share these successes with a broader audience, to network and learn more about the many remarkable personalities, and enterprises that make the industry great.

HE Endeavour Awards are celebrating 20 years in 2023, this year’s Endeavour Awards will highlight those innovative businesses and provide manufacturers from around Australia with industry-wide recognition. Throughout this preview, we give a brief overview of this year’s finalists ahead of the awards night. Get a copy of the February 2024 edition to learn who the winners were and for in depth analysis of each company. Tickets are still available for this prestigious event, head to the Endeavour Awards website to secure yours.

Technology Application Award sponsored by Beckhoff

38 DECEMBER 2023 Manufacturers’ Monthly

This award recognises a technology or smart solution designed to enhance manufacturing processes. These finalists are companies who sell their products to Australian manufacturing businesses and must have gone to market in the past two years.

Maple Glass Printing Maple Glass Printing aims to disrupt the linear life cycle of glass, by diverting landfill into its circular system and 3D printing with it. It builds empowering technologies that leverage the synergy between glass manufacturing and digital design. It allows the user to take waste glass and transform it into complex geometries with great artistic and architectural expression. Since 3D printing glass has not been a possibility until now, innovative projects are emerging that add another dimension,

compared to traditional glass manufacturing practices.

Advanced Composites Structures Advanced Composite Structures Australia (ACS Australia), in partnership with EM Solutions, is leading the way in the development and series production of state-of-theart carbon fibre composite azimuth arms for ship-borne satcom. The partnership between ACS Australia and EM Solutions is a testament to the strength and capabilities of Australian manufacturing and highlights the benefits of industrial collaboration in driving innovation in Australian industry. ACS Australia, based in Port Melbourne, specialises in the design, analysis, manufacture and repair of composite structures. With over three

decades of experience, ACS Australia has built a reputation for taking on composites development in the “too hard basket” and providing high-quality and cost-effective solutions to a variety of industries.

Verbotics Verbotics Weld is a smart software designed to automatically program welding robots. Industrial robots are great tools for automation, but programming them is expensive, time consuming and difficult. This means only high-volume manufacturers can use robotics, as programming is simply too expensive and inflexible for high-mix low-volume manufacturing. The software automates the entire programming process, making it quick and easy to program welding robots. Verbotics make robotic welding manmonthly.com.au

IN PARTNERSHIP WITH

automation viable where it previously was simply impossible to use. This enables manufacturers to gain the quality, productivity and safety benefits of robotic welding.

Avicena The Avicena Sentinel Ultra V3 is a very high-throughput molecular diagnostics instrument capable of 100,000 tests per day for the detection and diagnosis of diseases such as COVID-19, influenza, tuberculosis and STI’s. The Sentinel Ultra provides a test result with 30 minutes and up to 10 times faster than conventional PCR using novel industrial automation technology. The molecular diagnostics is implemented using Loopmediated Isothermal Amplification

Environmental Solution of the Year sponsored by Capral

endeavourawards.com.au

resource, stimulates the production of new products, and meets consumers’ demands to reduce the environmental impact of our everyday clothing. INOX Australia was approached initially with a process scope from the company and their engineering support team to collaborate, design and supply a system to meet their unique process to achieve their required product outcome. This process was a world first, so existing technology did not exist that matched their requirements.

DECO In June 2023, DECO Australia made an industry-leading move to became the first building product manufacturer to commit to switching all their Capral aluminium extrusions to LocAl® Green lower carbon aluminium. LocAl Green aluminium reduces the

Outstanding Start-Up Award proudly sponsored by BlueRock (LAMP) which is recognised in the industry as being comparable to the performance of PCR in terms of sensitivity. Recognising a process or technology that enhances environmental sustainability.

Packserv The Packserv PFM-4C Four Head Auto Filler is an automatic liquid and lotion filling machine that is both user friendly and versatile featuring four separate filling nozzles each capable of depositing up to 2 litres in volume per stroke. The Packserv 4-head filling machine represents a significant leap in environmental sustainability through its innovative design and capabilities. The reliability created from the quality of Australian made engineering means customers waste less.

embedded carbon of the aluminium by 50 per cent (when compared to the global average for primary aluminium). This switch to LocAl is part of DECO’s Sustainability Framework, which has a core environmental commitment to reducing emissions across the business and to support customers across the architectural and building industries to achieve their own sustainability initiatives and outcomes. Recognising an Australian manufacturing start-up that has introduced a new product to market, filling a market gap.

communities safe, builds stakeholder trust, and minimises environmental impact. Founded as a start-up in 2019, SiteHive has grown quickly into a successful organisation working with industry-leading clients in infrastructure development, construction, extractive industries and more.

Aeromech Aeromech was established to deliver the future and put Australia on the map for Advanced composites manufacturing. Its mission is to reach the pinnacle of aerospace industry training, manufacturing and consulting. To lead Australia to the forefront of advanced composites manufacturing in Aerospace, Space and Marine industries.

Hypersonix Hypersonix has taken delivery of a technology demonstrator version of its hydrogen powered scramjet manufactured in High Temperature Ceramic Matrix Composites (HTCMCs). HTCMCs are capable of resisting repeated cycles of extreme heating and cooling, which makes them a material of choice for Hypersonix’ planned reuseable hypersonic vehicles.

Safety Solution of the Year proudly sponsored by Weld Australia

Recognising a process or technology that enhances safety. The process or

technology must be new to market or have significant changes to an existin gversion.

Lindo Lindo chamber is a chemical free disinfection chamber for use on patient stretchers and other healthcare mobile assets. Utilising proven germicidal light sources, Lindo Chamber has been designed to mitigate the use of hazardous chemicals traditionally used to disinfect healthcare equipment. Mitigate chemical procurement, reduce chemical waste and improve equipment sustainment. Fully automated, a five minute disinfection cycle in the Lindo Chamber, replaces the reliance on paramedics to complete the same task,manually, in 25 minutes. Reduce burnout, increase productivity, and improve the health and wellbeing of frontline workers

Aeromech SARGO is pioneering the way forward in the Aircraft Deployable Search and Rescue (SAR) Uncrewed Surface Vessel category. It has a patent pending application, design registration and trademark. SARGOTM is a unique Search and Rescue device that is low cost, reliable, portable and made in Australia.

Advanced Navigation Hydrus, developed by Advanced Navigation, is a fully autonomous submersible vehicle transforming undersea research, inspection, detection and classification by making data capture simple, accessible and safe. Hydrus is operational straight out of the box, allowing ocean users of every grade to have access to an all-

SiteHIve INOX BlockTexx (INOX’s customer) is a clean technology company that recovers polyester and cellulose from textiles and clothing. The company’s mission is to divert textiles and clothing away from landfill and accelerate the global textile recycling industry toward a sustainable future. BlockTexx turns textile waste into a manmonthly.com.au

SiteHive is an innovative Australian technology company that provides real-time environmental monitoring devices and software. Designed and manufactured in Australia, its products transform how people manage the impact of environmental aspects such as noise, dust and vibration. SiteHive enables proactive environmental management that keeps teams and

Weld Australia have been a longtime sponsor of the Endeavour Awards and are also nominated for excellence in manufacturing skills development.

Manufacturers’ Monthly DECEMBER 2023 39

Endeavour Awards 2023 in-one underwater inspection team. The in-house development, vertical integration manufacturing techniques enable it to make decisions in real time without human assistance. This makes the overall package efficient, portable, fully autonomous, and negates the need to send qualified crew and divers underwater to maximise operational safety.

Packserv The Packserv PFM-4C Four Head Auto Filler is an automatic liquid and lotion filling machine that is both user friendly and versatile featuring four separate filling nozzles. The Packserv 4-head filling machine is extraordinary innovation in the world of manufacturing. This revolutionary technology has paved the way for a safer means of production.

Excellence in Manufacturing Skills Development proudly sponsored by Manufacturing Industry Skills Alliance

Recognising a program designed to develop the vocational skills of manufacturing employees. It could be a company offering an internal program, an educational institution offering a program to the wider industry, or a collaboration between a company and an educational institution.

Manufacturing Excellence Forum Sunshine Coast Manufacturing Excellence Forum Sunshine Coast (MEFSC) is a not-forprofit manufacturing industries industry group which became incorporated in March 2021. MEF was formed by industry to support and assists the regional manufacturing industries to have a unified voice, linkage to soft infrastructure across business disciplines, provide connection, education to assist manufacturing businesses to learn, connect, potentially shorten supply chain regionally, 40 DECEMBER 2023 Manufacturers’ Monthly

educate businesses to understand how they can progress to Industry 4.0 and 5.0, export, broker and leverage connection to researchers joint program linkages including R & D connections/partnerships with universities, Tafe Qld and other Government led programs/assistance, provide linkage to potential grant assistance, leverage knowledge/ technology providers, linkage and support skills demand current and futureand connections regionally and provide advocacy and partnership of other leading industry groups like Food and Agribusiness Network, and Cleantech Industries Sunshine Coast.

Weld Australia Weld Australia’s resources help simplify the learning process for students, teachers and training institutes and—most importantly— place the student at centre of the learning process. Weld Australia believes that a national industry, which has a national learning package, needs national learning resources. Whether you’re an apprentice in Kalgoorlie, Ultimo or Davenport, you should have access to the same, high-quality training.

over 20 years’ experience working in the Defence and Government sectors on complex platforms and public spaces. Joe is the founder and CEO of Aeromech, a specialist organisation that provides consulting, manufacturing, and training services to the advanced composites sector within the Aerospace, Space and Defence industries.

Antony Kittel For over 25 years, Anthony Kittel has served as the Managing Director of REDARC Group, a private, family-owned, innovative electronics company based in Lonsdale, South Australia. Since purchasing the 8-person business in 1997, Anthony has orchestrated immense strategic growth, overseeing REDARC’s expansion into international markets and growing a workforce of over 350. His leadership tenure has been characterised by strong strategic vision, the fostering of innovation, and the promotion of industry excellence.

Most Innovative Manufacturing Company proudly sponsored by SEW-Eurodrive

Leader of the Year proudly sponsored by COG Advertising

Recognising a leader who holds a senior position in a private, not-forprofit, or government organisation who has effectively shaped their business’ success, delivered financial growth, significantly and positively impacted the business’ culture, and championed the industry. The nominee must show their leadership contributions and illustrate their financial and cultural impact throughout the organisation.

Joseph Bryant Bryant is an accomplished aerospace engineer and business leader with

of choice for Hypersonix’ planned reuseable hypersonic vehicles. The multi-award-winning SPARTAN scramjet engine is now available in Inconel 718, 3D-printed in Australia in cooperation with Amiga Engineering, capable of speeds of up to Mach 7. This technology demonstrator project has can offer a version which can operate at speeds of up to Mach 12, sustaining the rigours of repeated flights. When traveling at Mach 5 or higher speeds, the high heat generated by friction can compromise the structural integrity of various critical parts of hypersonic vehicles.

Amiga Engineering Amiga Engineering is an Australian based manufacturing company known for its innovation and advancements in the industry. Starting as a small business in 1988, Amiga has grown into a leading manufacturer in the country, providing advanced manufacturing services to a range of industries. Amiga has made significant investments in additive manufacturing, also known as 3D printing, which has enabled them to create complex geometries and intricate designs with great precision. The company has also established Australia’s first metal powder atomising machine, allowing them to produce high-quality metal powders that are essential for advanced manufacturing processes.

Aeromech

MAKOMESH

In 2020, the Australian Maritime Safety Authority (AMSA) released a Request for Expressions of Interest to both the Australian and International markets looking for new and innovative products to increase their Search and Rescue (SAR) capabilities. In response, Aeromech designed and manufactured a world first Search and Rescue device named SARGO(TM) (Search and Rescue GO) to meet AMSA’s requirements.

As an SME operating in a highly competitive commodity market, its absolute vision about digital enablement and competitive manufacturing has seen the creation of a completely ‘online manufacturing’ business model designed to achieve cost leadership and sustainability. It has pioneered the self development of a sustainable ‘Fourth Industrial Revolution (4IR) ‘online manufacturing’ business model that connects customers to an automated fulfillment system.

Robotic Automation The Arnott’s Group officially opened its $65 million automated distribution centre on August 30, 2023 which is to become responsible for more than 60 per cent of its national inventory. The manmonthly.com.au

IN PARTNERSHIP WITH

palletising solution provided by RA is a combination of multiple technologies working seamlessly together. The adaptable modular system design, featuring 9 MOTOMAN Robots, achieves maximum floor space utility. The use of windows based, smart MAX AGVs provides increased flexibility, whilst achieving required productivity rates. Employing proprietary MOTOMAN MotoLogix software, Robots can be completely programmed and controlled via the host AB-PLC. This means all unique product programs can be simply changed in an instant, on the fly.

Excellence in Growth proudly sponsored by BDO Australia

endeavourawards.com.au

Sunset Sleepers In 2021, Damian and Miguel took charge and embarked on an inspiring journey dedicated to enhancing safety, quality, capacity, and environmental impact. From the early days of manual labour and heavy lifting, they have revolutionised the company’s operations. Though the journey is ongoing, the remarkable results speak for themselves. Each step forward has been driven by an unwavering commitment to excellence. Join the team on this extraordinary path of progress, where hard work and dedication have redefined what is possible. Experience the remarkable achievements on market growth, financial growth and people growth that make this journey truly worthwhile.

Marine Air Flow International

Recognising financial growth, people growth and market growth – all important to achieving sustainable consistent growth over the long term.

Buckaroo Leatherworks Buckaroo is an Australian manufacturing company producing high-quality leather goods specific to the construction, trades and mining industries. Its conception occurred by identifying an opportunity to utilise quality Australian materials and couple that with unique leather craftsmanship. Buckaroo manufactures beautiful, premium, quality tool belts and tool belt components designed to suit professional tradespeople whilst on the job.

REDARC Electronics REDARC Group are proud to nominate for the 2023 Excellence in Growth award. Showcasing a compound annual growth rate (CAGR) of 28 per cent over the last three years, REDARC continue to flourish in a challenging post COVID-19 manufacturing industry, with a market impacted by a cost-of-living crisis. With international travel on hold, the pandemic saw more people look to explore their own back yard particularly in Australia, Europe and the USA, leading to increased demand for enhanced offgrid capabilities. manmonthly.com.au

Marine Air Flow International is an ISO-9001 certified designer and manufacturer of quality and reliable engine room ventilation equipment for the marine industry including luxury, commercial, transport, industrial and defense sectors. Established on the Gold Coast since 2005, Marine Air Flow International proudly supplies renowned companies such as Riviera, Maritimo, Dongara, Sirena and Penguin, while successfully exporting to over 30 countries.

Celebrating an outstanding project utilising Australian manufactured products, that has reached stage- or fullcompletion within the past two years. This category may recognise multiple companies that have been involved in delivering the project, which could be in one of a variety of areas.

GeelongPort GeelongPort worked closely with Spirit of Tasmania for more than two years to transform its Corio Quay South precinct into the new home of Spirit of Tasmania. Its dedicated Project Team managed the construction of the new 12-hectare precinct, overseeing three extensive construction packages, including marine works, landside construction, and the passenger terminal building. As well as a state-of-the-art passenger and freight terminal, the new precinct includes a vehicle marshalling area for 600 cars, a parking area for 150 semi-trailers, crew accommodation, a café and a children’s play area. Through the construction of Spirit of Tasmania Quay, GeelongPort set a new worldwide standard of what a terminal ferry facility should look like and include. The project is an excellent example of best practice in engagement with local residents and traditional owners, as well as supporting the local economy by engaging majority Australian contractors and suppliers.

MULTIPANEL MULTIPANEL is an industry leader in the design and manufacturing of innovative waterproofing solutions. It is an Australian-owned and operated company driven to change the way people think about waterproofing. Its lightweight, eco-friendly building panels are CodeMark certified and designed to make waterproofing any space easy for everyone. With genuine passion, a forwardthinking approach and superior-quality products, we’re proud to be setting a new benchmark for waterproofing excellence.

Project of the Year proudly sponsored by Industry Capability Network

Hypersonix Hypersonix was recently awarded a major US Defense contract and announced in March 2023 to deliver a prototype hypersonic flyer, the DART AE, under the Defense Innovation Unit (DIU) Hypersonic and High Cadence Airborne Testing (HyCAT) Program. The prototype demonstrator will be used by DIU as a hypersonic test platform underpinning the company for the next few years. In addition, Kratos Defense and Security Solutions has teamed up with Hypersonix to bring its DART AE hypersonic system to the U.S. market with Kratos’ Zeus family of solid rocket motor systems. With a potential procurement of up to 20 DART AE vehicles planned once the combined flight system has been successfully completed and demonstrated.

BOC Leading gas and engineering company

RoboHelix took home multiple awards at the 2022 Endeavour Awards. BOC, a Linde company, and bp Australia celebrated the official opening of Australia’s first hydrogen refuelling station at a service station at the bp Port of Brisbane Truckstop in Lytton. This milestone marks the completion of BOC’s Bulwer Island end-to-end renewable hydrogen demonstration project funded by BOC, Australian Renewable Energy Agency (ARENA), Queensland Government and bp Australia.

All Metal Products The ICU Tower project represents a ground breaking leap forward in healthcare, redefining the way critical care is provided within hospitals. This pioneering innovation is a mobile platform that integrates life support and monitoring equipment, ensuring uninterrupted patient care during crucial transfers between intensive care units and specialised wards. Notably, it saves nurses approximately 40 minutes of work per patient transfer, eliminating the need to repeatedly connect and disconnect critical monitoring devices.

Manufacturer of the Year proudly sponsored by Bestech Australia

Manufacturer of the Year is chosen from the winners of the other Awards categories. Manufacturers’ Monthly DECEMBER 2023 41

Temperature Sensors Is your blood boiling? Blood can be a health dashboard for your body. It can show vitamin deficiencies, chemical imbalances and abnormalities. Keeping blood at a safe temperature is vital as this article explores. Given the significant consequences at hand, it is crucial to minimise the invasiveness of blood testing.

ITH so much at stake, it is imperative that blood testing be as painless as possible. Retesting costs money, it costs time, and in many instances, there is no slack, which means inefficiency in the system can cost lives. However, healthcare providers have noticed a trend toward acceptance, specifically the acceptance of retest 42 DECEMBER 2023 Manufacturers’ Monthly

requests as “normal.” If the lab gets a sample that is questionable for whatever reasons, they essentially kick the order back and the patient has to start over, getting poked yet again to restart the diagnostic process.. The function of blood is extensive. It moves nutrients, oxygen and waste, fights infection, all within the enclosed

human body operating at around 37.5°C. Take it out, and it’s not where it wants to be. First it wants to coagulate, to reseal the body to prevent attack from bacteria and unwanted visitors. Then, as it contains living cells, it begins to denature and die. It’s why there are very specific temperature requirements to which

you must adhere when transporting pathology samples, and they may or may not be the same as the blood products intended for transfusions. Though most cold chains and labs have quality monitoring and quality control systems in place, as well as RFID-based tracking systems, not all actively monitor the temperature inside blood transport manmonthly.com.au

TemperatureSensors bags. They may only keep tabs on the surrounding climate. Every member is up against the clock to get each and every sample to the testing facility and tested without it getting damaged by overly hot or cold temperatures on route. Zero to four hours is the typical window allowed from bleed to test! Get it wrong and the sample becomes useless. At best, it’s untestable and binned. At worst, the lab technician will deliver an incorrect result leading to misdiagnosis and treatment. That’s why it is imperative that temperature sensors are a part of the process. Sensors are very affordable and easy to include with every transported blood sample. It’s not uncommon for one to wonder if a blood sample changed temperature during transit. Perhaps the journey took longer than usual on a hot day and its insulated container began to warm. Or maybe things dipped out then back into the safe temperature zone. The blood could be damaged without anyone even knowing. Or it could be fine, but someone worried about safety uses a subjective ‘feel’ test to check the temperature and decides that a sample feels warm and it’s not risking an incorrect result, so they toss it. Either way, not good.

Temperature and inventory tracking at its simplest Because the quality of blood and other bodily fluid samples is so very important in defining and delivering treatment programs, Zebra has developed a solution in conjunction with independent software vendors (ISVs) to validate that you have a temperature-controlled transportation system in place capable of delivering a test-worthy samples to the lab in a timely manner. The solution can be tailored to meet varying needs, but there’s one very cool setup that I want to call out. You can put a tray of blood vials in a purpose-built insulated blood transport bag designed specifically for temperature-controlled shipment. Each vile is identifiable when matched to a database because each is tracked with a barcode label, written record and RFID tag starting at the time of collection. Having the barcode and RFID label cuts out mistakes from illegible handwriting, or mistyping labels, making the information system it’s feeding the single source of truth and the written manmonthly.com.au

Zero to four hours is the typical window allowed from bleed to test. If the sample integrity is affected, the test becomes useless.

record more of a redundancy. The vials are then tracked using a passive RFID system that reads as the bag is placed into a specially designed reading tray prior to leaving the hospital, clinic or surgery centre then scanned again as the tray arrives in a van at the lab before a third and final read again inside the lab upon receipt. The unique identification code on each sample links it to the patient electronic medical record (EMR) and also anonymously to software which shows a colour-coded dashboard should there be an anomaly such as an unexpected or missing sample. The driver has no access to personal data but can see if they are missing a sample, and they can also prove that they made a delivery within the specified time window. With everything captured and recorded in real time, the lab has visibility of where the samples are in transit and what tests are needed so they can prepare in advance. The solution also helps ensure the right sample gets to the lab in the right time. But how can you be sure it wasn’t denatured by a blast of heat along the way? That’s easy: an electronic temperature sensor quietly sits in a pocket in the insulated blood sample transport bag and systematically tracks temperature data every minute. When the blood arrives at the lab, the person who physically receives the bag of vials places it into an RFID reader tray in a blood hatch with a ‘bridge’ incorporated nearby. The bridge receives logged data from the temperature sensor and sends it up to the cloud

where it is collected by an application programming interface (API) and delivered to sample tracking software that’s running on internet-enabled devices, such as handheld mobile computers or tablets. A lab technician then officially checks in the entire lot of received blood, first checking the dashboard to ensure there are no missing or incorrect samples based on the advanced notice of inbound inventory. They then batch check the temperature of each vial, which was logged each minute starting at the time of collection and continuing during transport then aggregated in a dashboard graph on mobile and desktop devices. If they confirm the blood has remained within safe parameters and is test ready, then they move it to the next step in that process. If they spot an anomaly, such as a temperature dip or peak on the graph, they can then order an urgent retest. This fast validation process helps cut the risk of testing a damaged sample and reduces the risk of incorrect results and treatment. The addition of temperature sensors to every pathology sample transport bag adds a layer of safety to testing procedures, creating a checks and balances system that gives everyone confidence that things were done by the book and the results can be trusted. It also provides a paper trail should there be any allegations of incorrect procedure, giving patients peace of mind that their sample wasn’t comprised and protecting hospitals from litigation.

Technically speaking Zebra has been working with the ISVs involved to make sure all components are compatible with one another and will consistently operate as one – as if they were built for the same company as a single platform system. The even better news is that because this is a solution coming out of the Zebra ecosystem, Zebra can assist with rolling it out. It involves IT experts, lab technicians, supply chain operations managers, lab managers and quality control managers from organisations in the process to make sure the technology is supportive of existing procedures and compliant with all policies. It will also work together to design the system in a way that fits neatly into the tech stack and minimises disruption to workflows. Once the fixed RFID reader infrastructure is installed – or handheld RFID readers rolled out – and the proper software licenses are purchased, all front-line team members will need to do is print and label pathology samples.

Don’t forget! Temperature sensors are not just limited to healthcare. Any vertical where products have to remain within a specific temperature range, be it pharmaceuticals, food or vaccines, can be managed utilising this solution. Checking process adherence, maintaining safety standards, protecting products and people is a universal best practice. For more information about temperature tracking solutions, please contact your Zebra representative or visit its website. Manufacturers’ Monthly DECEMBER 2023 43

Engineering Focus Next generation batteries A team of engineers from Monash University have developed a new lithium-sulphur battery design with a nanoporous polymer-coated lithium foil anode, which has reduced the amount of lithium required in a single battery. Manufacturers’ Monthly spoke to PhD candidate and lead researcher Declan McNamara to find out more about the significance of their new battery design and the potential applications of the technology.

ONVENTIONAL lithium-ion batteries, typically found in electric vehicles, smart phones, and some house-hold appliances, require materials such as lithium, nickel, manganese, and cobalt. All these materials can only be extracted through mining, while pivotal, can still be damaging to the environment. As consumers move towards more sustainable modes of transportation and greater use of batteries generally, the demand for these critical minerals will continue to increase. McNamara said that manufacturers should be open to adopting technologies that contain less lithium. “The amount that we have, versus the amount that we can access in the near future is limited,” he detailed. “Reducing lithium is definitely a good prospect as it will be cheaper and there

44 DECEMBER 2023 Manufacturers’ Monthly

Declan McNamara is passionate about sustainable energy storage solutions, reducing the environmental impact of manufacturing, and finding practical solutions to the environmental crisis.

manmonthly.com.au

Engineering Focus In this highly magnified image, you can observe nanoporous polymer coating lithium metal.

are societal and environmental impacts from using it.” Not only does their lithium-sulphur battery design require less lithium to manufacture compared to other lithiumsulphur batteries, but it also does not require any nickel, manganese, or cobalt.

The design process The team initially conceptualised the battery design while working on an entirely different scientific project. “Our group does a lot of work in a bunch of different areas, but the thing that links them all together is porous materials and separations,” McNamara said. The idea occurred to the team while using polymer that had been used previously in gas separation membranes. “We thought, gases are functionally fluid – in our battery, we’ve also got a fluid. We understood the properties of this polymer quite well and we thought manmonthly.com.au

that it could work inside of a battery,” McNamara explained. “In terms of processing, we had this idea that we wanted to make a solution that would be scalable.” The polymer coating on lithium significantly improved the number of times their battery design could be cycled. “The polymer contains tiny holes less than a nanometre in size – one billionth of a metre – which allow lithium ions to move freely while blocking other chemicals that would attack the lithium,” McNamara said. “The coating also acts as a scaffold for lithium, and helps it charge and discharge repeatedly.” “Utilising the huge amount of energy stored in metallic lithium is a challenge, but when done correctly it can make some incredible energy storage devices that are easier to make. This coating is a step towards highly efficient,

easily manufactured Lithium Sulphur batteries,” McNamara continued.

Environmental impacts According to the 2023 Western Australia battery and critical minerals profile, Lithium mines from around the globe produced around 130,000 tonnes of material in 2022, with Australia producing almost half of that at 55,000 tonnes. Compared to 2010’s 28,100 tonnes, there has been a significant increase of lithium production in the past decade. The team from Monash University is determined to provide a more sustainable alternative to the current lithium-ion battery. “The first and probably most important thing for me is environmental sustainability,” said McNamara. “The main benefit of lithium sulphur batteries is that there is no need for traditional battery materials. In current

batteries, lithium-ion batteries that we use day-to-day, the cathode is comprised of nickel, manganese, and cobalt in varying concentrations.” “Those three elements are not fantastic, acquiring them is a problematic process at the best of times. “The processing of nickel has substantial environmental impacts, and then the processing of the ore, the leaching is awful for the environment, for cobalt, the same is true,” McNamara continued. Cobalt production alone is expected to produce up-to three million tonnes of carbon dioxide emissions annually by 2030. The team from Monash University are also determined to address the ethical dilemma of sourcing cobalt. “Most of the cobalt that’s used is sourced from the Democratic Republic of the Congo,” McNamara said. “There are some serious ethical concerns about the way the cobalt obtained.” Manufacturers’ Monthly DECEMBER 2023 45

Engineering Focus

Meet the team: Prof. Matthew Hill (left) is an Australian Research Council Future Fellow. Dr. Mahdohkt Shaibani (middle) is an energy researcher, inventor, and analyst. Prof. Mainak Majumder (right) applies materials science to areas of separation engineering.

According to the Cobalt Institute, 70 per cent of the world’s cobalt is produced in the Democratic Republic of the Congo. Twenty per cent of that cobalt is sourced from artisanal miners or smallscale mining operations. These, sometimes informal, operations are commonly associated with low levels of safety measures, healthcare, or environmental protection. Unlike, conventional batteries, the cathode in Monash’s new design requires only carbon and sulphur to be manufactured – which McNamara says are also environmentally benign, materials. “Using sulphur, which is ubiquitous, so it’s in the Earth’s crust, all over the world means that we won’t be as reliant on these critical minerals,” McNamara continued.

Alternative sources of lithium Typical methods of lithium mining involve either extracting minerals such as spodumene, lepidolite, petalite, amblygonite, and eucryptite from the earth, or brine reservoirs. “The majority of lithium that has been sourced at the moment comes from brines in countries such as Chile and Argentina,” McNamara said. 46 DECEMBER 2023 Manufacturers’ Monthly

“Currently lithium supply is split between Australia with hard rock, and South America with brines” McNamara said. “It’s quite a long process, what will happen is there’ll be water that has a very high salt concentration and it’s placed into enormous baths hundreds of metres, sometimes kilometres long, and left out in the sun to evaporate.” “The water evaporates, the other metals first form crystals, and then finally we’re left with the lithium in a crystal form – this process can take up to two years, depending on the size of the reservoir,” McNamara explained. This method often comes at the cost of the local populations water security, where communities near lithium mines will often face water scarcity. Each tonne of lithium requires around two million litres of water to be evaporated. The San Cristóbal Mine in Bolivia, uses around 50,000 litres of water per day. The process of converting lithium crystals to battery grade chemicals is also very carbon intensive. Apart from processing spodumene, the team is also considering sourcing lithium from the sea, as well as from brackish

waters or brines using membranes instead of chemical processes. While these alternative sources are financially viable and environmentally sustainable relative to conventional methods, there are still significant time constraints with processing. This is a challenge that the team will address later in the future. “Getting it out quick enough might be a problem, but it’s an active area of research,” said McNamara.

Challenges Throughout the design process, the Monash team encountered several challenges, which was always expected but still required a great deal of work to rectify. “There were a bunch of variables that we needed to kind of dial in,” McNamara said. One of the primary challenges was coating the lithium with the correct amount of polymer, which in-turn effected how the battery would cycle. “If the layer was too thick, then the cells would become too resistive.” When the cell becomes too resistive, the batteries efficiency declines.

“Getting the right concentration was pretty difficult, because if it was too low, then you would also get a phenomenon called shrinkage.” McNamara said. “Shrinkage is where you have a polymer that is dissolved into a solvent in a solution. When it dries out, as a total fraction of the initial mixture, the higher the proportion of the solvent, the more total mass is lost, causing the polymer to shrink.” With all batteries containing nickel, cobalt or manganese, there is always a risk of thermal runaway – where the internal temperature of batteries will rise, risking the possibility of fires or explosions. “Once they start heating up above a certain temperature they enter a feedback loop,” McNamara said. Current research suggests that lithium sulphur batteries have improved safety. “Research suggests that overcharging or over discharging will brick the battery,” continued McNamara. “The battery will not be happy about it, and it probably won’t work very well, but it likely won’t cause a catastrophic failure in the same way that a lithium-ion battery will. This is another area we are actively investigating.” manmonthly.com.au

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IN CONJUNCTION WITH

What’sNew Xxx METALMASTER ClearAir mobile welding fume bench The ClearAir mobile welding fume bench, a cutting-edge compact unit designed to revolutionise the way welding fumes are extracted and filtered. This all-in-one downdraft extraction and filtering unit marks a significant leap forward in ensuring the health and safety of both welders and the surrounding environment. xxx of the ClearAir B-H13 lies AtXXX the heart a meticulously engineered 1120 x 825mm xxx worktable. xxx Employing state-of-the-art S Duct aerodynamic technology, this design breakthrough in minimising the impact Subis aheading of turbulent air generated by varying Xxx. workpieces. xxx A high-volume airflow of 2000 m3/h, creating an abundant down draft tailored to suit diverse welding fume applications. The ClearAir B-H13 comes equipped with a hinged fume table shroud doors as standard, giving it the versatility to accommodate longer workpieces with ease. Safety is paramount, which is why the ClearAir B-H13 integrates spark separators and dual first-stage metal pre-filters. These advanced features significantly reduce the fire risk associated with welding

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processes, ensuring utmost peace of mind for operators. The filtered clean air discharged from the unit returns in an upwards direction from the rear of the unit this avoids disturbing the workshop dust that may have settled on the workshop floor as well as enhances operator comfort with no return air blowing at their feet. The HEPA H13 Class filter stands as a pinnacle of air purification technology, characterised by its exceptional ability to capture even the tiniest particles with remarkable efficiency. Designed to adhere to stringent standards such as EN ISO 15012 W3, the HEPA H13 filter ensures that the air passing through it is not only clean but also safe for respiration. With a particle separation efficiency of 99.95% for particles as minuscule as 0.3um particles. The ClearAir B-H13 is the ultimate solution for Mig, Tig, and Arc welding, catering to all materials that emit intense fumes and minor dust during the welding process. Its compact design, coupled with its powerful extraction capabilities, makes it an indispensable asset in any welding environment.

Company: Hare and Forbes Machinery House Phone: (02) 9890 9111 Website: www.machineryhouse.com.au/extractors-fume

Nord’s solutions for mechanical engineering Nord Drivesystems will present its large range of innovative drives for mechanical engineering at FMB 2023, from the 8th to 10th November 2023 in the exhibition centre in Bad Salzuflen. In Hall 20, stand D4, the presentation’s focus will be on the IE5+ synchronous motors and the decentralised NORDAC ON+ frequency inverters. Rising electricity prices, the CO2 footprint as well as the digital transformation require the use of highly efficient and powerful drives. The IE5+ synchronous motors and the decentralised NORDAC ON+ frequency inverters from Nord Drivesystems are the ideal solution for these requirements. Company: Nord Drivesystems Phone: 9394 0500 Website: www.nordfab.com/

48 DECEMBER 2023 Manufacturers’ Monthly

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New 40ECP delivers active cooling with unparalleled torque and speed capabilities Portescap is excited to introduce its latest motion innovation, the 40ECP brushless slotless motor. The 40ECP is available in two lengths: the standard 40ECP44 at 44mm; and the 40ECP55 at 55mm, which is Portescap’s first motor featuring an integrated fan for active cooling. Both solutions are cost-optimized, thanks to an innovative assembly process, thus delivering premium performance at an affordable price point. The 40ECP’s slotless design allows the motor to run up to 30,000 rpm, while its low weight of 230 grams and compact 40mm diameter not only facilitates continued application miniaturization, but also supports improved tool ergonomics. The integrated fan provides active cooling during the motor’s operation, which improves operator productivity. The special electromagnetic design provides high speeds at low voltage while simultaneously delivering excellent

peak torque capability; in fact, the 40ECP motor can sustain peak torque for 2 seconds up to 1.1Nm. The 4-pole motor is compatible with the R32 gearhead and the M-Sense encoder, allowing for higher torque at lower speeds and more accurate positioning. As with its entire product portfolio, Portescap offers the flexibility to customize the motor’s electrical parameters and mechanical interface to meet specific application requirements. Battery-powered hand tools will greatly benefit from the 40ECP, such as strapping/stapling, riveting, tightening, crimping, and cutting hand tools. A variety of other applications, including miniature pumps, electric grippers, and robotic actuators, are also well-suited for leveraging the 40ECP. This motor also helps support the transition from both manual devices to powered devices and the shift from brushed to brushless technologies.

Company: Portescap Phone: +1 404.877.2534 Website: www.portescap.com

iBase’s IB838 Intel Core i3 N-series Processor 3.5” single board computer Backplane Systems Technology is pleased to present iBase’s IB838. The emergence of the IB838 3.5” single board computer (SBC) marks a significant stride in industrial computer technology. Powered by the Intel Core i3 N-series, formerly known as Alder Lake-N, this low-power SBC promises impressive computational capability coupled with advanced features designed to cater to a wide array of sectors like industrial automation, retail displays, and transportation. What stands out is its capability to function reliably amidst varying power conditions, courtesy of its broad 9V~36V DC input range. This makes the IB838 particularly adept for transportation and outdoor settings. Its multifaceted connectivity options, ranging from Type-C, DP++, and either eDP or LVDS for display, enhance its adaptability. The board also boasts of two Intel® PCI-E 2.5G LAN ports, multiple USB ports, and support for DDR5 SO-DIMM, ensuring rapid and reliable data management.

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The future-ready design of the IB838 is evident with its support for CNVi, paving the way for 5G. Paired with a high-speed SATA III port and dual M.2 sockets, the board offers immense storage and expansion opportunities. Moreover, with integrated fTPM and a Watchdog timer, system stability and security are reinforced, cementing the IB838 as a dependable powerhouse for contemporary applications. Key Features: • Intel Core i3 N-series (formerly Alder Lake-N) processor • 1x DDR5 SO-DIMM, max. 16GB • Supports type-C & DP++ and eDP or LVDS • 2x Intel PCI-E 2.5G LAN • 2x USB 2.0, 4x USB 3.2 (1x Type-C + 3x Type-A), 4x COM, 1x SATA III • 2x M.2 sockets (E-key + B-key), supports CNVi • 9V~36V wide-range DC input • Supports fTPM, Watchdog timer, digital I/O

Company: Backplane Systems Technology Phone: 02 94576400 Website: www.blackplane.com.au

Manufacturers’ Monthly DECEMBER 2023 49

The Last Word

DR JENS GOENNEMANN – Managing director, Advanced Manufacturing Growth Centre (AMGC)

Is the upcoming Olympic Year where Australian Manufacturing makes a long jump?

S 2023 draws to a close, I am filled with optimism that manufacturing can continue to advance. Time is of the essence though. Such sense of urgency transpires when my team and I connect with manufacturers as we continue to meet businesses across Australia as part of our national program. So far, our Australian Manufacturing Matters roadshow has taken us to Perth, Melbourne, Adelaide, and Brisbane, with more regional locations planned in early 2024. At each event, the discussion has been consistent and clear: targeted government assistance is greatly appreciated – and without exception if we want to see Australian manufacturing capability to progress. This was evidenced by hearing from many manufacturers in the room who had co-invested with government through one of four AMGC’s project funds. These investments, strategically aligned with government priorities, have helped businesses scale and team up with leading research institutions along the way. Australia has slightly advanced in

50 DECEMBER 2023 Manufacturers’ Monthly

making more complex and diverse products onshore. Our mantra to compete on value not on cost and to embrace the broader manufacturing value chain is starting to make an impact. Yet, we are far from reaching the finish line. Four months ago, Harvard Kennedy School Growth Lab released its latest Complexity Index that ranks 133 countries. This long running data set captures products countries trade on a global scale and in doing so builds a picture of how complex, diverse, and globally competitive a country is relative to its peers. Australia ranks 93rd between Uganda and Pakistan. The lowest of any OECD nation by 15 positions, behind the second lowest, and significantly lower than what our level of collective wealth suggests. The more disturbing fact is that this position is the lowest we have ranked since Harvard started the study back in 1995. The ability to manufacture complex and diverse products offers a solution to many things, which has been proven time and again by nations such as Germany, Japan, South Korea, Sweden, Austria, and

numerous others. Making things are not only a pathway to maintain our prosperity (which will otherwise dwindle) but can tackle the challenges of the day and of the future. How about decarbonising iron ore onshore and to our highest Australian standards rather than leaving this to other countries which are, let us say, a bit more robust in processing commodities? Competitive manufacturing capability offers a country the ability to give its citizens better, more interesting jobs, and higher wages. Countries do not grow by producing more of the same. Countries do not grow equally – there is a pattern that they follow, and manufacturing is central to a nation’s advancement. That is why manufacturing is not a sector. It is a capability. Beyond the headline Harvard ECI figure of 93rd, Australia’s industrial capability is sparse, and widely distributed, and where it is not sparse, it is sub-scale which is a major impediment to growth. Countries that can diversify do so by moving into nearby, or related products that require similar know how to build on their already existing capabilities.

Australia’s opportunities to diversify are sparse – just like the makeup of its manufacturing industry, however, there are solutions. Take for example AMGC’s project lead Omni Tanker in SouthWest Sydney which has diversified from composite road tankers to hydrogen pressure vessels for space. Omni Tanker was able built on its core capabilities because it saw an adjacent industry opportunity and was able to tap into AMGC’s program to turn its idea into a commercial outcome. Usually, it is not rocket science. In this case it was. For Australia to grow its global influence, to diversify its capabilities, and to make more complex things, we must, as Harvard recommends, ‘take a strategic bets approach and back it in with solid policy and initiatives’. The silver lining here is that unlike many industrial powerhouses, Australia has most of the raw materials we need on our doorstep – and nothing but opportunity to add value to them onshore to make more complex things we and the rest of the world needs. Even better, we have a reasonable

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idea as to where these ‘strategic bets’ should take place with the Australian Government’s seven priority areas (previously six National Manufacturing Priorities) setting the direction with: renewable and low emissions technologies, medical science, transport, value add in agriculture, forestry and fisheries, value add in resources, defense capability and enabling capabilities key focus areas. These seven priorities signal to manufacturers and the market more broadly that this is where we should be focusing our efforts, investments, capabilities, and energies because, as Harvard puts it, “few nearby opportunities call for coordinated long jumps into strategic areas with future diversification potential”. I believe 2024 holds promise that we can take some long jumps – or strategic bets – with the assistance of substantial initiatives such as the $15 billion National Reconstruction Fund and the $392 million Industry Growth Program – targeted squarely at small-to-medium manufacturers.

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We agree with Prime Minister, Anthony Albanese that “There is nothing we can do that is more important than making more things here”. Not everything, but the right things dare I add. This is why next year holds so much promise for manufacturing. We have the resources and some funding. We have the areas of focus and most importantly – we have manufacturers eager to take their innovative products to the world. Outside of funding initiatives, we could improve the use of procurement as a lever to spur growth – it is a significant weakness at all levels of Government. It pains me to hear manufacturers talk about losing business to international manufacturers, not because their products or services were not competitive, but because local procurement rules work against them. Worse is the decision by certain jurisdictions to buy from overseas rather than from interstate manufacturers because it was not made in their State. In fact, procurement has been raised repeatedly during our roadshow. Manufacturers will always choose a purchase order over a handout any day as

Goennemann believes 2024 holds great promise for some long jumps. it gives them a customer. One manufacturer who is in the business of making degradable wet-wipes reminded the audience of the true price tag of importing non-degradable wetwipes from our offshore friends – basically importing 97 per cent of Chinese water. Longer term, we should also be seeking to address issues around access to capital by providing low-risk capital and in smaller cheque sizes that allows manufacturers to grow without having them to place their family home on the line as a guarantee.

Industry policy is not easy. If you look around the world at what is working and study the programs that have demonstrated impact, then you will find that we have most of the ingredients for success. The year 2024 brings with it substantive promise. Australia needs to have the public and political will to settle on goals and to ensure that these initiatives are around for the long-term so that we can take those long jumps towards an ECI ranking that better reflects the Australia I know we can be – smart!

Manufacturers’ Monthly DECEMBER 2023 51

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