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June 2008
Print Post Approved PP255003/00324
INSIDE: • Industry News • Freight, Transport & Logistics • IT@MM • New Products • Compressors & Pneumatics • Cutting Tools & Machining Techniques • Water Management • Materials Handling • Coming Events
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Editor Alan Johnson Ph: (02) 9422 2480 Fax (02) 9422 2722 email: alan.johnson@reedbusiness.com.au Deputy Editor Katherine Crichton Ph: (02) 9422 2964 Fax (02) 9422 2722 email: katherine.crichton@reedbusiness.com.au Graphic designer Ronnie Lawrence Production co-ordinator Mary Copland (02) 9422 2738 email: mary.copland@reedbusiness.com.au
this month 4 6 8
EDITORIAL INDUSTRY COMMENT NEWS
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Blowing off inefficient compressor systems.
Study compares location costs.
Cabinet coolers for tight spaces.
Broader thinking on packaging Covenant.
Victoria/overseas sales Michael Northcott PO Box 3069 Eltham VIC 3095 Ph: 0448 077 247 email: michael.northcott@reedbusiness.com.au
Clearing the air on ‘MEPS2’ compressors.
JSF project puts heat in the market. Major advances in warehouse automation.
Queensland sales Sharon R. Amos PO Box 3136, Bracken Ridge QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 email: sharon.amos@reedbusiness.com.au
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South Australia/NT/WA & sales David Murray Smith Unit 2, 497 Marion Road South Plympton SA 5038 Ph: (08) 8371 5800 Fax: (08) 8371 5900 email: david@agsmedia.com.au.
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Head Office Tower 2, 475 Victoria Avenue, Chatswood NSW 2067 Locked Bag 2999 Chatswood Delivery Centre Chatswood 2067 Ph: (02) 9422 2999 Fax: (02) 9422 2966
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Chip-breaking tap for threads up to 3.5 x D.
India: a rising giant.
FREIGHT, TRANSPORT & LOGISTICS Freight gets smarter and leaner.
Micro-fluidisation system. Cutting fluid for hard metals.
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IT&MM RFID technology and the supply chain.
India offers huge opportunities for manufacturers, but patience and perseverance are needed. Page 16.
WATER MANAGEMENT Being water-wise is good business.
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ERP system breathes fresh air into company.
MATERIALS HANDLING Smart conveyors go online. Conveying investment keeps meat in motion.
Putting intelligence in your supply chain.
Foodmach innovation stacks up.
Marketing Co-ordinator Nicole Conti Published 11 times a year Subscriptions $140.00 per annum. (inc GST) Overseas prices apply Ph: 1300 360 126
CUTTING TOOLS & MACHINING TECHNIQUES Sustainable cutting fluids.
INSIDERSERIES - INDIA
Publisher Chris Williams Ph: (02) 9422 2957 Fax: (02) 9422 2966 email: chris.williams@reedbusiness.com.au.
Changes in materials have cut production time in half. Page 11.
Dust control unit for industrial workplaces.
Baby boomers drive company’s success.
New South Wales sales Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067. Ph: (02) 9422 2368 Fax: (02) 9422 2722 Mobile: 0414 644 664 email: anthony.head@reedbusiness.com.au
COMPRESSORS & PNEUMATICS
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Counterbalance electric forklifts.
NEW PRODUCTS Australia's leading guide to the latest products available.
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Lubricants can now be recycled rather than thrown away. Page 48.
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Behind the cover
14,131 as at September 2007 ISSN 0025-2530
June 2008
Print Post Approved
PP255003/00324
ATLAS Copco has yet again proven its world leadership in air-compressor manufacturing with the introduction of the new GA range of oil-injected compressors. Every component in the new GA range has been carefully evaluated and designed to provide Atlas Copco’s customers with a product offering the highest levels of reliability and energy efficiency. Efficient, reliable and built to last, the GA 90+ - 160+ / GA 132 – 160 VSD compressors are designed to provide high quality compressed air even under harsh conditions. Thanks to Atlas Copco’s long-standing experience and pioneering innovations there’s a GA compressor available to cut costs and enable smooth, continuous operation right across your production processes. For more information please call 1800 023 469. INSIDE: • Industry News • Freight, Transp • Cutting Tools ort & Logistics & Machining • IT@MM • New Techniques • Products • Comp Water Manag ressors & Pneum ement • Mater atics ials Handling INSIDERSE RIES - INDIA • Coming Events
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MANUFACTURERS’ MONTHLY
JUNE 2008
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Howard’s investment ready for take-off, but… While the F-35 JSF (Joint Strike Fighter) project is on track, further delays by the Rudd government could put this vital contract for many Australian manufacturers in doubt.
From the Editor Alan Johnson AS most MM readers will remember, I was never a ‘truebeliever’ of the way the Howard government treated our manufacturing industry. His hands-off policy might have been fine in the ivory towers of Canberra, but out in the real world of industry it was another matter. However Howard did make one or two positive policy decisions that did and still do benefit our industry. The one most readers would know is ACIS, which has assisted in keeping our car industry viable over recent years. The other was the signing of a $150m SDD (System Design & Development) participation contract back in 2002 for the F-35 JSF project being built by Lockheed Martin in Fort Worth, Texas. And I was lucky enough to be invited to the US last month to see a few of the company’s operations. While the other plants were impressive, Fort Worth just
blew me away. Whether it was the shear size of the production plant, the accuracy these guys work to, the equipment and tooling they use, or the actual plane we saw (and touched) I don’t know, but it sure was outstanding. The plant sits on around 640 acres of land, with more than nine million square feet of buildings. The actual JSF production building is over one mile long and covers over one million square feet. Over the life of the program, Lockheed Martin estimates it will invest over $5bn in fixtures, tooling and plant. Inside this giant air-conditioned facility is similar to stepping into one of the latest car industry plants, but ten times bigger. Passing through this giant production facility, I drooled over a huge CMM (Co-ordinate Measuring Machine) positioned within its own building the size of a large house, with every major part of the JSF checked. Lockheed Martin has gone to extraordinary lengths to ensure parts are consistent. New milling machines, accurate to less than the width of a human hair, ensure that the F-
35s outer shape is exact on every plane. I also saw a giant one-off Cincinnati drilling machine capable of drilling thousands of holes per day. It drilled 14,200 holes in the first JSF. They also have the largest titanium forging machine in the world, used to manufacture the planes’ wings. The planes are actually built on a moving production line, with the wings assembled on large AGVs before being attached to the fuselage, with incredibly elaborate tooling/fixtures to locate the wings. I could go on, but the interesting part is Australia’s involvement in this $US300bn project. By Howard signing the SDD contract, it has allowed Australian manufacturers to get involved in the “bestvalue” program. To date over 20 Australian manufacturers are on the JSF partner listing, with the potential for many, many more as production ramps up. If all goes according to plan, this JSF contract could mean $US10bn of lucrative work for Australian manufacturers over the life of the project due for completion in 2013.
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this year. But the longer Rudd delays, prices keep rising. At the moment each plane is around $50m, but any delay could increase the price 1020% or even more. Industry minister, Kim Carr must do some heavy lobbying with his colleagues in Canberra to make sure this contract goes ahead. This is a once in a lifetime opportunity to expand our manufacturing skills set. While Lockheed Martin talks of this not being an offset program, with no cap on the amount of work on offer, if we don’t buy the planes, all bets are off. I understand it has been a steep learning curve for most manufacturers, both in working with composites and high speed machining of aluminium and titanium. But the skills learnt can only benefit our industry’s capability and make us more competitive in other global supply chains. I plan to include more information in the next issue of MM, but in the meantime if anyone wants any specific information please drop me an email at alan.johnson@reedbusiness.co m.au.
Make-to-stock • Make-to-order • Job-shop
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However, Australia hasn’t actually ordered any planes yet. While the Dept of Defence has recognised the need for 100 such planes, the fat lady’s not singing for Lockheed Martin yet. The Rudd government is sitting on its hands at the moment, and judging by last month’s budget no decisions will be made prior to the new defence white paper due by December. In the meantime those Australian manufacturers on the partner list will be having some nervous moments regarding investment decisions. According to the folks at Lockheed Martin it’s business as usual, with Australian manufacturers picking up contracts almost on a monthly basis. But the real question is whether defence minister Joel Fitzgibbon will actually choose the JSF or expand the number of Super Hornets presently on order from Boeing and loose out on this valuable deal. Somewhat surprisingly Lockheed Martin says it will have not have a firm price for Australia, or the other overseas partners, until the end of
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JUNE 2008
MANUFACTURERS’ MONTHLY
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INDUSTRY COMMENT
Addressing Australia’s skills challenge Skills Australia will develop a sophisticated understanding of current and emerging skills needs.
Comment Heather Ridout CEO Australian Industry Group A RECENT Ai GroupDeloitte survey has found skills shortages are clearly limiting industry’s ability to innovate. While we knew skills shortages constrain industry’s productivity, this finding added another layer of complexity to this issue. According to the Skilling for Innovation survey, of the 68% of businesses citing skills shortages, almost two in every three say this shortage is affecting their ability to be innovative.
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Without innovation, the risk is Australia will continue to undershoot in the global competitiveness stakes as our offshore rivals adopt and adapt their technology, processes and practices to become more productive. The report serves to highlight yet again the critical importance of tackling skills shortages in Australia through better resourcing and creative solutions. It suggests policies that help to boost Australia’s skills base will have a direct and positive effect on business innovation. This report has added further weight to Ai Group’s calls for the Federal Government to implement practical solutions to upskill and reskill the workforce and will underpin my contribution as a member of the recently established and industry-led Skills Australia. The Federal Government’s
MANUFACTURERS’ MONTHLY
establishment of Skills Australia is an important step forward in lifting Australia’s capability. There are few areas more important to Australia’s economic prospects and few areas more important in supporting the aspirations of individuals. Our latest report estimates that as many as 240,000 fulltime employees are needed to satisfy current skills needs. The majority of vacancies are for technicians and tradespersons, however, significant shortages also exist for managers, professionals and engineers, along with labourers and process workers. Businesses recognise the need for a mix of generic or ‘soft’ skills for innovation, with communication skills considered to be the most lacking, according to our Skilling for Innovation survey. Expenditure on upskilling is
expected to lift moderately in 2008, with businesses planning to increase their average spend as a percentage of turnover to 0.54% from 0.46% previously. However, the survey found that costs, as well as access to and availability of formal inhouse training, may be factors restricting current upskilling efforts. The departure of staff following training is also considered a major barrier to upskilling. The survey results are very powerful. They put education and skills in a sharper light than they have been before. Ai Group, together with the Australian Council of Trade Unions and other leading employer and union groups, recently presented the Federal Government with a 10-point plan aimed at tackling these skills shortages, which are acting as a constraint on industry
in so many ways. What we called for together included: • A renewed focus on apprenticeship completions; • A long-term strategy to improve Australia’s investment in education and training; • Skill infrastructure partnerships between public and private sectors; • Lifting Year 12 or Certificate III completion rates; • A national vision and consensus on the future of TAFE; and • A review of the traineeship program. A key element of the plan is to support teachers, trainers and their leaders to improve their qualifications and knowledge. It also centres on making education and training more responsive to the needs, interests and aspirations of the learners.
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86 shopping list items All fresh, affordable and in stock One happy customer
DEM54
Another logistics result
Like all working mothers, Carole McCormick does not have a lot of time to spare. When she shops, she needs everything on the shelf, fresh and at the right price. That’s why she shops at Woolworths. In partnership with Dematic and others, ‘The Fresh Food People’ have transformed their national supply chain. Goods are handled less, delivered “store friendly” for quick restocking, and are available when Carole needs them. Huge savings from their new distribution network are being passed back to customers like Carole. That’s what we call a logistics result.
Dematic Pty Limited 02 9486 5555 www.dematic.com.au
Carole McCormick Dematic employee and working mum Woolworths’ customer
ANALYSISNEWS
Study compares location costs
Returnable plastic crates are ‘green’
BY JOHN ALLEN
PLASTIC, often vilified in some environmental literature, has triumphed in a new research study of materials handling and packaging products commissioned by Coles. The study into the life cycle of returnable plastic crates (RPC), found that the plastic products outperformed competing materials such as corrugated fibreboard, waxed corrugated fibreboard and expanded polystyrene. Conducted by international environmental engineering consultants, Hyder Consulting, the key findings included: · Water use – Using RPCs requires consumption of only 7.8% of the water of alternative products. · Energy use – RPC usage for the fresh products requires only 35.9% of the energy required when using alternative products. · Greenhouse gas emissions – the RPCs emit 38.2% of the greenhouse gases of alternatives. · Resource use – RPCs have a mere 40.7% impact on non-renewable resources compared with the alternatives.
KPMG has released the results of its 2008 Competitive Alternatives study— an independent analysis of major cost factors affecting manufacturing site selection around the world – including Australia. The 6-month research program for the study, the 7th in a series dating back to 1994, covered more than 100 cities in Australia, Canada, France, Germany, Italy, Japan, Mexico, Netherlands, the UK, and the US. This edition measured 27 significant cost components, including labour, taxes, real estate, and utilities. Even more interesting, these cost components are cross-referenced with 17 different vertical industries over a 10-year planning horizon. Eleven of those industries are in manufacturing, and most qualify as advanced manufacturers. This year marked the first time the study compared an emerging industrialised country—Mexico—with the control group of mature industrialized countries. Mexico clearly separated itself from the competition with a
Australia fares well in global manufacturing site comparisons.
20% overall cost advantage. Australia on the other hand rated very favourably, our closest competitor was usually Canada or the US. Australia, Canada and the US were the cost leaders among the nine established industrialised countries examined. Business costs in these three countries were virtually equivalent, with less than 1%
separating the countries. With figures broken down further, business costs expressed as an index (with US assigned the baseline index of 100) revealed Adelaide at 97.9; Melbourne 99.4, Brisbane 100.1; and Sydney 102.7. The study is available at no cost by visiting www.competitivealternatives.com.
ANALYSISNEWS
Broader thinking on packaging Covenant BY DEREK PARKER
THE National Packaging Covenant, a collaborative initiative between industry and government to reduce packaging waste, has entered a new phase, with changes to the agreement and the release of a publication from the Packaging Council of Australia (PCA) highlighting some of the new generation of packaging products. Gavin Williams, chief executive of the PCA, notes that the revised version of the Covenant includes a series of KPIs on sustainability and environmental issues. Williams admits to some initial concerns over the 2005 decision at the ministerial level to establish a benchmark of 65% for the recycling of used packaging. “Everyone understands the importance of recycling, and it is useful to have a target figure,” he told Manufacturers’ Monthly. “But it should not be seen as the sole issue. Generally, industry thinking has developed to encompass aspects such as raw material use, the energy required in production, and water
usage. This shows the flexibility of the Covenant, which can incorporate new issues and approaches. It would be difficult for that to happen in a legislation-based regime.” The second Covenant has about 600 signatories across the supply chain. It covers, Williams estimates, between 80 and 90% of goods on supermarket shelves, although the Covenant also affects many packaging products that do not directly reach the consumer. As a result of the first Covenant, the current recycling rate for used packaging is about 56%. For plastics, about 30% is recycled, up from 21% in 2003. “The message we keep hearing from packaging firms is that brand owners want sustainability in packaging. So in that sense packaging firms are responding to market demands. It means that sustainability issues are now locked into the industry picture – and many firms have found that it improves their own bottom line as well,” Williams said.
Projects The National Packaging Covenant will
soon announce the projects to receive financial assistance in the second round of funding for 2007/08. A total of up to $6m is available each year, half from industry contributions and half from state governments. Ed Cordner, CEO of the National Packaging Covenant says the focus is again on assisting projects which will divert substantial tonnes of packaging from landfill into new uses. “We always look for innovative proposals, and projects diverting over 5,000t from landfill are given priority.” There are now 50 projects with Covenant funding under way, with a total value of $47m and the capability to divert an additional 500,000t of discarded packaging per annum from landfill. The PCA publication Australian Packaging: Real Examples of Change and Innovation provides a series of examples of innovative packaging. One of the most interesting is the Brita Fill & Go bottle, a 700ml sports bottle with an activated carbon filter inside, enabling users to fill from any tap.
Target figure should not be seen as the sole issue – Williams.
The filter, which removes any unpleasant tastes and odours while retaining fluoride, processes up to 57L, or 80 refills, effectively reducing the amount of water bottles that would otherwise go to landfill. “The technology was meant for industrial uses but it works very well for a consumer product,” said Mike Alborough, marketing manager of Brita. “They see it as a cost-effective option.” An example of redesign for better resource use is Golden Circle’s 440g steel food can. The thickness of the can was reduced from 0.19mm to 0.16mm, providing an estimated saving of 125t by late 2007. The steel is entirely recyclable.
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Free advisory service available in Australia and overseas 10
JUNE 2008
MANUFACTURERS’ MONTHLY
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ANALYSISNEWS
Baby boomers drive company’s success Ingram said. The Next Generation motorhome fe atures an eight air bag suspension, traction control, an ergonomically-designed wraparound dash with integrated full colou r touch screen GPS and reversing camera, a one piece front widescreen, and fully ducted air conditioning with climate control. Ingram says it’s like driving a Bentley. “We don’t use a truck chassis; we have our own purpose-built motorhome chassis. “People don’t understand until they get in it and drive it, it’s just beautiful.” Ingram says the company will be exporting all the components up to China.
BY investing in exciting new technologies and manufacturing techniques, Queensland motorhome manufacturer, Swagman, is experiencing significant growth locally, and is on the verge of breaking into the US and China markets. The company, based in Labrador on the Gold Coast, has developed a new way of building a motorhome using a carbon fibre Kevlar composite body as opposed to the traditional construction methods of motorhome building. Neil Ingram, Swagman’s MD said by developing the composite body they have taken a lot of weight out of the vehicle, which means much better fuel consumption, “plus they’re a lot stronger and a lot safer”. “We’ve also increased production time so we can actually build these a lot quicker,” Ingram explained. With an automotivestyle production line, Ingram said it used to take three months to build a motorhome, “now we can turn them around in half that time now. We used to produce around 50 a year, Changes in materials have cut production time in half. we’ve doubled that now. “They’re building them in China for “The new one-piece carbon body the Chinese market, then we will look Kevlar shell, called the Armour Shell, at exporting them to North America. fits straight on the chassis, and then “We’ll keep the Australian operathe way we’ve constructed the rest of tion, but what it gave us is the opporthe motor home has allowed us to cut tunity to be one of the first into China the build time,” Ingram told to actually build them up there for Manufacturers’ Monthly. that market. The fully moulded, seamless body “It’s an exciting project, but we’ll frame, which incorporates the roof, control the intellectual property all the sidewalls, rear and front headers, is way through which is the key to the said to be eight times stronger than whole thing. current designs and is supported with Ingram believes the company’s suca totally new chassis. cess is mainly due to its innovative use With a 100 strong workforce, Ingram says the company is now look- of technology. “When we took this task on, it wasn’t a matter of just ing to take the Next Generation copying from someone else, we took motorhomes to the world, recently the innovation approach and if you’re signing a joint venture agreement with innovative, opportunities are still Chinese bus manufacturer Zhongtong there. Bus Holdings. “There are some great products that Ingram sees the partnership with come out of Australia for the world Zhongtong as a great opportunity to market and we believe that this prodgrow the brand internationally by uct will be accepted throughout the establishing a low-cost base for both world. That’s the exciting thing.” the emerging Chinese market and the Competing with Winnebagos and lucrative North American market. “The interest we have already receiv other A-Class motorhomes, the Next Generation motorho ed from Chinese consumers indicates t hat the passion for travelling in a luxu- mes range in price from $350,000 to over $800,000 for motorhomes ry motorhome isn’t restricted to the A ranging from 28ft up to 40ft. ustralian culture by any means,” www.manmonthly.com.au
THERE IS
NO
SECOND CHOICE.
Loctite is a Registered Trade Mark of Henkel Corp. USA. ©Copyright 5/2008. ART0865
BY ALAN JOHNSON
We’ve built our reputation on this red bottle and so can you. Since 1953, the Loctite® brand has led the industry in threadlocking and retaining solutions. Our commitment to excellence hasn’t changed. Choose the original, choose the LOCTITE ® BRAND.
THERE IS NO SECOND CHOICE.
Phone: 1300 LOCTITE or visit www.loctite.com.au MANUFACTURERS’ MONTHLY
JUNE 2008
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ANALYSISNEWS
Boeing sues Alcoa BOEING is now in the process of suing Alcoa, alleging manufacturing defects in an unknown number of titanium forgings, which are structural components attaching wings to the fuselage of the F-22 fighter aircraft built by Lockheed and Boeing. The suit alleges that Alcoa failed to heat treat the titanium forgings effectively to achieve the necessary "damage tolerance," which could lead to "the catastrophic loss of the aircraft." Boeing is said to be seeking over $US12m in compensation and legal fees. For more information go to www.manmonthly.com.au/articles/Bo eing-sues-Alcoa-over-defective-forging_z172186.htm.
China wants higher tariffs CHINA is seeking to persuade the World Trade Organisation to let it keep higher tariffs on industrial goods in any global trade deal, sparking fierce opposition from developed countries. China wants to be able to charge tariffs above the 23% level proposed for developing countries. With time running out before the US presidential elections in November, a ministerial meeting could be on the cards soon in a bid to unblock the key dossiers of agriculture and industrial goods, trade sources said.
‘Green plastics' from plants AUSTRALIAN researchers are a step closer to turning plants into 'biofactories' capable of producing oils which can be used to replace petrochemicals used to manufacture a range of products. Scientists working within the joint CSIRO/Grains Research and Development Corporation Crop Biofactories Initiative (CBI) have achieved a major advance by accumulating 30% of an unusual fatty acid (UFA) in the model plant, Arabidopsis. CBI is developing new technologies for making a range of UFAs in oilseeds, to provide Australia with a head start in the emerging 'bioeconomy'. It is said to be low greenhouse gas generating and a sustainable alternative to petrochemicals.
Mett wins GM award NOBLE Park based automotive manufacturer Mett recently received the General Motors 2007 Supplier of the Year award for its significant contribution to GM’s global product and performance achievements. The Australian company was selected as the ‘best of the best’ by a global team of executives from purchasing, engineering, manufacturing and logistics divisions who based their decision on supplier performance in quality, service, technology and price.
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JSF project puts heat in market BY LEN HOBBS
BRISBANE-based Heat Treatment Australia is poised to enter major international markets as a participant in the massive nine-country F-35 Joint Strike Fighter (JSF) Program valued at $70bn. As the only Australian heat treatment processor to take up a Federal Government invitation to be involved, the company has installed two new $1.5m furnaces with capabilities never before available in Australia. In fact very few companies around the globe have this technology. The JSF’s 10-year SDD (System Development & Demonstration) phase aims to create a new generation strike fighter with cutting edge technologies including short takeoff and vertical landing. One of Heat Treatment’s new furnaces provides the ability to braze aluminium, a process requiring exact control mechanisms because the melting and brazing temperatures of aluminium are very close. The second furnace, from Seco Warwick, is a vacuum hardening and carburising furnace. Also with strict controls, it has the ability to provide better metallurgical properties for very high end products using stainless steel for example, or precision valves and gears. The highstress, high-quality components used in aircraft are other examples. Heat Treatment’s GM, Karen Stanton, said the decision to invest such substantial sums was made both for the sake of enhancing the company’s service capabilities, and the unparalleled business opportunity the program offered. “To our knowledge there is only one other Australian organisation with the heat treatment standard required for the aerospace industry,” she said.
Australian customers who previously sent high-end aerospace-standard equipment overseas for heat treatments now can have them done in Brisbane.
“Most have the ISO 9001:2000 standard but a few years ago the giants of military aircraft manufacture set their own, the NADCAP standard and that’s what we are working towards achieving relatively quickly. “At the same time, it is also about being part of something exciting and new. “Previously we would get an order, do the process and return it. But right now we working with engineers and customers from Australia and overseas who want to know our capabilities, and who have input that can help us. “At the same time we are presenting our case and discussing with them the challenges and possible solutions we all have. It’s a collaborative thing that achieves the result we all want.” Quality manager Gary Coffey said behind the scenes talks had been ongoing for at least 12 months with other suppliers to JSF who required heat treatment of their products.
“This is a huge opportunity made available to us at the highest levels of world business and politics,” he said. “The Australian Government, for example, has teams in both Canberra and Washington dedicated to this single project. And major companies have sent people from the US. “They have not just spoken with us, but spent days with us looking at our facilities and learning about our capabilities. Then we’ve exchanged emails for several months ironing out various matters. “The result is we’ve already undertaken several projects. And while we might be playing a relative small part in the overall scheme of things, we have a vital role. “Without our work on, say, an aluminium box, the avionics might not be securely housed and the aircraft might not fly.” For further information call Heat Treatment on 07 3345 4944.
Victorian manufacturers honoured at awards BY JOHN ALLEN
VICTORIA’S manufacturing industry came together last month (May 19) at a gala dinner held at Crown Casino to celebrate the industry’s successes over the past year. Victoria’s automotive component manufacturers dominated the night making up five of the 11 inductees. Companies from the aviation, design, textile, plastics and scientific sectors were also recognised for their contribution to Victorian manufacturing and exporting. The 11 companies inducted into the 2008 Victorian Manufacturing Hall of
Fame were: Aerostaff Australia; Aisin Australia; Armstrong World Industries; Basell Australia; Ecotech; FMP Group; Hilton Manufacturing; Injectronics Australia; Lumen Australia; SGE Analytical Science; and Schiavello Group of Companies. In keeping with the event’s “lean, clean and green” theme, a number of the organisations inducted demonstrated their commitment to best manufacturing practices and ongoing sustainability initiatives. Peter Carthew, MD of AME Systems, an electrical wiring harness and signal distribution manufacturer located in Ararat, was recognised for
his ongoing contribution to the manufacturing sector. Douglas Maxwell, MD of Steele and Lincoln Foundry in Dandenong, and Alistair Murray the MD of Ronstan International, a yacht fitting manufacturer in Melbourne’s bayside suburbs were also recognised. All three have been inducted into the Hall of Fame Honour Roll in recognition of their significant role in developing Victoria’s vibrant manufacturing industry as well as the growth and management of their own organisations. Luke Dwyer, a 30-year-old GMof OzPress in Ballarat, was named the 2008 Young Manufacturer of the Year. www.manmonthly.com.au
ANALYSISNEWS
Major advances in warehouse automation BY HARTLEY HENDERSON
WAREHOUSE systems and technology have made enormous advances in recent times including the introduction of automated mobile racking, automated order picking, and dynamic conveyer systems, and this in turn has led to major productivity benefits. Harrie Swinkels, CEO of logistics services provider, Schaefer Noell in Germany, was recently in Australia to outline the latest developments in automated warehousing. He says high pressure on costs, particularly labour, means that the typical warehouse is struggling, especially when dealing with smaller orders and just-in-time requirements. “Many different factors are impacting on the efficiency of today’s warehouses in dealing with the global supply chain including different units of measurement which in turn can lead to quality issues,” Swinkels told Manufacturers’ Monthly. “Products also have an ever-shortening life cycle so there is a need to continually reorganise warehouses to ensure that the right products are in stock. “Over 50% of out-of-stock situations in stores are caused by poor logistics where the product is actually in stock but not on the shelf. This type of problem can be largely overcome by improving the efficiency of warehouses through automation. “There is a range of reasons to consider automation including response time, article range, temperature requirements, staff availability, ergonomics, space, article dynamics, traffic congestion, transport cube utilisation, and the cost of warehouse logistics. “In relation to response time, pharmaceutical companies were amongst the first businesses to introduce automation because of the wide range
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of products and the need for fast supply of medicines. “For chilled food or frozen products warehouses, automation provides better control of products and significant savings in space and the cost of energy. Picking processes can be simplified, there is a reduced error rate, and because there is no need for experienced people there is greater flexibility as part-time staff can be utilised when needed. “Automation can minimise the
to build the most efficient pallet is now available to optimise transport cube utilisation, and pallets up to 2.5m high can be built by automated systems. “At 7-10% of overall cost, stock is a heavy cost factor for businesses, so warehouse logistics should receive close attention. There is an increasing trend to fully automated systems without people, except for a skilled engineer to run the operation.” Customised warehouse solutions can
Today, the industry standard is said to be up to 1,000 picks per person per hour.
number of people and uncouple work areas so that a balanced workloaddriven system can be introduced. Space can be optimised through the use of high-bay warehousing, and article dynamics can be improved because products can be presented in a logical way to pick-faces. “The industry standard is now up to 1,000 picks per person per hour, and it is possible to pick up 600,000 lines per day in a single DC. “Fast movers and slow movers can be categorised to avoid traffic congestion and mono-rails, which may be hung from the ceiling, can be utilised to present product to pickers. Software
be designed for various system elements, including racking and conveyor systems, and order picking strategies can include intelligent pick-by-light and pick-by-voice systems as well as picking via RF technology. Minimal use of space with high density modular storage systems can be complimented by high speed order picking to produce real productivity and profitability benefits. Like building blocks, the units can be combined and scaled to meet specific needs. Swinkels believes that through automated warehousing, zero error order picking can be a realistic aim through the integration of efficient conveyor
systems and sophisticated control technologies. “Fully automated order picking can also be applied to medium and slow moving products by placing products into picking channels at various levels in order to save space and have them available at any time. When required, the products are automatically ejected onto a conveyor belt for transport to the despatch area,” he explained. “Automatic storage and retrieval machines are also available for use in high-bay warehouse operations. These can be single or double mast units depending on required capacities and travel and lifting speeds. With automation providing continuing high throughput and quick, economic order picking, less than one sixth of the energy consumption of conventional systems can be achieved. “Fully automated mobile racking systems can also be installed together with laser navigated high-bay stackers without operators. In particular, this type of technology can bring significant efficiencies for the food industry and help to offset the rising cost of energy for cold or freezer storage.” According to Alan Clark, director of sales and marketing at Schaeffer Systems International in Sydney, the huge land mass and geographical location of Australia means that efficient logistics is critical in helping enterprises maintain competitiveness. “We are likely to see more high-level warehouse automation, particularly amongst larger companies with volume throughput. “There can be big benefits in manufacturers and suppliers with the same customer base getting together to form distribution hubs, rather than relying on third party logistics companies. “This type of arrangement, combined with advanced automation systems, can deliver significant economies of scale,” Clark said.
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INSIDERSERIES-INDIA
DID YOU KNOW? Trade between Australia and India is growing by more than 30% per year, and India is now Australia’s fastestgrowing export market.
INDIA: A RISING GIANT The subcontinent presents huge opportunities for Australian manufacturers, but don’t expect success to be easy or quick. Patience and perseverance are required, and an understanding of the culture and the changes under way in the country are vital. Derek Parker reports. OR half a century, it hovered to the edge of the horizon, noticed only for disasters and assassinations. But in the past decade India has moved steadily onto the global stage, and is now taking a role more fitting its size and potential.The country veered dangerously close to the economic precipice in the early 1990s, when it had to use part of its gold stocks as collateral for loans to stave off national bankruptcy. It was a shock that led to a series of reforms to free a backward, over-regulated economy, opening key sectors to international competition and triggering a wave of entrepreneurial energy, often tied to the technology sector.Gurcharan Das, a respected commentator on the country’s affairs
F
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and author of the book India Unbound: The Social and Economic Revolution from Independence to the Global Information Age, made a series of telling observations and predictions on a recent tour of Australia. India, he noted, is already the world’s fourth largest economy, and it will soon overtake Japan to become the third largest. Over a hundred Indian companies have market capitalisation of US$1bn, and over a thousand Indian companies have received foreign institutional investment. Inevitably, there are comparisons with the other Asian giant, China. Das points out that the Indian financial sector is much stronger, with the bad loan rate in Indian banks being only 2%,
against around 20% in China. About 80% of credit goes to the private sector in India; the figure for China is about 10%. The rate of broad economic growth for India is forecast to be around 8% for the next several years; the figure for 2006-07 was above 9%. Das also notes that by 2010 India will have the largest number of English-speakers of any country in the world, over 300 million. Especially with the boom in net-based technology, English has become the national language of business. While there are still areas of economic stagnation – the agricultural sector, for example – the overall picture is one of a society looking towards the future, aware of the country’s huge problems but starting to believe that the obstacles can be overcome. The potential economic benefit to Australia from India’s rise has not been lost on the Commonwealth government. The first overseas trip by the trade minister, Simon Crean, was to India. He notes that trade between Australia and India is growing by more
than 30% per year, and India is now Australia’s fastest-growing export market. “There are business opportunities in India worth more than $50bn available in India in the next 12 months,” said Crean, when launching a new report in April, prepared for Austrade by KPMG*. “The Australian Government is committed to raising the trade and economic relationship with India to a new level. The Indian Government has identified that, to sustain its rate of growth rate, significant infrastructure development is required. Investments in the order of $536.6bn are expected to take place in coming years for developing ports, airports, roads, railways and real estate.” Major Australian companies already working in India include Leighton, Hydro Tasmania, BHP Billiton, Rio Tinto, Thiess and BlueScope. Others are in the process of entry, but the KPMG report notes that they will need to move quickly, as firms from the UK, US and Spain are already carving continued on page 18 www.manmonthly.com.au
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INSIDERSERIES-INDIA
“Contracts are taken very seriously in India - it’s not like China.”
continued from page 16 places in the Indian market. Looking ahead, there is a prospect of a Free Trade Agreement between Australia and India. The previous government began the process but the current government plans to continue it, so long as an FTA does not cut across multilateral trade arrangements. The FTA is currently in the joint feasibility study stage, after the Terms of Reference were agreed in April. The study, expected to be completed by early 2009, will examine the potential impact on Australia and India of an FTA, including implications for economic growth, trade in goods and services, and investment, as well as for other commercial linkages.† New Zealand recently signed a Free Trade Agreement with India, the first developed nation to do so.
Reputation to build on Michael Moignard, Austrade’s Senior Trade Commissioner for South Asia, believes that the awareness of the opportunities presented by India’s rise amongst the Australian business community is, by and large, fairly high, with the past few years seeing a distinct change from exploration to engagement. Based in New Delhi, he points out that India is generally welcoming to Australian businesses: its ‘Look East’ policy focuses on the Asia-Pacific region, and the government is constantly exhorting Indian businesses to
take a global perspective. Moignard says Australia is seen as a sophisticated country with good niche technology. “It is seen as a good destination for tourism, which is already a huge industry in India. And there are a lot of people in business with an Australian connection, either because they studied in Australia or studied in India at an Australian-badged institution. “In fact, the quality of Australian education is an important benefit for Australia in this respect. So far, it has mainly been university-orientated, but I can see a lot of opportunities for trade-level education and training provided by Australian institutions. It is an area where the India education system is not strong, and Australia has a good reputation to build on.” For Australian companies looking to partner with Indian firms or employ Indians, the quality of Indian education can be a serious constraint, especially in finance and management. While there are a few world-class management education institutions, the number of qualified people they turn out is very small compared to the demands of the economy. While the lower tiers of institutions produce huge numbers of graduates, the quality often leaves much to be desired. Many Indian university degrees are comparable to trade-level qualifications in Australia, and Indian business education tends to emphasise
rote learning rather than creative thinking. Moignard says Indian management tends to be thin in the middle. “There is a tendency to delegate upwards, much more than in Australia, and that can lead to rather slow decision-making. “I should say that the best Indian managers are very good indeed. But they are expensive, and have a clear idea of what they are worth. Nevertheless, you might consider it as a worthwhile investment. India is a place where you get what you pay for.” Moignard notes that Australian companies looking to enter India have a number of options, and should consider the alternatives in light of business needs. The use of import agents is very popular, but some research to establish to credentials of the agent is advisable. A new area showing great promise is franchise agreements with Indian partners. Joint ventures are also common, and some very large ventures have emerged, such as the alliance between Woolworths and the Indian giant Tata. “Most business regulation is done by the national government so there is a high degree of uniformity across the country, although there are some differences in taxes between states. “Product registration, such as the regulation of food products, is also done at the state level, although Australia’s reputation as a ‘clean and green’ food
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producer gives Australian companies a head start in this area.” Moignard also advises Australian firms to ensure that their legal documentation is in order. Indian business law is similar to that of Australia but not identical. In the case of a dispute, Indian courts move slowly, paying great attention to technical details. Moignard says contracts are taken very seriously in India. “It’s not like China, where a contract is seen as a general framework for the development of a personal relationship. “So any business agreement should be carefully examined, especially regarding the exit strategy in case of non-performance. “My advice is to not make any hasty decisions about choosing business partners or signing a contract under pressure. Austrade can provide help in checking the suitability of potential partners, and putting in a bit of extra time is a good investment.” Moignard also notes that Austrade is also seeking to build the profile of Australian expertise in India through ‘Utsav Australia’ (Celebrate Australia), a program of industry-focused activities and seminars which aims to extend Austrade’s reach beyond the capital cities to major regional centres that are experiencing significant growth and which present potential opportunities for Australian firms.
Right ingredients The experience of several Australian companies operating successfully in India underscores the importance of finding the right partner. Perth-based JV Global has entered into a joint venture with pioneering Indian construction company, Shapoorji Pallonji & Co. Ltd, to establish a factory outside Mumbai to manufacture steel door frames for the Indian market. The joint venture was set up in 2006 but had been proceeded by several years of discussions to build good relationships. Production began in late 2007. Terry Opie, MD of JV Global says India is a considerable market for his company. “Our research indicates that 80 to 90 million additional dwellings are needed by 2015. The market for door frames alone is 100 million units in the next five years, and currently most manufacturing is done at a local level using wood. “Our roll-formed steel door frames can be mass produced and deliver a high quality product that is cheaper than wood. “The Shapoorji Pallonji Group has a significant market share in India. By partnering with them, we had an immediate and major client for our joint venture. We will soon be moving into complementary manufacturing lines, like steel housing frames.” Through the joint venture, JV Global plans to set up manufacturing facilities in New Delhi, Kolkata and Chennai over the next five years to cater to the local market. Alex de Wit, director of the family-owned gourmet food company The Chilli Factory, points to the need to demonstrate the quality of the
product to Indian customers. “Indian produces a huge amount of chilli at very low cost, so we knew we couldn’t compete on price,” he told Manufacturers’ Monthly. “But we realised that there was a new class of more affluent consumers in India who were interested in quality, and that gave us the opportunity. “We presented a sample set to representatives of Mumbai’s largest department store, HyperCity, and it is now selling our chilli sauces, pastes, jams and salsas. It took time and perseverance, especially with the amount of government red tape, but HyperCity has one million people going through its doors every month, so it was worth the effort. “Even more, HyperCity is planning a chain of 100 gourmet stores, and we will be a part of that. It comes down to picking up on market trends and being able to show what is special about your product. It’s not an easy market, Indians need to be persuaded. But they are certainly not closed to new ideas,” de Wit said. Another Australian company to have done well in India is Adelaide-based Steriline Racing, which has supplied moveable running rails to the Hyderabad Race Club. MD John Fargher, who is now exploring other opportunities in India, highlights research, patience and perseverance as necessary for success. References and recommendations, he notes, are important tools. “You need to structure your approach to meet their needs,” he said. “Our clients have a very clear understanding of what they want but are cautious when making decisions. The key is to present a total package: understanding their commercial context, explaining the quality of the product, and providing follow-up service. “You have to be willing to put some time into researching the culture. A good start is to spend a bit of time simply walking around, and Austrade is also very helpful at filling in the picture,” Fargher said. Moignard believes that these cases provide useful lessons on how to operate in India. “For most Australian companies, the best strategy is to start with one region, building a solid business there and using it as a base for further expansion. “You need to look at long-term commitment to the market, understanding that you might not make a profit for at least several years. “But for those willing to stay the course, the rewards can be very substantial. And India’s recent growth is built on a solid foundation. There’s a lot more to come yet.” * The report Opportunities in Infrastructure and Resources in India can be purchased through the Austrade site; go to www.austrade.gov.au/india for an order form. An Executive Summary is also available. † For further information, go to www.dfat.gov.au/geo/india/fta-study § For more information on Utsav Australia, go to www.utsavaustralia.in
ANALYSISFREIGHT, TRANSPORT & LOGISTICS
Freight gets smarter and greener The latest trends in freight logistics are not only aimed at improving operational efficiencies but are also ensuring greener operations. Hartley Henderson reports. HIGH-TECH solutions such as warehouse automation, the use of GPS for route planning, and specially designed IT systems to reduce paperwork are having a significant impact on physical distribution efficiencies. Actions to reduce greenhouse gas emissions include improvements in the design of truck trailers, which in turn can provide fuel savings. Logistics services provider AirRoad is a company that is implementing carbon management strategies and carbon footprint measurement processes that are benefiting both the environment and the bottom line. Hybrid forklifts have been introduced and sensor lighting has been installed in the company’s Melbourne warehouse facilities with plans to roll out nationally. But the company’s most notable carbon management achievement is in its trailer design. The company specialises in transporting high technology products, with chief engineer Michael Egan involved in designing trailers for the company that are not only freight friendly but are more efficient. “New designs have resulted in B double and B triple trailers with larger cubic capacity while at the same time maintaining a focus on safety and stability,” Egan explains. “While we are very conscious of sticking to the rules governing areas such as mass and fatigue management, there is an urgent need to rationalise and standardise prescriptive rules which vary in each state,” Egan told Manufacturers’ Monthly. “We have made significant advances in designing smart trailers which incorporate innovations such as our own independent suspension with a low centre of gravity, and the ability to split trailers into two decks. “A two-deck split significantly reduces freight compaction during long-distance haulage and provides better protection against damage to goods and cartons.” According to Egan, the greater load stability that this design offers has resulted in the ability to carry more freight and achieve improved fuel economy per tonne of freight. “In cubic capacity, one prime mover can now tow 35-50% more freight using the same amount of fuel. The face of competition in the logistics services industry is changing. “As a key component of our customers’ supply chains, we are very aware that more companies are now 20
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Logistics companies are now getting a move on when it comes to reducing their carbon footprint.
choosing suppliers that assist them to reduce their carbon footprint – so we need to play our part in providing green and lean supply chain management,” he said.
Innovation centre Global logistics company, DHL, has established an innovation centre near Bonn in Germany with the aim of developing marketable, highly innovative products in relation to logistics trends of the future. In addition to serving as a laboratory of the future, the centre will provide a showroom to display the interrelationship of global product streams and logistics networks. Prototypes of current development projects will also be on show including a robot that can unload delivery vehicles, and that can recognise different sized packages, pick them up and place them on a conveyor belt. In Australia, DHL has launched GoGreen Express which is a carbon neutral shipping service for the Asia Pacific region. Corporate communications manager, Sara Carden, says the service has been created for customers that are looking for a more environmentallyresponsible shipping option. “DHL calculates the carbon emissions generated by transporting each specific customer shipment from the country of origin to destination, and offsets these emissions by reinvesting in certified carbon management programs such as alternative vehicle fuel technology and solar panels,” Carden told Manufacturers’ Monthly. “Other environmentally sustainable initiatives include the introduction of bio-fuelled or hybrid vehicles into our
operations in various markets, including India and Japan,” she said. “We have also launched a shipping service that eliminates the need for manual paperwork by enabling customers to submit shipment details electronically using DHL eMailShip,” she said. A complimentary copy of eMailShip can be downloaded at www.dhl.com.au. Carden says security is another area in global supply chain management that is receiving greater attention. “At the DHL Express facility in Perth, some unique security features have been introduced including full CCTV monitoring of cargo process flow, and an X-ray machine has been installed to assist in checking all inbound shipments.” As well as a focus on operational efficiencies, there is also a trend towards implementing greener solutions in freight logistics. VP of global marketing at CargoWise edi, Melinda Elmowy, believes there are many obvious and cost–effective opportunities for compa-
nies to reduce their logistics carbon footprint. “Greening issues are becoming more important with realisation that distribution services can account for some 75% of a company’s carbon footprint. As a result, relationships are changing between suppliers, partners and logistics providers. “There is a growing recognition that many of the initiatives that companies can institute to achieve a greener environment simply involve eliminating waste while improving productivity,” Elmowy said. “For example, software systems such as our ediEnterprise are now available to help companies green the supply chain by adopting a paperless approach and moving to automated documentation. “Efficiencies can be created and overall operational costs reduced by ensuring that customer relationship management is an integral part of the supply chain process.” AirRoad 02 9741 0407. CargoWise 02 8001 2200. DHL 02 9317 838.
Heavy truck range ISUZU's new product roll-out is continuing apace with the launch of all-new FX models into the lower end of the heavy truck market. Available in five models with further models planned in the future, the FX will be positioned in the market between the current FV models and the Giga range. Built on the Giga chassis, FX models are fitted with new F Series cabins, in keeping with the company's focus on
parts commonality among its truck ranges. Powering the range is the new SiTEC Series II 325 engine.The 9.8 litre 6-cylinder powerplant features high pressure common rail fuel injection, four valves per cylinder overhead camshaft (OHC) design, twin exhaust gas recirculation (EGR), a variable geometry system (VGS) turbocharger and a diesel particulate diffuser (DPD). Isuzu Australia 03 9644 6666. www.manmonthly.com.au
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TECHNOLOGYIT@MM
RFID technology and the supply chain Moving beyond the pilot stage, RFID is now being used by manufacturers around the world in many exciting applications, and not just asset management. Alan Johnson reports. A RECENT US study into the effect of RFID technology on retail-inventory accuracy demonstrated that an automated, RFID-enabled inventory system improved accuracy by about 13% in test stores. The investigation, conducted by researchers in the RFID Research Center, a research unit of the Information Technology Research Institute in the Sam M. Walton College of Business, also revealed that manual inventory adjustments by store personnel significantly declined in test stores due to the automated, RFID-based system. The study shows RFID technology can significantly reduce unnecessary inventory, with the potential for savings for major retailers, with numerous suppliers, measured in millions of dollars. However, while the retail industry gets the majority of the headlines regarding the use of RFID technology, particularly those applications in the US and Europe, that’s not to say this exciting technology can’t be used elsewhere. As Chris Kelley, director of RFID for Intermec, explained on his recent trip to Australia, RFID technology has a wide range of applications within the supply chain, especially with reusable containers. “For example, we’ve seen a high uptake of RFID technology in the automotive supply chain, where a part is manufactured by a supplier, loaded onto a part specific container, then that container gets transported to an OEM, and then routed back,” Kelley told Manufacturers’ Monthly. “In this case the tag is on a specialised metal container, the size of a truck trailer. Technologies like barcodes have not done a great job, mainly because of the intrinsic nature of barcode optical which rubs off. Whereas RFID is much more durable and can stand up to the life of that asset as it traverses the supply chain,” he said. But Kelley warns manufacturers not to think of RFID as a replacement for the barcode. “That would be a mistake, for a couple of reasons. “From a planning horizon point of view, at the item level, for most categories of items, the bar code will for a good for a while. If not indefinitely, it will be much lower cost than an RFID tag. “In fact, I have a hard time seeing that cross over point. It isn’t so much the ink that goes on that label as much as it is the real estate it consumes. “Certainly there are some categories
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Soon, manufacturers will be able to order their new forklift with RFID readers, antenna, cabling etc straight from the factory.
of items such as apparel where RFID offers some intrinsic benefits. But if you look at RFID simply replacing barcodes, you’re missing the opportunity. “What RFID offers enterprises, in this case consumer goods or a retailer is the ability to step back and evaluate their processes and find new ways to improve their processes. If you just put RFID tags wherever you’re using barcodes, you’re not getting any benefit; you might as well continue using barcodes. “The benefit comes from stepping back and saying, okay, what are my real business issues? How might RFID enable me to refine or improve my business processes to get better efficiency or better customer service or reduce costs or whatever it might be? “For example, we’ve an automobile manufacturer here in North America called Chrysler. “If you could imagine a circular assembly process which the vehicle goes through, with the vehicles built on carriers as they go around. “But these carriers need to go through preventative maintenance, periodically. Welds need to be checked and bolts need to be tightened and the like.
But they had no good way of ensuring that these carriers were going through preventative maintenance, they couldn’t identify those carriers. “They’d tried doing it with barcodes but these carriers work in a pretty nasty, dirty grimy place and visual barcodes didn’t work. “A partner of ours went in and put RFID tags on each one of the carriers and RFID readers in strategic locations along the process so they could identify each carrier against a database. “When needed, the carrier was diverted over to preventive maintenance. They saved over a million dollars in the first year, just in overtime avoidance. They had a return on investment of over 200%,” Kelley said. “This is just one example of using RFID in a novel way that they couldn’t do with other technologies.”
RFID in the warehouse Kelley said Intermec has being working closely with Cisco Systems, RedPrarie and Cascade Corp, to develop ‘the forklift of the future’. Through its use of RFID technology, the forklift can identify and track products on it when loading or unloading.
The prototype forklift incorporates RFID readers built into the forklift’s infrastructure, replacing today’s bolt-on approach to data collection, and features Cisco’s Wireless Location Appliance and RedPrarie’s open Mobile Resource Management software integrated with the forklift RFID reading system developed by Intermec and Cascade. With the complete system, drivers can conveniently read and encode RFID tags without leaving the vehicle, and managers can get real-time data on vehicle locations and activity. The Cisco Wireless Location Appliance provides location tracking for devices on a Cisco 802.11 wireless network. With the RedPrarie software, it can be used to provide the X, Y coordinates of an RFID-enabled forklift, report movements, monitor dwell time and collect other data useful for security, employee performance auditing, maintenance and asset management applications. Kelley says mounting the RFID readers on the forklift offers users a number of advantages in a warehouse or a distribution centre. “Early deployments of RFID readers were in fixed portals, at choke points, dock doors and doorways, for example. But you’re tying up a fair amount of capital in an inflexible infrastructure, plus you are limiting yourself to capturing RFID data just at that point. “ Kelley suggests a typical warehouse/distribution centre has a ratio of one forklift to four dock doors. While admitting it costs a little more to equip a forklift, he says clearly the savings are there. “While there are lower capital costs by putting the readers on the forklifts, more importantly now you’ve got the flexibility. You’ve got the potential for
continued on page 24 www.manmonthly.com.au
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ERP system breathes fresh air into company BY DAVID GIANG*
LIKE many successful manufacturing companies in Australia, ActronAir, Australia’s largest manufacturer of air conditioning systems, was outgrowing its existing IT system. The company was experiencing major growth, with the number of employees growing to 70, and needed a system that would grow with them. Some of the challenges the company faced with its existing system were poor reporting, no standard costing information, financial data was very basic and didn’t handle variance reporting, was not user friendly, and no inventory ageing capability. After reviewing several systems including SAP, Sage and Pronto, ActronAir selected Microsoft’s Dynamics AX., with the system installed and configured and staff trained with an accelerated implementation process of only several months.
continued from page 22 many more read points, capturing more data in your operation. “It will pick up when you are pulling pallets out of the warehouse or building pallets, case picking for example, or taking pallets to a shrink wrap station, or putting pallets on or off a truck. “So you can gather a lot more information about where your goods are, the state of your goods and what they are. “And rather than welding and drilling to equip and re-engineer each forklift to have RFID on it, we are working with companies like Cascade, a major manufacturer of forklift back rests, to make retrofits easy. “We are working with them to design back rests and RFID equipment from us that allows users in the field to rapidly install RFID equipment flexibly to their specific requirement, with cable routing, antennae placement, in all the right
The company has now been running live on Dynamics AX since October 3rd 2006 and has 35 concurrent licences with approximately 70 total users. As the system has now total acceptance and is providing the base information and processes as required in the original plan, ActronAir is now moving onto enhanced functionality to take advantage of the flexibility and features of the product. The company selected ePartners to implement the ERP system. Steve Bryant, ActronAir’s financial controller said the implementation of Dynamics AX was impressive. “All our staff has quickly grasped the new technology. This has enabled us to achieve greater productivity, higher retention of valuable staff and most important a more satisfied workforce”. Luke Schweizer management accountant and power user of Dynamics Ax for ActronAir said the next phase for the system will be to automate more
places to make it happen very quickly. “But with the forklift of the future we’re working on, users will be able to order a forklift already RFID enabled. When you call up your forklift distributor, in addition to saying ‘I need LPG, I need a double high mast’, I will also say ‘I need RFID’. And it comes to you from the dealer already equipped with RFID and mobile computing and wireless networks.” Kelley says there are a number of truck manufacturers who see the value and see the differentiation they can provide to their markets by providing RFID. “I believe it will happen relatively quickly.”
Original RFID thinking One UK company has certainly thought outside the square when it comes to RFID in the supply chain. If you've ever owned a cat, you know
functions such as bar coding, service automation and to install business intelligence tools. “The system design to meet the requirements of ActronAir was very important in the decision of implementing Dynamics AX. “One of the key selling points was the quick development by ePartners for specific business requirements to meet ActronAir’s business processes. “These included modifying the standard cost function to enable ‘on costs’ to be calculated automatically which involved four new fields in the item master and calculations based on these fields. This modification was written in Dynamics within one hour of the spec being signed,
We’ve seen a high uptake of RFID technology in the automotive supply chain – Kelley.
the problem. The cat flap that you bought to let your beloved feline in and out of your house has suddenly become a portal for every other moggy in the neighbourhood too. However, thanks to the ingenuity of engineers at Sureflap
ActronAir upgrades its ERP system to keep pace with company’s growth.
tested and implemented successfully within one day,” Schweizer said. * David Giang is a practice partner with ePartners 02 8876 8300.
(www.sureflap.co.uk), who have teamed up with RFID company Cambridge Resonant Technologies (www.cambridge-resonant.co.uk), all this is a thing of the past. The engineers have developed a battery- powered cat flap with a built-in high-performance RFID reader. And that reader can be 'taught' the unique ID code of a standard microchip implanted in your pet, allowing your cat - and only your cat - to pass through the flap. Of course, first of all your pet has to be chipped. But since microchipping is now common for pets as a form of permanent identification, that shouldn't be such a big deal. So if your cat hasn't already received an implant, all you need to do is take it down to the local vet where a small tag the size of a grain of rice will be injected under its skin. Intermec 03 9867 9300.
THE MOST RELIABLE PORTABLE PRINTER In the harsh and punishing environment of mobile computing, 98.06% of all O’Neil 4t printers sold in the past 12 months continue to run trouble-free. More remarkably, over the past six years, 9 out of 10 have never experienced a single problem...and this includes the entire family of 4t printers.* No other portable printer manufacturer comes close. When your customers need a portable printer, demand reliability. Demand O’Neil. For the white Paper “Mission Critical Printing: A Case for Reliability” visit www.insignia.com.au ©2008 O’Neil Product Development. All rights reserved.
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*
89.46%
your labelling people Contact insignia T 1300 467 446 F 1300 780 049
E sales@insignia.com.au W www.insignia.com.au
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TECHNOLOGYIT@MM
Putting intelligence in your supply chain BY PHIL LANGDALE*
SUPPLY chain efficiency is the holy grail for any manufacturer and can make or break a retailer in today’s globalised, fiercely competitive market. The push for ever decreasing costs and timelines, combined with rising demands and requirements for quality, security and customer satisfaction often seems an unachievable combination especially with ever more complex internal supply chains. When you add to this the wildcard of forecasting quantities and timelines with brand-disloyal consumers, for many companies it seems just too complex a challenge to overcome. However, when a wholesaler's inability to adequately maintain inventory control or respond to sudden changes in demand for stock means that a retailer cannot meet final consumer demand, or, conversely, poor sales data from retailers results in inadequate forecasting of manufacturing requirements, then it’s time to recognise that the supply chain can no longer be managed in isolation.
Companies can gain positive results from improved analysis, measurement and reporting through the introduction of business intelligence tools in the supply chain.
Business planning Companies can gain positive results from improved analysis, measurement and reporting through the introduction of business intelligence tools in the supply chain.
Tangible benefits include increased customer service and lower costs from improved inventory and delivery management, and soft benefits, such as improved teamwork
and better decision-making. Examples where integrated business intelligence can support your supply chain include: * Know your customer / supplier service levels and align to them Aligning to how your customers measure your service so you can measure consistently with how they do, is really important to ensure you command shelf space, move stock and are not wearing unnecessary overheads due to incorrect shipments. To understand who you’re servicing well, which products are causing problems and which ones aren’t, technology support in the form of a business intelligence tool can help you analyse and draw insight from your data so you can benchmark and measure performance at a granular transactional order by order level or top-line aggregated level. * Profile your stock and deliveries Analyse your stock, delivery and demand history regularly to ensure you know which items are generating 80% of your sales revenue and to which class of customers they are being delivered, and are they being delivered correctly, in full.
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is now online! Visit www.manmonthly.com.au For all the latest: • industry news • white papers • products • feature articles
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A performance dashboard can pull core transactional data from your ERP system (Oracle/JDE, SAP, BPCS, MFG Pro, Movex and others) and present it in a visual way that makes sense to you, the way you work and your business targets. It will help you see how you are performing day in, day out and view trends over given periods. Implementing an effective data analysis and reporting solution isn’t complicated and shouldn’t take a long time to deploy (weeks, not months).
Integrated intelligence In summary, there needs to be consistency between business drivers and the objectives of the supply-chain. Business intelligence solutions integrated into the supply chain facilitate sharing of quality information for optimal planning and ensures businesses know ahead of time how they’re performing to service levels, stock and other key success factors at a granular customer, product, region or supplier level. In turn, this reduces complexity in the supply chain and simplifies processes within, and between organisations, to allow every member of staff involved make better decisions, faster.
Loctite is a Registered Trade Mark of Henkel Corp. USA. ©Copyright 5/2008. ART0864
Then check your service levels and holding costs of the remaining products represented by 20% of sales. You could be serving your customers perfectly but hold too much stock at high cost,, holding just the right quantities of stock to satisfy demand will minimise cost. Reviewing, for example, movement and Delivery in Full on Time (DIFOT) of product by tonne, pallet, carton, each can lend amazing insight to achievement of service levels, operational issues and dynamics. This is a key issue facing many manufacturers today. With both of these analyses, managers can detect issues and formulate a corresponding strategy easily. * Make better decisions, faster - If the aim of the supply chain is to deliver customer requirements at the lowest possible cost, then you have to address impediments to optimal performance and outcomes. Optimising supply functions demands that all participants understand the impact of failure in any one part of the supply chain – an effective analysis and reporting solution will deliver this. In understanding the root cause of an issue by tracing cause and effect, better analysis and understanding of supply chain deliveries and inventory held can foresee issues ahead of time, such as when and for how long you have low or no stock, as well as which customers are impacted.
OR
* Phil Langdale is co-owner and services director of Inside Info www.insideinfo.com.au, 1300 768 110.
Synchronous PLM technology SIEMENS PLM Software has announced what the company claims is the next big breakthrough in digital product development with synchronous technology. According to the company, the technology combines the best of constraintdriven techniques with direct modelling, and is being integrated into the company’s next versions of NX and Solid Edge software for delivery in July/August. The technology simultaneously synchronises geometry and rules through a new decision-making inference engine. The company says the technology accelerates innovation in four key areas: Fast idea capture: Synchronous technology captures ideas as fast as the user thinks them, with up to 100 times faster design experience. The technology defines optionally persistent dimensions, parameters and design rules at time of
creation or edit, without the overhead of an ordered history. Fast design changes: The technology automates the implementation of planned or unplanned design changes to seconds versus hours, with or without the presence of a history tree. Improved multi-CAD reuse: The technology allows users to reuse data from other CAD systems without remodelling. A technique called “suggestive selection” automatically infers the function of various design elements without the need for feature or constraint definitions. New user experience: The technology simplifies CAD and makes 3D as easy to use as 2D. The interaction paradigm merges historically independent 2D and 3D environments. PLMA 02 9410 4701.
Fast-start ERP software SAP has launched a purpose-built Australian version of SAP Business Allin-One designed to deliver fast-start ERP for Australian midsize companies in six to eight weeks. The Fast Start Program for SAP Business All-in-One delivers fixed price, fixed scope, on-premise ERP.The software comes pre-packaged www.manmonthly.com.au
with an IBM x3500 server. The solution has been purpose built by SAP’s SME Solution Centre for the Australian market and is designed to meet the needs of fast-growing enterprises with between 100 and 500 employees in services, manufacturing and wholesale industry sectors. SAP 02 9935 4845.
You’d better cross your fingers if you still depend on washers, locknuts or other mechanical devices to keep your fasteners tight. Fact is, they do little to prevent fastener loosening - one of the leading causes of catastrophic equipment failure. There’s a better way to secure fasteners. Use Loctite® threadlockers. You’ll get a solid, dependable threaded assembly that won’t loosen and cause breakdowns. That means more uptime and productivity.
Loctite® threadlockers come in a variety of strengths to match your application. They lubricate for easy assembly, seal against leakage, protect from rust and corrosion, and improve breakloose and prevailing torque strengths - all for about one third of the costs of mechanical devices. So don’t take chances. Reach for the sure thing, Loctite®.
1300 LOCTITE www.loctite.com.au
Removable
High-Strength
Penetrating
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SOLUTIONSNEW PRODUCTS
Non-contact 3D optical profilers
Intelligent positioning controller
THE new Talysurf CCI Lite range of non-contact optical 3D profilers from Taylor Hobson is said to bring a new level of performance to non-contact 3D measurement. The profiler is based around the Coherence Correlation Interferometry technique which provides both long scan ranges and a single mode of operation; and avoids the compromises associated with both phase mode and vertical scanning (white light) mode. The result is a non-contact 3D surface texture, step height and micro dimensional measurement system that can provide The system is offered as standard with a high sensitivity results in seconds. 1 million pixel image sensor. The instrument is said to be extremely versatile. All types of rough or highly reflective materials, including glass, metal, photo resist, polymer, liquid inks and pastes, can be measured. The instrument has applications in the manufacture of automotive components, bearings, MEMS (micro electro-mechanical systems), super-polished optical components, semiconductor devices and many other applications. Rosebank Engineering 03 9721 1300.
EPOS2 is the name of the new product from the maxon motor control range -- a digital positioning controller designed to control brush and brushless dc motors with encoder. The controllers are suitable for applications that require decentralised drive intelligence. These modular digital positioning controllers, based on CANopen standard, cover a performance range from 1 – 700W. They can operate in position, speed and current control mode, and can be configured to operate with both dc and EC motors, depending on software commands. A variety of operating modes means that they can be used flexibly in every kind of drive system in automation technology and mechatronics. Maxon Motor 02 9476 4777.
The controller is designed to control brush and brushless dc motors with encoder.
Shaft-mounted gear reducer THE Posiplan range of gear reducers has been expanded to 12 sizes with peak torque now up to 89,000Nm, with a ratio range from 13:1 to 10,000:1. Continuing development will see larger sizes being released in the future. Manufactured by PIV Posiplan of Italy, the compact winches can be used in conveyor drive applications; fitting in restricted spaces. Other applications include screw conveyors, travel cranes, and continuous casting machinery. According to the company, the winch’s hybrid design, which combines planetary with helical gears, or planetary and bevel-helical gears, allows the gear reducers to provide high reliability, with little maintenance. The company says efficiencies greater
Winch drive range has been expanded.
than 97% for two-stage units are typical, with slightly lower efficiencies for three and four-stage units. All units come with a torque arm as standard. Optional accessories include shrink discs, common bed frames, backstops, brakes, auxiliary drives and cooling/lubrication systems. Brevini Australia 02 9671 1000.
Pallet wrappers are modular NEW generation Wulftec pallet wrappers have been introduced by Australian Warehouse Solutions. According to the company, the pallet wrappers are distinguished by their sturdy steel structures and a no-nonsense 4-year unlimited cycle warranty. The 'Smart' Series of pallet wrappers have been designed with modularity in mind, allowing customers to continue customising their pallet wrapping machines, even years after purchase. Updating a pallet wrapper is as simple as removing the old module and attaching the new. Australian Warehouse Solutions 1800 023 890.
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Modularity allows customers to continue customising their pallet wrapping machines after purchase.
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SOLUTIONSNEW PRODUCTS
Engine/exhaust filters DONALDSON Australasia has released a wide range of liquid filters including mobile hydraulic filters, long life filters, supplemental coolant additive (SCA) filters, transmission filters, and oil filters. The mobile hydraulic filter media includes cellulose, synthetic, wire mesh with a broad line of replacement spin-on and cartridge filters for low, medium and high pressure applications. Donaldson 02 4350 2000.
Adhesive lubricants WURTH has released the HHS range of adhesive lubricants: HHS Fluid is a fluid grease resistance to centrifugal force. HHS Lube is a dirt-repelling sprayed grease for a long-term action. HHS Grease is a maintenance product containing PTFE and lithium soap. HHS 5000 is a fully synthetic lubricant for a creep action. HHS Drylube is a dry synthetic wax type lubricant resistant to centrifugal force. HHS Clean is a quick acting preliminary cleaning agent which improves the bond of all subsequent lubricants. HHS 2000 is a high pressure resistant adhesive lubricating oil with no solid content. Wurth 1300 657 765.
Food industry bearings A NEW bearing called Iglidur A200 is suitable for direct contact with food. The bearings are said to have good abrasion resistance and are highly suitable for low speed, rotational, oscillating and linear movements. They are said to be ideal for implementation when a bearing comes in direct contact with food, for low speeds, when quiet operation is important, or when dirt needs to become embedded. The material is FDA (US) approved for use in direct contact with food. Treotham Automation 02 9907 1788.
Entry-level dust collectors THE new 'Eximo Dust' range of products includes dust collector technology separates the dust (about 98% of the content) before it actually reaches the filter to ensure a much longer filter life. The company says the key to the performance of this new product is that it does not use the concept of 'reverse air', which can reach a point where the filtration media blocks and it won't work any more. This portable collector technology is described as inexpensive and is supplied in modular flat packs so it is easy to assemble. The system is said to work on a small footprint to provide excellent ground floor space utilisation, yet it can also be mounted above any machinery from which it is cleaning dust output, therefore operating completely off the floor. The dust collectors can be situated inside or outside, on a rooftop or anywhere else. Because of the way this technology is built, a user does not have to use long ducting or large diameter
The dust collectors are demountable and easy to install.
Single-turn magnetic encoders TURCK has introduced new Sendix encoders with 12-bit analogue and 14-bit CANopen outputs designed for applications requiring rugged, high-resolution encoders. Die-cast housings, resistance to humidity and condensation and an IP69k protection rating make them suitable for outdoor use. The Kübler single-turn magnetic absolute encoders use Sensor-Protect technology to deliver fully encapsulated electronics and separated mechanical assembly, providing a high resistance to shock (rated to 500g) and vibration (rated to 30g).
ducting to reach just one dust collector. With this technology, any factory or plant can have several little dust units so that only a little bit of ducting is used to connect to each unit. Eximo 02 9757 1233.
Dunnage bags AUSTRALIAN Warehouse Solutions (AWS) has been appointed exclusive Australasian distributor for Bates Cargo Pak dunnage bags. Bates Cargo Paks is a leading manufacturer of dunnage bag systems. Quick inflation of the Cargo Paks is due to an innovative valve. The valve can be turned 360°, allowing it to inflate the airbag from The innovative valve allows for quick inflation of the bags. all angles. The inflatable airbags adapt to most types of cargo and transportation. Australian Warehouse Solutions 1800 023 890.
Encoders come with 12-bit analogue and 14-bit CANopen outputs.
This technology utilises interlocking bearings on the flange and a mechanically-protected shaft seal to protect the encoder from external debris during installation. The encoders come equipped with an LED to help ease installation and simplify diagnostics, as well as an integral cable or M12 connector. Since the encoders’ diameter is only 36mm, they may also be applied in space restrictive locations. Turck Australia 1300 132 566.
Linear Motion Control Servomotor Brake
Roller Pinion
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Linear Brake
Rod Locks
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SOLUTIONSNEW PRODUCTS
Here’s the cutting edge you need! This unique and massively popular 112 Autoloading Knife is made to the highest quality standards. The all metal construction makes the 112 operate better than any other knife and is ideal for all cutting applications.
The 112 Knife has changed the way you change blades!
1 5 blade magazine
2 Push to expose blade
3 Press to release blade Code 112-1
button back to 4 Pull reload new blade
Pick and place robot ABB Australia has introduced the FlexPicker IRB 360 pick and place robot featuring increased speed, 50% higher payload and a smaller footprint. The increased payload capacity provides two benefits: the first is the ability to handle heavier objects; the second is to accommodate the mass of the increasingly sophisticated grippers required in handling diverse products. The new robot succeeds ABB's FlexPicker IRB340 system. The average cycle time performance of the IRB360 has improved by more than 20%, and is said to offer a competitive edge where there is a particular requirement for movement on a fourth axis. The fourth axis has an extensive work range and does not limit the robot performance. ABB Australia 03 8544 0112.
The robot features a 50% higher payload.
Condition monitor
Modular belt conveyors
IGUS has developed a push-pull force detection system (PPDS) as a condition monitoring solution especially for large energy chain systems. By monitoring the push-pull forces on the energy chain, the system helps avoid damage to, and failure of the system by allowing correct and timely maintenance or remote intervention. This online monitoring system has another even easier to use sibling called PPDS easy.
ROBOTUNITS has introduced a rage of belt conveyors which can be configured exactly to the customer’s specifications. Length, width, height, drive option, speed, belt-type and height of sideguides can all be individually specified.
Sterling gives you the edge for all cutting applications
Code 29-701
Code 440-1
Code 700-1
The conveyor sizes range from a miniature 40mm wide belt conveyor to 1200mm wide as standard.
The push-pull force detection system (PDDS) is suitable for large energy chain systems.
FREE CATALOGUE! Call 1800 656 911 today for your FREE Catalogue and your nearest Sterling distributor
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This entry-level conditioning monitoring version provides protection from mechanical damage in energy chain applications, with complete monitoring of push-pull forces with selectable parameters, emergency system switchoff in the event of overload, and a data logger for up to 40,000 entries. PPDS easy does not have the remote intervention option: the system shuts down if a pre-determined maximum value is exceeded (instead of through a permanent reference/actual value comparison as with the "big" PPDS solution). Treotham Automation 02 9907 1788.
According to the company, the specification and enquiry stages of the belt conveyor application have been made even easier for the customer with the company’s new online belt conveyor configuration system. This enables customers to construct an individually tailored conveyor for their needs, giving a full technical description with price in a matter of minutes. Sizes range from a miniature 40mm wide belt conveyor to 1200mm wide as standard. Special widths up to and exceeding 2000mm are also possible. The customer can specify any length required up to a standard of 6000mm (longer conveyors available upon request), with a variety of speed options and construction heights, ranging from 40mm through to 100mm. Robotunits 03 9334 5182. www.manmonthly.com.au
SOLUTIONSNEW PRODUCTS
Container cooling system USING an assortment of its own technologies, Fanquip has developed an innovative 'container cooling system' that regulates the internal temperature of transport containers. The cooling system is permanently mounted where required to keep workers comfortable and safe during industry-approved manual handling tasks. It is complemented by a movable arm that can be maneuvered from one position to another to comfortably hook up to any container access point. Cool air is produced by an air-conditioning module and then moved through
The cooling system is permanently mounted where required.
flexible ducting by an industrial blower. The system is adaptable to any size of transport container. The size of the air conditioning unit as well as the length and diameter of ducting is relative to each application. Fanquip 1800 224 308.
Entry-level microwave devices ENDRESS+Hauser has launched major performance enhancements to its range of free-to-air microwave devices. The new Pulsemaster eXact technology is said to boost the performance capabilities of radar (microwave) level measuring devices across the range for tough applications, while allowing entry level radar-based instruments to rival high-end competitors at no additional cost. The devices now incorporate an Advanced Dynamics 26GHz high frequency module with new intelligence added to patented Pulsemaster algorithms. These enhancements are designed to create stronger reflected signals and more advanced filtering analysis which ensures dramatically improves the accuracy and reliability of the level readings. Endress+Hauser 1300 363 707.
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Supersonic flow meters COMPACT supersonic DUB flow meters from Kobold Instruments are for operation in water and aqueous media. The inserted delay time method with supersonic measurements operates almost free of maintenance. As no mechanically movable parts are used, devices are resistant to different contaminations. Five different metering ranges cover from 0.04 - 10L/min to 0.68 - 170 L/min. Respectively related thread connections are G AG, G1 AG, G11/4 AG and G2 AG. In addition different electronic versions with switch, frequency, diagnosis and analogue outputs are provided. The compact electronics can either be attached directly to the measuring probe or placed separately. A microprocessor evaluates measurements and shows the result on a well visible four digit red LED display. The device can easily be controlled by a membrane keyboard. Reliable measuring instruments are very well suited for metering tasks with the high repeat accuracy of ±0.1% of the upper range value. In the process, upper limiting values of pressure and
The flow meters are available in five different metering ranges cover from 0.04 10L/min to 0.68 - 170 L/min.
temperature are 25 bar and 130°C. Protection class is IP65. Switching outputs according to common standards and analogue output as an option provide connection to automation systems. Due to functional implementation, supersonic flow meters type DUB meet the requirement for efficient and cost effective measuring technique according to industry usual standards. Kobold Instruments 02 9630 5444.
Automatic band-sawing machine CAPABLE of operating in both automatic and semi-automatic modes, the Shark 410 CNC HS automatic band-sawing machine cuts both sectional and solid structural and stainless steels, as well as light alloys. The machine can accommodate sections up to 410mm in diameter, or rectangular dimensions of 450 X 410mm. The machine's multi-microprocessor allows 32 different lots in different The machine's multi-microprocessor allows 32 lengths and quantities to be cut from different lots in different lengths and quantities to be cut from the same bar. the same bar, while a self-aligning vice can also feed deformed and misshapen bars, with a minimal automatically feedable rest piece of 100mm. Fed by a brushless motor and screw/nut system with recirculating ball-screws and 700mm stepper motor, bars weighing up to 3000kg are cut by a cast-iron bow-head of rigid construction allowing greater cut control and a longer blade life. Rotation of a bi-metal band (suitable for both sections and solids) by a vectorinverter motor means the cutting speed can be continuously adjusted from 15m/min to 110m/min. Comparative parameters for cutting load, cutting pressure, and cutting deflection are all programmed in 'real time' through a programming console. This console comprises an LCD screen to display cautionary and diagnostic messages in the language of use, and touch-tone polyester thermal shaped buttons. A movable control keypad can be positioned to allow the control and monitoring of cutting operations - such as the regulation of the band-guide head - all from a safe distance, while the control and function systems are protected from ingoing and outgoing electrical and electro-mechanical phenomena. Additional features include: chip collection drawer/optional chip evacuator, convenient location of the coolant tank in the steel base, a motorised wire chip brush, an electromechanical actuator with dynamic control for blade tensioning, as well as the expected service keys, instruction manual, and spare parts list, all in the language of usage. Power Machinery 02 9971 1755.
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SOLUTIONSNEW PRODUCTS
Sealing machines
Durable washroom sensors
G. MONDINI and Select Packaging Systems have launched the new generation tray sealer, the EVO. With the Evolution range of tray sealers as its design base, the The entire packaging line can now be controlled from the EVO has a smaller footone operator panel. print; manufacturers can utilise their factory space more efficiently. Access to the machine has also been improved so maintenance or cleaning downtime is minimised. The PC base interface, with individual usernames and passwords, is easier to use and requires less time for operator training. The entire packaging line is controlled from the one operator panel; tray sizes can be changed without having to reset all upstream equipment. A packaging line diagnostic is also controlled from this single source. Features which are fully integrated into the EVO include: check weigher, snap on lid machine, double sealing station, tool chip, panel integrated options, gas mixer and infra-red vision system. With flexible sealing capabilities, the EVO has been designed to accommodate an assortment of packaging formats. Select Packaging 03 9720 6333.
Color Coded Screw Terminals
ISO 9001 Certified Manufacturer
TURCK's line of uprox+ Factor 1 sensors now include IP69k-rated washdown versions with temperature ratings from -40 to 100°C. These sensors are designed to be highly resilient to the high-pressure cleaning agents often found in The sensors have been designed the food and beverage and pharmaceutical industo be resilient to high-pressure tries. cleaning agents. The sensors incorporate durable 316 stainless steel construction and a liquid crystal polymer front cap that aids in resisting moisture ingress. They also consist of a polypropylene cable jacket that stands up to harsh chemicals and extreme temperatures. The uprox+ sensors feature longer sensing ranges for detecting all metals, including non-ferrous metals such as stainless steel, at the same rated distance. These features are said to be especially useful in applications like food and beverage where the targets are often made from stainless steel. TURCK Australia 1300 132 566.
Robotic load/unload system MIDACO Corporation has introduced a new series of robotic part loading and unloading systems adaptable to most CNC lathes and vertical machining centres. Available with a variety of different robot brands, these units can load and unload one or two machines. Mounted on linear guides, the system can be moved out of the way when not in use to facilitate conven-
tional operation of the machine tool. Optional parts conveyors allow for maximum run time. A pushbutton lock pin accurately positions the unit in the run position. The company’s full line of pallet changers and machine tool accessories are US-made, available globally, and are thoroughly tested to provide reliable service. Midaco Corporation +1 847 593 8420.
®
NPA PTY LTD., 15/18-28 Gray St., Kilkenny 5009 South Australia Tel: (08) 8268-2733 • Fax: (08) 8268-1455 Web: www.npa.com.au • e-mail: info@npa.com.au
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SOLUTIONSNEW PRODUCTS
Metal drum storage products ACTISAFE has released a line of products aimed at solving metal drum storage. The range offers different options to suit different needs. The solutions are designed to lift the drum from the ground, plus they are designed for spill containment in the event that this may happen. Products in the range include metal sump pallets which have been developed to provide a robust and safe storage or turned into drums. Designed to contain at least 50% of the total volume stored or 100% of the largest container, whichever is greater, the pallets are available to store one, two or four 205L drums. Another product in the range is for enclosed drum storage, designed to
help prevent spillage of hazardous liquids. These are available in several sizes to store between one, two and four 205L steel drums. Bunded floor mats are also on offer, designed to give protection in areas where hazardous liquids are being used or moved. They are said to be ideal as a catchment facility for certain types of plant and machinery likely to allow the escape of cutting oils, lubricants and other industrial fluids. Completing the range is the Spilguard, designed to transform an ordinary 1200mm by 800mm pallet into a safety bund pallet to contain spillage and leaks safely and help protect the environment and workplace. Actisafe 1300 852 397.
PVC-free temperature sensor WITH its M3000 series, EPCOS has developed a temperature sensor with a PVC-free cable that contains no halogens, environmentally harmful plasticisers or stabilisers with heavy metals. This means no corrosive or toxic gases are released in the event of a fire, and little smoke is produced.
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In addition, no dioxins hazardous to health are formed at the end of its life cycle when the product is disposed of. The sensor is said to already meet future specifications for restricting environmental hazardous substances in household appliances. Ramelec Electronics 1300 309 150.
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SOLUTIONSNEW PRODUCTS
Compact checkweigher JL LENNARD has introduced the new generation VersaWeigh 300 Checkweigher, suitable for a broad range of food and pharmaceutical industry applications. The compact checkweigher, manufactured by Thermo Scientific, is said to be widely adaptable, serving a broad range of checkweighing applications from lightweight packages to packs up to 10kg. New features and benefits include Windows XP operating system with large, easy to read, colour touch screen operation and configurable security access levels; modularity allowing for upgrades without substantial reinvestment; sanitary design to better enable clean-in-place, with the open design allowing routine cleaning to be accomplished in less than five minutes; easy maintenance as most repairs can be completed within 30 minutes and no tools are required for belt replacement or replacement of most electronic modules; durable components with hightorque sealed brushless dc motors, stainless steel frame and electronics enclosure and conveyor beds, troublefree operation with minimal maintenance and; metal detection as the
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The checkweigher range includes models with package weight capacity from 1.510kg and motor power rating range 100400W.
VersaWeigh can be combined with Thermo Fisher Scientific metal detection systems.
JL Lennard 02 9475 9000.
Intelligent transmitters THE new M400 transmitter series from Mettler Toledo is described as a versatile and intelligent solution for advanced process control. It features advanced ISM (Intelligent Sensor Management) technology and covers pH /ORP, oxygen and conductivity measurements. Thanks to the mixed-mode input functionality, the unit accepts any conventional (analogue) or ISM sensor. Stable product quality, process safety and cost reduction are essential success factors for chemical, pharmaceutical or biotechnology companies. Intelligent systems for pH and oxygen sensors are said to reduce the maintenance cost and offer diagnostic tools that improve lifetime, performance and reliability of process analytical measurement technology. According to the company, the transmitter supports these industry demands and is equipped with advanced ISM functionalities such as Dynamic Lifetime Indicator, Adaptive Calibration Timer and Time to Maintenance Indicator. These diagnostic tools are said to enable true predictive maintenance,
The one unit can handle different parameters such as pH/ORP, oxygen or conductivity.
where the time to next calibration or sensor replacement is estimated in real time, based on dynamic process parameters and the current sensor condition. According to these real-time statements, the maintenance can be planned accordingly. The transmitter in combination with the iSense asset suite enables users of the ISM technology to apply new plantwide maintenance concepts with pre-calibrated sensors. Mettler-Toledo 1300 659 761.
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SOLUTIONSNEW PRODUCTS-Sensors & Analysers
Precision infrared calibrators HART Scientific, a division of Fluke Corporation, has announced the 4180 series of precision infrared calibrators. The new 4180 and 4181 infrared calibrators use special design technology to ensure ease of use and provide high accuracy through the use of target sizes recommended by thermometer manufacturers. The 4180 calibrator has a temperature range of –15°C to 120°C, with radiometric (non-contact infrared) display accuracy of ±0.4°C. The 4181 calibrator measures from 35°C to 500°C, with a radiometric display accuracy of ±0.35°C. According to the company, the calibrators have features to address quality issues not often covered by similar cali-
The calibrators use special design technology to provide high accuracy through the use of target sizes recommended by thermometer manufacturers.
brators, including emissivity and size of source effect. Fluke Australia 03 9329 0244.
Portable USB digital I/O device NATIONAL Instruments has announced the NI USB-6509, a bus-powered, portable, USB digital I/O device for acquiring data in a broad range of applications. With 96 bi-directional digital I/O channels and plug-and-play USB connectivity, the device is ideal for industrial control and automated test applications yet verThe I/O device is bus powered. satile enough for general-purpose data acquisition and academic applications. The device delivers, to a portable USB form factor, an industrial feature set of four high-reliability features for industrial or harsh applications previously available only in PCI and PXI systems. The industrial feature set includes programmable power-up states, digital I/O watchdog timers, change detection and programmable input filters. With programmable power-up states, engineers can pre-define the state in which the device powers up, ensuring consistent, reliable operation when connected to industrial actuators such as pumps, valves, motors or relays. Digital I/O watchdog timers can detect a variety of faults, such as a computer crash, and automatically respond by setting the outputs to a user-defined safe state. National Instruments 1800 300 800.
Pulley torque transducer INTERFACE has announced the new Model T22 pulley torque transducer. Available in capacities from 20 to 5000Nm, the transducer can be ordered with bore sizes to fit drive shafts with either DIN 6885.1 or SAE keys. A central fixing screw holds the sensor to the end of the shaft while the pulley mounts directly to the torque sensor. Features of the transducer include high-level ±5V output, 12-28V dc supply, high resistance to radial forces, 2X safe overload and ±0.1% combined error. The contactless digital design offers high 16-bit resolution and low noise. Options include ±10V output and a +5V TTL speed signal. AMS Instrumentation 03 9017 8225. www.manmonthly.com.au
Press controller TO complement its new PRAXXIS position controllers, Jemtech has launched a press depth control application. Applications for systems are loaded into the hardware keyboard and count controller modules and represent a complete application-specific machinery control solution. The controller application requires no further programming and is a fully tested and documented system. It provides up to 30 programs, each with an upper and lower press position and a number of repeats at this position. The controller also controls press slowdown at a programmed position above the bottom or the material, depending upon the mode of operation. The depth controller also works with press safety systems, by providing light curtain mute positioning and mute test signals. Jemtech 02 4227 6047. MANUFACTURERS’ MONTHLY
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SOLUTIONSCOMPRESSORS & PNEUMATICS
Blowing off inefficient compressor systems Waste not, want not: new design technologies are helping manufacturers eliminate excessive air usage in compressed air systems, with some remarkable results. Katherine Crichton reports. DESPITE the fact approximately 10% of power consumption in Australia is used for compressing air, eliminating excess air usage has only recently become a top priority for governments and industry. Driven by the threat of climate change, diminishing natural resources and increases in fuel and energy prices, air compressor systems manufacturers are constantly looking for ways to increase energy efficiency and reduce costs. While variable speed drive (VSD) technology is not a new concept, continuous development of power electronics has meant that VSD technology is becoming more accepted in the market place. According to Nick Iser, product manager – oil free air division with Atlas Copco, using speed control to regulate the capacity of a compressor enables more precise delivery of the required amount of air for a system. “This can lead to average savings of 20%,” Iser told Manufacturers’ Monthly. “Traditional systems need to unload or blow off air as there is only a limited choice of how much air they can deliver, while VSD air technology can match the exact system requirements and therefore minimise wastage in power consumption. “Additional compression stages can increase the theoretical efficiency of a compressor, however we need to look beyond the screw element and look at the efficiency of the package as a whole and take into account the additional pressure drops and frictional losses. “The overall efficiency of a com-
pressor package is commonly published as the electrical power required to operate the compressor package divided by the FAD flowrate. “This is the equivalent of a car's fuel consumption figure (L/100km) and provides a comparison between compressors. “In addition to the increased capital cost of adding compression stages, increased maintenance costs such as overhauls need to be factored in to the Life Cycle Costs (LCC)."
wastage, air leaks, pressure drops and blow offs, with around 80% of the LCC of compressors calculated by energy consumption. “Other flow on effects include low starting currents, reduced mechanical shocks during starting and lower average speeds of the bearings. “It is important to ensure the technology is implemented to improve reliability and efficiency and not just for the sake of putting in the technology.” Iser says VSD technology can also
Air audits are not so much devices used to save energy, but rather a means to measure inefficiencies in pre-existing systems.
Iser advises that VSD technology can come at an initial capital price premium compared to traditional fixed speed systems, but says ROI can be within 12 months depending on the application. “The capital cost of the system is far outweighed by the benefits. “Customers only pay for what they use and VSD technology can minimise
be used with significant benefits in other areas of compressor operation. “While VSD technology has been traditionally used to vary the speed of the compressor drive motor, recent developments have led us to also include variable speed cooling air fans in some of our compressor models. Iser believes as the price of energy
increases VSD technology will be more widely used. “Certainly anywhere the price of energy is very high, such in Europe and the Pacific Islands where they generate their own power, the ratio of VSD compressors to non-VSD compressors is relatively high.
Getting air One of the biggest inefficiencies in any air compression system is air leakage, which David Green, GM - sales & marketing at CAPS Australia says was once totally underestimated by industry. “A 5mm hole in a pipe, with a system running at 7 bar and 100psi results in significant air loss, Green explained. “Anything up to 30% of air leakage comes from the pipe system. This could equate to a compressor running fully loaded just to accommodate pipe leaks.” Green says regular air audits are vital for any company wanting to reduce their energy consumption. “Air audits are not so much devices used to save energy, but rather a means to measure inefficiencies in preexisting systems. “What a full air audit can achieve is a thorough assessment of system efficiency. Even with a brand new system you should allow for 5% air consumption through the pipe system and this figure increases as the compressor gets older,” he said. Green says there is a distinct trend towards incorporating air audits in any companies’ regular maintenance routine, irrespective of size. continued on page 42
HIGH ACCURACY AND REPEATABILITY With
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PIES Australia Pty Ltd, Ph. 03 9303 2060, Fax 03 9303 2099 email: sales@piesau.com.au www.piesau.com.au
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Introducing the amazing new GA 90+ –160+ Air Compressor Packages Beyond a superior screw element
Outpace the competition Regardless of your field, staying ahead means having an edge over your competitors. In the same way, an efficient and reliable compressed air supply for your manufacturing facilities is a key element in successful business operations. A superior screw element, unrivalled reliability at temperatures of up to 55˚C (131˚F), 3.5 to 14 bar(e) pressure range {51-200 psig} and optional integrated air treatment equipment make the new GA range your ticket to a gold medal. With the highest compressor package efficiency on the market, Variable Speed Drive (VSD) and Full Feature variants, you will always outpace the competition. Committed to your superior productivity.
For more information 1800 023 469 ausairinfo@au.atlascopco.com www.atlascopco.com.au
SOLUTIONSCOMPRESSORS & PNEUMATICS continued frrom page 40 “The industry has gone from having basic air audits only performed in large companies 5-10 years ago, to an increasing number of businesses investing in complete air system audits.” Green largely attributes this trend to customer demand – not only motivated by a need to save money, but to also reduce their impact on the environment. “The type of companies performing air audits is also changing. “Traditionally only carried out by independent bodies, advances in air testing equipment is not only allowing a more accurate assessment of the compressor system but this now can be done by the manufacturer of the equipment,” Green told Manufacturers’ Monthly. “Users can now get a comprehensive audit of air quality produced in the system showing what it should be producing. You can get a full energy consumption profile, simulate what the energy consumption will be with an alternative compressed air system and also get an extremely good view of actual air quality.” The ability to be able to simulate air compressor efficiency in particular applications is a valuable tool in the quest towards eliminating excessive air
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usage as Green explains. “We recently evaluated an existing compressed air system which was running three shifts, 24 hours a day. After examining the results we decided to implement a two stage compressor with a purchase price in the region of $80,000 to replace the existing single stage compressor, which was still working quite well, and the customer is looking at savings of around $30,000 a year with an immediate payback in three years. “There was nothing wrong with the initial system but there were many benefits of changing it to a two stage compressed air system,” Green said. “For plants that have an old inefficient system the savings could be significantly larger,” he added. “A complete air audit can give companies a visual representation of what’s happening with their compressed air system. Green says to get the best results, an air audit should occur over one to two weeks rather than just one day, “so compressor users can get a full picture of their system performance and have all the information they need to gain maximum energy efficiency in their compressor”. Atlas Copco 1800 023 469. CAPS Australia 1800 800 878.
Cabinet coolers for tight spaces EXAIR's new side mount kits make the mounting of a NEMA 12 cabinet cooler possible when an electrical enclosure has limited space on the top or side. The compact cabinet cooler is a low cost way to purge and cool electrical control panels, protecting sensitive electronics from heat, dirt and moisture. Cabinet coolers convert an ordinary supply of compressed air to -7°C (20°F) without refrigerants or CFCs. The cold air is circulated through the enclosure to eliminate high temperature malfunction. Cooling capacities up to 5,600 Btu/hr. are available. The systems include a compressed air filter to assure no moisture or dust is introduced inside the panel. Optional thermostat control minimises compressed air use. The coolers are UL listed and have no moving parts to wear out. The side mount kits maintain the NEMA 12 rating of large and small electrical enclosures. Models for use on NEMA 4 and 4X enclosures are also available. Applications include cooling PLCs, microprocessors, variable frequency
The cools have been designed to be a low cost way to purge and cool electrical control panels.
drives, industrial computers, and robotics. Compressed Air Australia 1300 787 688.
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SOLUTIONSCOMPRESSORS & PNEUMATICS
Steel ducting accessories EXIMO has launched a range of accessories for its 2mm-gauge solid ducting line, Speedlock 2. New accessories include standard lock rings, lever lock rings, wide lock rings, flexible hose spigots, flanges, hanging brackets and bracket legs, worm drive clamps, duct end seals and weld ends. In addition, there is also a new range of straight pieces; bends at 90°, 60°, 45°, 30°, 15° and 7.5°; telescopic pieces which can be put into ductwork to eliminate cutting and beading; branch pieces, T-pieces, Y-pieces; reducing cones; and blast gates (manual and pneumatic). The solid ducting line is designed to be a high strength 2mm-thick ducting product for most industrial applications where durability, applicability and availability are key requirements. Provided in diameters ranging from 100mm to 1000mm, this new concept in industrial ducting, which is hot dipped galvanised for extra wear and durability, also works in conjunction with company's Speedlock 'quick lock' system. The ducting is a fully-welded galvanised steel ducting system which can
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donaldsonfilters.com.au
INTELLIGENT & ENERGY EFFICIENT
The New Ultrafilter Compressed Air Filter New Design Developed for high efficiency and economic filtration, the flow optimized design guarantees minimum pressure loss while the innovative, filtration technology ensures high separation efficiency. New Flexibility All filters can be used either as coalescence filters or as particulate filters – easy switch over in seconds! Easy to use, simple to mount and designed to fit even the smallest spaces. With the combination of UFM-TT electronic condensate drain, Ultrafilter offers a flexible integrated, system solution. EEconomizer i andd UFM l
Quality Air Refrigeration Compressed Air Dryers Accessories include a range of standard lock rings, lever lock rings, wide lock rings, flexible hose spigots, flanges and weld ends.
be bought off-the-shelf or ordered and delivered within four weeks. According to the company, the product line is suitable to all industries where ducting is exposed to high flow rates and constant use, as well as in areas where the working environment can severely test the durability of a ducting system. Eximo 02 9757 1233.
Working for the environment inside and outside your business. Provides consistent, quality, compressed air. Energy efficient. Ozone safe. Low global warming potential. Two different types of heat exchangers. The Euros CQ 00220 A up to CQ 0125 A dryers are equipped with a stainless steel plate type heat exchanger while the Euros CQ 0150 AE to CQ 0850 AE dryers are equipped with an aluminium plate type heat exchanger. The key advantages of the Euros dryer include: as standard, DDewpoint i iindicator di d Level-controlled drain “float drain”, Energy saving controller from size CQ 0150 AE as standard, One component refrigerant R-134a, Lightweight and compact, Easy to install and Service friendly.
Unit 29, 41-49 Norcal Road Nunawading VIC 3131. Ph (03) 9874 2600 Fax (03) 9874 2611
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Dust control unit for industrial workplaces TWO strong brands in the air quality sector have been brought together in a strategic partnership providing industry with solutions to dust problems in the industrial workplace. Eximo has released its new Unimaster dust control unit based on the technical expertise of dust handling company Donaldson Australasia. The dust control unit is said to be an economical and effective solution for the diverse range of nuisance dust problems encountered during industrial processes. Contaminated air from the dust generation source is drawn through the inlet to the filter by the fan. Initially some pre-separation takes place as heavier dust particles lose momentum and fall into the collection bin or hopper. Finer dusts are carried up to the filter elements where they are retained on the surface of the filter fabric. The cleaned air passes through the filter fabric into the fan chamber and is discharged back to atmosphere. For cleaning, when the fan is
The dust control unit can be configured to suit over 500 combinations.
switched off the filter fabric cleaning cycle is automatically activated. The dust is dislodged from the filter elements by the oscillating motion of the shaker motor, and falls into the collection bin below. The company says the unit is an ideal dust collector for intermit-
tent operations in plant processes. Several small self-contained units can be placed at the points of dust generation. This integrated concept brings many benefits including lower capital cost: lower operating and energy costs, simplified maintenance, plant flexibility, and minimisation of safety hazards. With over 500 combinations and numerous ancillaries, the unit incorporates compact technology which uses a flat envelope shaped, multipad filter to provide maximum fabric area for minimum floor space. Additional features include a range of filter fabrics designed to suit any application; advanced fan design results in reduced noise levels. Its controller makes it easy to install/connect and ensures the filtration efficiency is properly maintained. The unit range can be fitted with an array of accessories including acoustic diffuser, filtration media, static earthing and explosion relief. Eximo 02 9757 1233.
Safety air nozzles COMPRESSED air safety has now been joined by energy efficiency with the new Silvent compressed air blowing nozzle range. The company is said to have patented the first lownoise blowing nozzle in the late seventies. In many industries, compressed air is installed through an open pipe, leading to excessive noise, waste of expensive compressed air and a hazardous working environment. The nozzles combine high blowing force with low energy usage and low noise level. According to the company, replacing compressed air usage through open pipe systems with the nozzles will provide a reduction of air usage by at least 30% and a safer working environment as it decreases sound levels by 50%. Spray Nozzle Engineering 03 9583 2368.
The nozzles combine high blowing force with low energy usage and low noise level.
Industrial ventilation range WITH increasing pressure in work sites for worker safety and comfort, Hurll Nu-Way is now offering the Patterson Fan range of commercial and industrial ventilation products. The company offers these industrial and commercial high velocity fan units which are said to generate 2-3 times greater air flow than typical pedestal or cage fans, creating a cooler air flow, with breeze conditions. The high velocity range consists of large fans which are ready to install. Models may be bracket mounted to walls or columns, chain suspended or 44
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fitted to a portable trolley. High volume low speed roof-mounted fans are also available to provide air movement in large warehouse or hangar applications. The new fan products are said to offer high performance and reliability and may be used for a wide range of applications. Used as part of a tailored air movement solution, the fans can reduce high temperatures, improve productivity and cool workplaces and people. Hurll Nu-Way 1300 555 380. www.manmonthly.com.au
SOLUTIONSCOMPRESSORS & PNEUMATICS
2-stage VSD compressor INGERSOLL-Rand has released a 2stage variable speed drive (VSD) rotary screw compressor to deliver greater efficiency and reduce associated running costs when compared with a single stage compressor. To achieve peak efficiency and reduce operating costs, the 2-stage VSD uses two compression stages. In the first stage the rotor uses a profile for high displacement and a discharge at relatively low pressure. The second stage profile achieves compression to final package pressure. The two stages are said to require the use of less energy to compress a given volume of air when compared to a single stage compressor. Combined with the compressor's hybrid permanent magnet (HPM) synchronous motor technology, this allows the system to run at 95% operating efficiency throughout its entire speed range. The motor is controlled by variable speed inverters which match compressor output to demand at all times. It is designed to produce the most air using the least amounts of energy - and continues to do this down to loads as low as 20%.
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The motor is controlled by variable speed inverters which match compressor output.
The company says it also features an inherent leak-free design. The cast iron separator tank joins the airend using an integral, single-point connection. Designed to be easy to maintain, the compressor’s HPM motor houses fewer parts than conventional motors so that any necessary repairs are low on cost, and can be completed within hours, not days. In addition, as the HPM directly drives the compressor on magnetic field principles, there are no gears. CAPS Australia 1300 858 763.
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Clearing the air on ‘MEPS2’ compressors BY PAUL FRY
THE latest revision to the MEPS scheme has raised the benchmark of electric motor efficiency in Australia. The onus is now on the compressedair industry to ensure ‘MEPS2’-compliance, and to leverage the resultant energy savings from improved motor efficiencies. In an era when efficient use of energy resources is in the spotlight, businesses, governments and communities everywhere are being called upon to find new ways to cut energy usage. Nowhere is this more apparent than in the compressed-air industry approximately 10% of power is used in this country is used in compressing air. In such a power-intensive operation, the effect of even a small efficiency gain is magnified when applied across the whole industry. A case-in-point is the use of more efficient electric motors in compressedair systems. ‘Minimum Energy Performance Standards’ (MEPS) have governed the use of electric motors in Australia since the Australian Greenhouse Office (AGO) introduced the system in 2001. In April 2006, however, the mandatory standards were revised upwards. A more stringent set of requirements, known as ‘MEPS 2006’ or ‘MEPS2’, was published and came into force. For the compressed-air industry, the legislation covers three-phase electric motors from 0.73kW up to, but not including, 185kW. The requirements of this legislation,
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The simplest way to adhere to MEPS2 is to build-in compliance from scratch.
covering both imported and locally manufactured motors, are set out in the Australian standard, AS/NZS 1359.5-2005 Rotating electrical machines which defines two levels of efficiency for electric motors: the base MEPS level performance and a ‘highefficiency’ level.
MEPS compliance According to Champion Compressors engineering manager, Andrew Fraser,
the onus is on motor and equipment importers to ensure that their products conform to Australian MEPS2 requirements. Further, each motor must be registered in an online database, in accordance with AGO procedures. “While the system relies on self-regulation by the industry, compliance is mandatory,” Fraser said. “The AGO has the right to stop the sale of a product if it is found to be
non-compliant.” A consequence of this is a degree of risk for suppliers of equipment incorporating electric motors, if they cannot show that the packaged motor is compliant. While the responsibility for compliance rests with the motor supplier, manufacturer’s representative or motor importer, it is in end-users interest to know that their equipment is MEPS2compliant. Fraser says that overseas standards are not identical to Australia’s MEPS2 system. It cannot be assumed that motors complying to the European Committee of Manufacturers of Electrical Machines and Power Electronics (CEMEP) or the US Energy Policy Act (EPAct) can be used legally in Australia. Importers of air compressors therefore need to ensure that the overseasbuilt machines conform to the Australian standards. Similarly, importers need to ensure that electric motors integrated into other equipment, but capable of being used in ‘stand-alone’ mode, are also compliant, and have been properly registered for use in this country. For compressor manufacturers and importers, the simplest way to adhere to the MEPS2 requirements is to buildin compliance from scratch. According to Fraser, design changes in typical motors, introduced to achieve higher efficiencies, have resulted in generally reduced starting torques, and in some cases, larger frame sizes. The need for larger frames is due to the larger volume of active material
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SOLUTIONSCOMPRESSORS & PNEUMATICS required to achieve the efficiency levels required. The larger motors can be dealt with in a number of ways, depending on the compressor design philosophy. As with any new development, the technology behind the improved electrical motors does have a cost impact. However, the higher capital expenditure is compensated for by the power savings and lower compressor life time operating costs. Fraser points out that the payback period may vary, depending on the extent of use of the compressor. “An operator that only uses the compressor occasionally, or on light load cycles, faces a much longer payback period than an operator using the machine more often, or on heavier demands,” he said.
Beyond MEPS Fraser says the efficiency improvement for MEPS2-compliant motors used in compressors is generally slightly less than 1%, which corresponds approximately a 10 to 20% reduction in internal motor losses. While this improvement may sound small, over the life of the compressor, the energy and cost savings become significant. Similarly, provided all compressor
manufacturers supply equipment incorporating MEPS2-compliant motors--and by law, this should be the case--the impact across the industry becomes even more significant. In the continuing drive to improve energy efficiencies and reduce operating costs, there is incentive to go beyond the mandatory requirements of MEPS2, and introduce additional measures wherever possible. According to Fraser, innovations in compressor design provide for additional efficiency gains. “While Champion recognises the importance of MEPS compliance, we also understand that the motor is not the only source of efficiency gains. “By thoughtful compressor design, significantly larger efficiency improvements are possible,” he said. For Australia to reap the full benefits, the obligation is now with the compressed-air industry to adhere to the policy of MEPS self regulation. “For MEPS to be truly successful in the compressed-air industry, the electric motors used in the compressors must be both MEPS2 compliant and registered in the AGO’s online database,” Fraser said. “It is up to the industry to take on this responsibility.”
Air knife for wide surfaces The air knife directs the compressed air across a precise machine surface said to ensure uniformity and low noise. The compact 45mm x 37mm profile along with inlets on each end and the bottom permits easy mounting in tight spaces. The knife is designed to be maintenance free and has no moving parts. Compressed Air Australia 1300 787 688.
EXAIR's new 54" (1372mm) Super Air Knife produces a laminar sheet of airflow to blow-off, dry or cool wide surfaces. Suitable for parts, webs and conveyors, the energy efficient design minimises compressed air use by entraining 40 parts room air to one part compressed air. At 80psig, the sound level is at 77dBA.
AeroGo SYSTEMS AeroGo Air Floatation Equipment uses a variety of Aero-Casters to float heavy equipment and assemblies on a frictionless film of escaping air. When ‘push comes to shove’, Aero-Casters provide a clean, quiet and safe alternative to rollers, skates and rails, and is guaranteed not to damage floors.
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3/7 Clearview Place (PO Box 419) BROOKVALE NSW 2100 Tel: 02 9939-6199 Fax: 02 9938-5972 Email: sales@ahs.com.au Email: Airandhydraulics@msn.com.au Website: www.ahs.com.au
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SOLUTIONSCUTTING TOOLS & MACHINING TECHNIQUES
Sustainable cutting fluids Recently biodegradable lubricants have been pushed as the clean alternative to traditional products, but this ‘green’ solution may have problems of its own. Katherine Crichton reports. WITH the awareness that climate change is not going away, many companies are working hard to reduce their impact on the environment and improve their green image. While there are many ways businesses can minimise their carbon footprint, since being green has become en vogue, there’s been a flood of products and solutions to hit the market claiming to be the answer to this problem. It can be confusing to know which are ‘the real deal’ and what is just part of the green wash, and this is never more so the case than when it comes to cutting tool lubricants and coolants for metalworking applications. Biodegradable lubricants and coolants, for example, have been offered as a viable alternative to petroleum and chemical based products and often deliver the same benefits but can, contrary to popular belief, also encounter some of the same issues. The idea behind biodegradable lubricants is that they are derived from natural renewable sources (usually vegetable based) and are formulated in such a way to as to eventually break down after use for easy disposal. In machining situations however, cross contamination between the different machining lubricants can occur, often rendering biodegradable lubricants as chemical waste. Geoff Mahoney, technical manager with ITW Polymers and Fluids, says while many manufacturers want to use more environmentally friendly products in their operations, depending on the application, using biodegradable lubricants can be a false economy. “Because there are often other fluids involved in the machining process such as gearbox oils, hydraulic oils and mill
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fungal degradation. “Manufacturers want a fluid that will last longer in their machines, reduce the downtime required to change the fluid, and which will not corrode the equipment or workpiece they are machining. “A good quality, extreme pressure cutting fluid that provides effective cooling and lubrication can achieve this,” he said.
Less is more
Lubricants can now be recycled rather than thrown away.
oils from the workpeice itself, biodegradable coolants can quickly be contaminated by these fugitive oils. “This means the biodegradable lubricant can no longer be disposed of in sewage treatment plants or released into the environment in a controlled manner, so people expecting it to be disposed of less expensively as other lubricants often find this is not the case,” he told
Manufacturers’ Monthly. However the recent trend for formulators to develop ‘bio balanced or bio stable’ lubricants and coolants which are designed to last longer, means that solutions can now be recycled rather than disposed of in landfill etc. Mahoney says with bacterial growth one of the main causes of reduced cutting fluid life, these solutions allow improved resistance to bacterial and
Regardless of what solution is used in cutting fluids, there is no doubt that using less coolant is infinitely better not only economically but environmentally as well. Robert Resch, MD of ProTUBE says bio-balanced machining coolant (cutting tool) formulations are enabling a lower consumption of fluids in machining and cutting operations. “The emulsion droplet size does not change substantially over time, which provides a number of benefits including maximum coolant flow at the cutting edge for efficient cooling and extended tool life. “Excellent coolant run-off capabilities avoids deposition of sticky residues on CNC machine windows, fixtures and components, and draining of coolant in chip disposal systems also reduces consumption,” he said. According to Resch, bio-balanced coolants are healthier, safer and last longer with extremely good performance levels. “Because the fluids are designed to have a low pH value (8.6-9.0), they cause less skin irritation and are less aggressive to materials susceptible to attack by alkaline solutions. continued on page 50
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SOLUTIONSCUTTING TOOLS & MACHINING TECHNIQUES
Chip-breaking tap for threads up to 3.5 x D of chips and with a flank which has an outstanding surface quality. It is also possible to use the tool for short-chipping materials such as grey cast iron. Besides the chip-breaking properties, the short thread section with the patented TiN-coated chamfer with additional steam treatment also contributes to prevent cold welding in soft materials. For these reasons the
LONG-chipping materials such as construction steels, mild steel and similar materials, can soon become a problem when cutting threads in blind holes. Very often the long chips cause bird nesting and this leads to oversize tapping or the risk of tool breakage. Walter Australia has offered a new remedy for this problem, the Paradur Short Chip soft.
The tool is said to be well-suited to automated production operations.
The new HSS-E tap from Prototyp is designed for tapping threads up to 3.5 x D in long-chipping materials with a maximum strength of about Rm = 850 N/mm2. A special chamfer geometry and a small helix angle make optimum chip breaking possible in soft materials. The short chips are flushed out of the thread by the axial internal coolant. The internal threads are free
tool is said to be well-suited to automated production operations. It is also possible to use the taps for rigid tapping, with compensation chucks or self-reversing tapping attachments. The new taps are available in the main dimensions: metric threads M5 M20 and metric fine threads M8x1 to M16x1.5. Walter Australia 03 8793 1000.
continued from page 48 “Therefore, little or no staining on aluminium and little or no attack on painted surfaces. The pH level never needs to be increased as with some solutions to slow bacteria growth,” he said. Recycling is also made easier because of the unique formulation of the solution. “Due to demulsifying properties of less than 1%; a very small amount
(less than 1%) of tramp oil emulsifies in the coolant. The tramp oil easily separates from the coolant and may be skimmed off.” “Synthetic ester based cutting oils are providing high cutting performance at an economical cost, saving tool life and providing higher productivity as heavier cuts are possible than with mineral oils or soluble coolant,” he said. Advances in cutting tool and
Micro-fluidisation system THE Unist Coolubricator system is a standard off-the-shelf system that can be configured and integrated according to specification. The systems are designed primarily for the application of high efficiency lubricants and will dispense almost any viscosity lubricant and deliver it with precision and reliability. They are completely self-contained, positive displacement spray systems. The user supplies an air source to the system. A variable rate pulse generator allows for automatic, infinite repeat cycling of the lubricant pump from a single air source. Atomising air flow is controlled with an air metering screw which determines the density and distance of the spray. Liquid volume output is adjusted with the knob on each metering pump, allowing an output of .003 -.03ml per stroke for standard ‘onedrop’ pumps.
The system comprises a variable rate pulse generator delivering automatic, infinite repeat cycling of the lubricant pump from a single air source.
Output frequency for pump actuation is controlled by a pneumatically operated pulse generator at a rate of 5200 pulses/min. The system can be wired to the machine signal so that the desired rate of output is only delivered when the machine is operating, or performing a certain function. Unist Australia 02 8850 2022.
Thru-the-tool fluidisation THE Tornado system is a high velocity, thru-the-tool system for fixed machine tools using coolant inducers with high efficiency lubricants. It is said to be unique in that it permits nearly unrestricted air flow and minimum pressure drop to the cutting tool. To turn the unit on and off the air supply must be interrupted by either a ball valve, solenoid valve, or air pilot valve.
The unit dispenses lubricant at the rate of 0.2 to 1.0 drops per cycle with 5200 cycles per minute.This produces a total range of output of 1-200 drops/minute (.033cc to 6.67cc per minute). Threaded tool connection allows for direct connection to a coolant inducer or the addition of a quick connect socket. Unist Australia 02 8850 2022.
machining techniques and developments in cutting tool materials such as the introduction of ceramic tips in cutting tools, are said to reduce the need for cutting fluids altogether, though both Mahoney and Resch do see a need for lubricants in the future. “To get a good finish on the end product, the use of a cutting fluid can help to prevent metal build-up or damage to the surface of the workpiece, giving a better quality finish,”
Mahoney said. Both men also say there is a place for biodegradable lubricants in manufacturing operations particularly in situations where they can be pumped directly onto equipment and can be lost directly to the environment after use, such as in mining or railway applications. ITW Polymers & Fluids 02 9757 8800. ProTUBE Asia 08 8363 1311.
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SOLUTIONSCUTTING TOOLS & MACHINING TECHNIQUES
Cutting fluid for hard metals
Machine shop quoting software
THE Tap Magic range of cutting fluids, available from Specialty Tooling, has been expanded with the introduction of Tap Magic Xtra-thick. According to the company, the Xtra-thick version is the extreme performance heavyweight champion for hard metals and is highly effective on inconel, titanium, stainless steel or any metal up to 45 rockwell hardness. The cutting fluid has been designed to stay with the tool especially for big, deep hole cuts and virtually eliminates work hardening. The clinging action makes it appropriate for lathe and mill work because the fluid isn't prone to sling off. Tap Magic Xtra-thick is an addition to the Tap Magic EP-XTRA formula and Tap Magic aluminium range of cutting fluids. Tap Magic fluids are available in a range of pack sizes including 120ml and 472ml spout top cans, 354g aerosol cans, and 5L and 25L bulk plastic container supplies. Precision Specialty Tooling 03 9416 7077.
A NEW software program called QuoteCam has been released which easily allows a business owner to see exactly the real cost of manufacture, and to know precisely how much profit will be generated. The program works on a strictly cost basis and all the data entered refers to the cost of doing business such as machine rates, labour rates, materials purchases, etc. Incorporated in the software program is a range of features including the Work Centre Rates calculator. The calculator takes all aspects of machine tool costs, such as finance charges, running costs, future value and maintenance charges, into account, even machines bought with cash or those purchased through a financing arrangement. It has a sophisticated but very easy to use Overhead Burden rate calculator which correlates the overhead costs down to a simple hourly rate which is automatically included in the cost when quoting. The software program also offers a large range of machine process simulators for milling, turning,
The extra thick cutting fluid is ideal for any metal up to 45 rockwell hardness.
etc., which accurately predicts exactly how long the machining will take. It does this with the help of a large library of built in material types complete with feed and speed information and the user simply answers a few basic questions and gets realistic answers immediately. Additional features include a sales price analyser in the form of a simple graph. The graph visually displays the cost of each component in a batch and displays the cost per par and per batch. It also calculates the selling price based on the expected profit margin or mark-up. The company says one of the most useful features of the program is the fact it allows users to perform ‘what if’ scenarios. For example, it will instantly recalculate the entire batch costs if the batch size is changed, so if the quote is for 100 pieces but the subsequent order is for only 50 pieces, the software will give a new selling price instantly that preserves the initial margin requirements. CIM Solutions 02 8824 9095.
ProTUBE
www.protube.com.au
Profile Cutting Systems
Kaltenbach The FULL RANGE of circular and band sawing machines, structural steel processing MACHINES and SPARES available from ProTUBE. PCS Heavy Duty Gas/Plasma High speed Profile Cutting Machine
PCS Fineline with Innerlogic High Density Plasma Cutting System
For details and demonstration machinery please contact us at 08 8363 1311.
We also provide: • • • • • •
Motorised Gas Cutting Torch Lifter with Auto Ignition
Optional Drilling System
Telephone: (03) 9305 2555 • www.profilecuttingsystems.com
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Sawblades/saw bands Coolant Tooling MMKS units and lubricants Service and back-up Shotblasting and painting
PO Box 457, Kent Town SA 5071 Australia Tel: +61 8 8363 1311 Fax: +61 8 8363 7922 Email: info@protube.com.au Brisbane: Colin 0414 820 437 • Melbourne: Roger 0407 608 577 Sydney: Steve 0411 632 607 • Adelaide: Robert 0414 451 513
MANUFACTURERS’ MONTHLY
Quality Certified AU881-QC ISO 9001:2000
Environmentally Certified AU881-EC ISO14001:2004
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SOLUTIONSWATER MANAGEMENT
Being water-wise is good business Despite being one of the driest continents in the world, Australians are among the biggest users of water globally. However local manufacturers are reversing this trend. Katherine Crichton looks at how. AUSTRALIA has one of the lowest rates of rainfall of all the continents, and while two thirds of all the people on earth use less than 60L of water a day, the average Australian uses more than twice that amount during a single shower. Unfortunately this casual attitude to water consumption also extends to Australia’s commercial sector, but with rapidly increasing water costs draining profits, companies are looking at innovative ways of reducing the consumption and cost of mains water in their operations. A case in point is Melbourne-based water pump and pressure system manufacturer, Davey Water Products. In 2006, the company installed a rainwater capture system as a demonstration project at its pumps production plant in Scoresby, and in 2008, is literally reaping the rewards, both environmentally and financially. Max Ekins, Davey Water Product’s market manager - water conservation and treatment, told Manufacturers’ Monthly while the company had long been enjoying market success with its water conservation products, they came to the realisation they needed to improve the company’s own water management practices. “We believe in ‘walking the talk’ and after identifying a number of high water consumption processes in our new manufacturing plant, we initiated one of the first commercial rainwater
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harvesting projects on our own roof, not only to reduce our own consumption but to demonstrate the potential for this approach in an industrial setting,” he explained. “We had all the necessary equipment, so it was basically a matter of retrofitting our guttering to a syphonic drainage system and then storing the water run-off from the plant’s 2,500m2 in three 45,000L above ground rainwater tanks for delivery to the paint line using the company’s new HM series multi-stage electric pump set,” he said. After simple filtration, the rain water is also used in the factory and adjoining office area for non-mains water needs such as toilet flushing Rainbank automatic controllers at each use point automatically switch the supply back to mains water should there be insufficient rain water in storage. “As a result, we have reduced potable water use by 50% or one million litres per year.” Ekins believes there are many drivers for companies to invest in this kind of technology, especially for inner city companies with large commercial usage of water and the company has also been working with the Queensland Water Authority to write regulations for rainwater harvesting and in January this year, the practice was mandated in all new commercial properties.
Local companies are enjoying the flow on effects of implementing a structured water management program.
“Without a doubt water prices are going to rise in the future, so rainwater harvesting is a way of future-proofing your business, particularly if you are a high water user.”
Tapping into water savings Queenland's iconic Buderim Ginger factory at Yandina on the Sunshine Coast produces quality confectionary ginger products with a capacity to process in excess of 6,000t of raw ginger each year. The company’s core objectives in establishing water and energy saving technology at the facility was to lessen
the impact that ginger processing and production had on the local region’s natural resources. Harvested ginger is held in preservation vats until is it ready to be processed. The ginger is preserved in a brine solution of town water and sodium metabisulphite. Sulphite is an oxygen scavenger that removes all bacteria, bleaches the ginger and softens the rhizome. To ensure the end product is of the highest quality, all sulphite is then removed from the ginger rhizomes. In the past, this cleansing was done using copious quantities of hot water,
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SOLUTIONSWATER MANAGEMENT Underground Water Tank all of which was dumped into the sewer drain. Buderim Ginger Chief Executive Gerard O’Brien said a major consideration for the company was to ensure that the implementation of any new methods of water and energy usage did not slow the process of ginger production down and therefore have a negative financial impact on the business. “Over a six year period we trialled several new technologies and after further investigation, decided that Ozone technology would be a suitable oxidant to remove sulphite and impurities in the re-used water,” O’Brien explained. With the support of the Queensland Government’s $55m Business Water Efficiency Program (BWEP), which provided almost $90,000 in funding to assist Buderim Ginger install the technology, a sulphite stripping system was designed to reuse flushing water from ginger and return it to a central storage system. The storage system holds approximately 300,000L and is continuously ozonated to remove the sulphite. An additional chlorine dioxide dosing unit controls bacteria levels. Water is circulated through the system from the storage tanks to syruping
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and returned via six pumps. Each syruping chain has a supply and return line with recycled water available to all 63 processing tanks. “As well as significant water savings of over 25.6 million litres a year, we are also experiencing massively reduced operating costs as this technology allows us to recover the heat from the water used in the flushing process, eliminating excessive use of energy,” he said. “Because this is a highly efficient method of removing sulphate from processing water, the heat exchanger takes already-used hot water from the factory and uses it to heat the ozonated cool water coming into the factory, saving 22 million litres of water per annum and a reduction in energy usage of approximately 20%,” he said. The Queensland-based ginger producer is not only enjoying a reduction of more than 50% in town water usage but is revelling in the clean corporate image this project has provided. “Our green efforts are good for business, resulting in significant bottom line results, and we have set a new global benchmark for water efficiency in the ginger industry,” he said. Buderim Ginger 1800 067 686. Davey Water Products 1300 367 866.
Rotamould half tool Cast in Aluminium weighing 260kgs Complex castings for the Plastic Industry is our specialty
TP CASTINGS PTY LTD Tel: (03) 9768 3255 • Fax: (03) 9768 3575 www.tpcastings.com.au Aluminium and Bronze Casting Specialists
MANUFACTURERS’ MONTHLY
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SOLUTIONSMATERIALS HANDLING
Smart conveyors go online The concept of modularised ‘Meccano like’ conveyor systems is not a new one, but the move to online configuration is. Katherine Crichton reports. THEY are the ideal partner in any working situation: strong, dependable, smart and sensitive, and now anyone with internet access can get one delivered straight to their door. Built to order custom designed and manufactured conveyor systems are just one of the latest trends in a number of innovations materials handling manufacturers are developing in order to address increasing ‘just in time’ market demands. According to Jurgen Mennel, GM of Robotunits Australia, this ability to offer customers a conveyor system exactly how they want it not only has significant cost savings associated with it but also leads to a stronger more robust conveyor design. “With the availability of standard conveyor components, we are seeing much better engineering of systems as there is more time spent designing a product you can reuse rather than worrying about the time it takes to put something together,” Mennel explained. The company has given integrators and end-users alike the possibility of configuring their conveyors online at its website, which Mennel says gives the customer the opportunity to save an enormous amount of time during the specification phase of the conveyor project. “Traditionally it takes three months from time to order to delivery but with online specification and by using modular components, this can be done within a week,” he told Manufacturers’ Monthly. “With the online configuration tool, the customer can use automatic design software to design a fully tailor a belt
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The success of any materials handling operation depends on the speed, efficiency and dependability of its conveyor system.
conveyor for example to the application at hand, including the conveyor length, width, speed, drive option, belt material etc, he said. “Once this process is complete, the customer has a detailed description of the conveyor including the article number needed by our company for the manufacture, and of course the price.
“The customer can then either print out the conveyor specification or order it directly online with the company’s ecommerce facility, as well as any auxiliary components or assemblies,” Mennel said.
Automatically flexible While the configuration of conveyor systems online is increasing in popular-
ity, it doesn’t look to totally replace manual input in the design process, as Peter Hutchings MD of FlexLink notes. “Though many people use online applications to design their conveyor systems, a majority just want to explore their options and do some preliminary drawings/layouts online but then seek to approach conveyor suppliers for their final design so they can draw on the company’s experience,” Hutchings said. “Though we offer customers the option to go online and access our engineering tools, we find many greatly benefit from the full project, engineering and installation support they get from their equipment supplier,” he said. Hutchings does believe however, that there will be an increase in the use of computerised and automated conveyor systems. “The innovations in conveyor system design are not so much about new materials but how these systems are integrated with new automated technologies,” he said. “Automatic guidance systems for example can now be connected through PLC’s to allow the readjustment of rails on a conveyor system without the need of manual intervention. “This technology is particularly beneficial when conveyors are placed at higher levels where it is hard to manually adjust,” he explained. And Hutchings says automation also gives customers more flexibility in their systems. “Nowadays many of the products continued on page 56
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SOLUTIONSMATERIALS HANDLING
Conveying investment keeps meat in motion BY JAMIE WADMAN
WHEN national supermarket chain Woolworths needed to expand and upgrade the boning room at its meat subsidiary Brismeat, located in Queensland, they turned to InMotion Engineering for assistance. The installation at Churchill-based facility involved approximately 20 conveyors at a total estimated value of $425,000, comprising a range of equipment, all made from stainless steel construction. InMotion National
continued from page 54 going through conveyor systems change rapidly often driven by different market trends. “Through the use of modular conveyor systems combined with integration of automation allows for a system that can meet the demands of an everchanging consumer market,” he added.
Sensitive solutions Another innovation adding to conveyor system flexibility and adaptability is recent advances in control technology
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Account Manager Neville Sonter said the company’s products helped Brismeat by improving the production flow from the boning area through a new Cryovac vacuum sealing machine to a pack-off station. “This has resulted in improved labour allocation in the boning room and addressed ergonomic issues.” According to Sonter, one of the key benefits of the technology for Brismeat is that the installation is entirely made of acid-proof stainless steel which means it can tolerate the most hygienic
which not only allows for more intuitive systems, but also reduces the amount of components needed in each setup. John Sorohan, sales engineer – standard conveyor systems group with Dematic, says with the development of ‘smart’ conveyors, the same system can be used to perform a number of different tasks. “The ability to maximise the accumulation capacity between processes is important for manufacturers who need to have a temporary buffer between processes or have a stoppage but don’t
wash-down requirements. “Each conveyer has a maintenance-
free transmission with a worm gearbox and motor which is mounted directly on the drive shaft. “The machinery is also sprocketdriven for more accurate belt-tracking and drive, and designed to minimize ‘pinch points’ for operational safety,” he added. The project was designed using Solid Edge 3D Design Software which allowed managers and operators to comprehend the equipment design and fit-for-purpose. InMotion Engineering 07 3279 2020.
want to stop the whole line,” Sorohan explained. “Modular conveyors combined with a visualisation system, sensors and some form of tracking capability can provide valuable information such as conveyor status and accumulation numbers,” he said. “It can also provide increased OHS and environmental benefits for users. “For example we have a 24V conveyor range that is powered by a series of motorised rollers placed every one to two metres connected by drive bands.
“The control system has a drive card connected to each of the rollers and a PE (photo electric sensor) within each motorised roller.” “The conveyor is quiet not only because of the smaller motors, but also because when the conveyor doesn’t ‘see’ anything coming, it automatically shuts down which saves energy and also helps to minimise noise in the workplace and improve operator comfort,” he said. Dematic 02 9486 5555. FlexLink 03 9542 4400. Robotunits 03 9334 5182.
Production flow has been increased with the installation of 20 new stainless steel conveyor systems.
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SOLUTIONSMATERIALS HANDLING
Foodmach innovation stacks up BY BEN LAZZARO
INNOVATION is crucial to long-term success in the manufacturing sector. It enables companies to offer unique solutions and stand-out in the marketplace, while at the same time providing the continual improvements in productivity demanded by manufacturers. One company with a focus on integrating innovation into its products is packaging machine manufacturer Foodmach Australia. The company provides a range of robotic and automated packaging systems, and recently combined two of its automated packaging systems to create a hybrid palletising machine-the Robomatrix Hybrid. The new system combines features of the company’s series of high-speed pattern-forming palletising machines, along with elements of the company’s S3000 floor-level case-palletising system. Almost all of the machine’s motion processes rely on electronic drive control technology from SEW-Eurodrive as well as standard and servo gear motors.
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The machine’s robotic arm manipulates and orients finished packaged product into pallet layers. Each pallet layer is then hoisted and stacked from the ground up to form a pallet. With the machine requiring a range of motor and drive capabilities, from simple conveying, to pin-point positioning, the company opted for the advantage of an inverter module that could be used across-the-board to
meet each requirement. Each of the system's twelve motors, whether servo or standard, is combined with the Movidrive 'B' application inverter said to provide a valuable combination of versatility and processing power for both standard variable speed drives and sophisticated positioning and synchronous applications. It allowed Foodmach to deploy the inverter across the various servo and
The hybrid machine offers fast single-level palletising capabilities.
standard motor drive applications on the machine. It was just a matter of which encoder card and application module was used. According to Ken Orr, Foodmach’s software engineer, the pre-programmed application module libraries were a key feature of the inverter. "We utilised the application modules extensively," he said. "Ten of the twelve drives used in the palletiser employ pre-programmed application modules. “For instance, we used a sensorbased positioning module at the in-feed servo-motors, and then a different extended positioning module for the squaring plates, and servo gripper head. “Basically, it saved an enormous amount of programming. It's just a matter of picking the right application, putting the correct parameters in, and you're up and going," Orr said. "If we had of done the positioning programming on a PLC, we could spend two or three days attempting to program that during commissioning on site," said Orr. SEW-Eurodrive 03 9933 1000. Foodmach Australia 03 9551 5333.
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SOLUTIONSMATERIALS HANDLING
Counterbalance electric forklifts THE Australian forklift industry will be introduced to a new range of Komatsu AE50/AM50 counterbalance electrics following an agreement with Komatsu Utility. The new series will be introduced with 3 and 4-wheel, 1.8-2.0t counterbalance units. The series is said to boast many advanced features and is designed to be an affordable option for manufacturers. Key features include total ac system - for reduced maintenance costs, finger tip operator controls, side access battery removal, dual
New forklifts include 3 and 4-wheel, 1.82.0t counterbalance units.
drive, enhancing the turning radius and stability under a number of conditions, airtight wet disc brakes that don't require extensive periodical maintenance except for oil changes. Standard features include integral side shift, gull lighting including high mounted rear lights, suspension seat and seat belt. Additionally the forklifts also have a waterproof design and monitoring system and adjustable individual operator system setup. Red Australia 07 3376 3355.
Forklift attachment can handle double pallets GERMAN forklift attachment manufacturer Meyer has introduced a new generation of multiple pallet handlers that are said to incorporate a unique shaft guide system to ensure easy handling, improved visibility and exact arm travel. The modern bar type design can lift two pallets side-by-side (even with a gap between them) or a
single pallet when closed. The optimum visibility and synchronised movement of the bolt-on forks increase the efficiency and safety of the forklift. The fork arms are hydraulically adjusted by a single lever from the driver's position. Designed with chromed and hardened shafts and a dual enclosure of the bush-
ings, the multiple pallet handler series provides excellent glide characteristics with synchronised forks. The provision of wiper seals, together with bushes that have a guaranteed 10,000 hour life, makes the series suitable for operating in hostile environments. Eurolift 07 3271 4799.
COMING EVENTS June 26-27: Reliability National Forums Series Planning4Reliability Workshop will be held at Hotel Conrad, Gold Coast, Queensland. Call 03 9697 1105 or email anna.civiti@sirfrt.com.au.
July 21-24: Foodpro 2008 will be held at the Sydney Convention & Exhibition Centre, Sydney. Contact Peter Petherick on 03
8420 5402 or email peterpetherick@dmgworldmed ia.com. 31: Queensland Supply Chain & Logistics Conference will be held at the Sofitel Hotel, Brisbane.Email info@qldscc.com or visit www.qldscc.com.
August 12-14: WA Safety Show and Conference will be held at the Perth Convention Exhibition
Centre, Perth. Call 03 9654 7773, email safety@aec.net.au or visit www.wasafetyshow.com.
September 1-2: Reliability National Forums Series - Electrical Maintenance & Safety will be held at Star City, Sydney. Contact Anna Civiti at SIRF Rt on 03 9697 1105 or email anna.civiti@sirfrt.com.au.
Commercial Vehicle Expo will be held at the Homebush Exhibition Precinct, Olympic Park, Sydney. Email info@exhibitionmanagement.c om or visit www.sydneytruckshow.com.au
October 7-9: AUSPLAS will be held at the Melbourne Exhibition Centre, Melbourne. Email info@exhibitionmanagement.co m or visit www.ausplas.com.au
7-9: National Truck &
ADVERTISING REGISTER Acromet 28 Air & Hydraulic Systems 47 Air Technology Group 43 APICS Victoria 8 Atlas Copco Compressors 1,41 Australian Colloidal Technologies 33 Australasian Industrial Marketing Services 48 BAC Australian Systems 10 Caps Australia 42 Champion Compressors 46 Citect 2 Compair Australia 35,45 CRC Industries Australia 31 Davcor Manufacturing 9 Dematic 7 DHL 21 Donaldson Australia 43 Eastlink 15 58
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MANUFACTURERS’ MONTHLY
Endress & Hauser Australia 39 Flexlink Systems 58 Fresco Systems Australasia 47 GE Commercial Finance 17 Hanna Instruments 3 Henkel Australia 11,27 Hi-Tech Metrology 29 Hubtex 57 Insignia 24,60 Integrated Transfer Solutions 36 Intrinsic Software 4 JLG Prolift 59 John Hart 37,38 JS Melbourne Controls 37 Kaeser Compressors Australia 44 KD Fisher & Co 23 Locker Group 54 Maxon Motor Australia 52 Micromax 6 Millsom Hoists 59
Naismith Engineering Norman G Clark (Asia) NPA NTP Forklifts Pacific Hoists PIES Australia Profile Cutting Systems Protube Asia SEW-Eurodrive Sheffield Blades Sick Sinclair & Rush Spill Station Spray Nozzle Engineering St George Bank TP Castings Tronics Turck Corporate Walter Australia Zilon Engineering
33 30 36 56 25 40 51 51 55 32 5 45 13 53 18 53 34 19 49 14
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SOLUTIONSMATERIALS HANDLING
Industrial deep cycle batteries EXIDE has released a new range of industrial deep cycle batteries which have been developed for maximum performance in demanding industrial and manufacturing situations.
qualities of a long-term powerful deep cycle industrial battery. They boast optimum performance in the most extreme circumstances thru the ability to fully deep cycle, and a
The Right Advice, The Right Solution THE RIGHT CHOICE Vacuum lifting devices VacuMaster are the ideal tools for the handling of sheets of metal, wood, glass and stone slabs, weighing up to 2000kg. Product can be handled horizontally, or turned through 90º or 180º.
VACUUM SHEET LIFTERS JUMBO ERGO & HANDY The Vacuum tube lifter is particularly suitable for frequent and fast lifting and moving of porous and non - porous cardboard boxes, sacks, barrels, sheets of wood and many other objects weighing up to 300kg. Also for Explosion Hazard Areas
The batteries combine the latest technology while retaining all the traditional qualities of a deep cycle battery.
Made in the USA to top quality standards, the batteries are said to combine the latest technology while retaining all the traditional lead-acid
long operating life. Applications include materials handling, stackers, lifts, carriers, forklifts, etc. Exide 03 9270 0100.
WORKSTATION CRANE Lifting, Shifting and precision placement of product at the workstation and the job made light and simple with Millsom low friction track.
JIB CRANE Standard, low head room or wall and column mounted. Capacity from 80kg up to 5 tonnes with jib length from 1.5 to 6 metres.
ELECTRIC CHAIN HOISTS Our electric chain hoists can be customised to suit your particular needs. For this purpose, "SWF Krantechnik" offers a wide range of accessories and optional equipment. Challenge us - we are sure we will be able to provide you with a suitable solution!
ROTO LIFT - Pallet Elevator Rotating table and elevating table for loading and unloading of pallets and stretch wrapping.
NEW PRODUCT
email - sales@millsom.com.au
FREECALL 1800 99 22 11 MELBOURNE, SYDNEY, BRISBANE, PERTH, ADELAIDE & NZ www.manmonthly.com.au
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