Industry Update issue 104 October 2018 by Industry Update

AUSTRALIA'S LARGEST CIRCULATING MANUFACTURING MAGAZINE

Industry Update

Issue 76 February 2014 $12.00 INC.GST Issue 104 October 2018

$12.00 INC.GST

MANUFACTURING MAGAZINE

CYBER INSECURITY

The allegation that a significant number of the world’s computer servers are compromised with a hardware hack has sent the IT community into meltdown, with claims, counter claims and denials issued daily. If the article published in Bloomberg Businessweek proves to be true, it will cause the world to re-evaluate the whole subject of cybersecurity. If it proves to be false it will still have undermined the global supply chain of the electronics industry. There is no doubt that data (in)security is a growing concern. According to the latest figures from security expert Gemalto, data

breaches compromised 4.5 billion records in first half of 2018 – up a staggering 133% on the same period last year. But the hardware hack alleged by Bloomberg is another thing entirely. The story reports that in late 2015 a security company was investigating computer servers manufactured by Elemental Technologies. And when the investigators came to look closely at the motherboards, they found a

device that was not in the original design. On further investigation this additional chip was found to a device that would allow an attacker to create a stealth doorway into any network to which the server was attached. The servers were assembled for Elemental by Super Micro Computer, a US company that is also one of the world’s biggest suppliers of server motherboards, which are subcontract manufactured in China. What makes the discovery all the more worrying is that servers like those investigated were in use in some very Continued page 4

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NO SUBSTITUTE FOR EXPERIENCE IN ABRASIVES BLASTING At first sight, the process of surface preparation through abrasive blasting might appear simple: create a rapid airflow through a nozzle, introduce your abrasive and point at the target. But while that may be fine for taking the paint off a set of wrought iron gates in preparation for renovation, once you try to apply that technique to valuable assets on an industrial scale you will find out very quickly that there is more to abrasive blasting than meets the eye. Today it is possible to buy imported abrasive blasting machinery at some very attractive price points. But you do have to question exactly what you are getting for the money, says Ben Noble of Protoblast, Australia’s most experienced designer and manufacturer of abrasive blasting equipment.

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Continued page 4

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• EDITORIAL

PUBLISHER SCOTT FILBY

EDITOR LAURENCE MARCHINI

PAY UP AND HELP SMALL BUSINESS

NATIONAL INTEREST OR NATIONAL SECURITY?

Much has been written about the problems facing small businesses, and in just about every survey cashflow is identified as one of the key problems faced. In Australia, at any given time, there is around $26 billion in unpaid debts owed to small businesses. However, the situation is improving, and late payments are on the decline.

vast majority of Industry Update advertisers pay up well within 30 days, but there are always the odd one or two that drag their heels and make the statistics look wrong. Perhaps it’s time to make quicker payment the norm. Two years ago, the US Government reduced its settlement term to 15 days and the

Perhaps it’s time to make quicker payment the norm. Two years ago, a Dunn & Bradstreet survey put the average time to pay back an invoice in Australia at 45 days. Today, that same company (now called Illion) says that the situation has improved markedly, and has switched its emphasis to analysing late payments (ie those beyond 30 days), which have fallen from an average of 22 days in June 2013 to just 11 days in June 2018. Clearly, dealing with averages does cloud the real issue. The

result was a boost to the US economy. Now, much closer to home, the New South Wales State Government has announced that it will instigate 5-day payment terms for SME contracts up to $1 million. When this fast-track payment plan is rolled out by the end of 2019, it will make NSW the fastest paying government in the country – if not the world!

If there was ever an over-used (and mostly misused) term in the current political lexicon it would have to be the “national interest”. We are told that it would not be in the national interest for Chinese companies to control too much of our national energy infrastructure. And a short while ago it was decided that it would not be in the national interest for Chinese tech suppliers to supply our 5G mobile communications systems. So, what really is in the national interest? How about creating jobs and wealth? But, when do we ever hear that a major contract has been won by an Australian company because it is in the national interest? Having national assets under foreign ownership is nothing new. Nor is it uniquely Australian for us to feel uneasy about such a loss of economic sovereignship. (Ask anyone in the UK what they think about the water supply being under French ownership!) Certainly, if there is a security issue with any given supplier or contractor, then that is reason enough to disqualify them from taking part in any part of the nation’s infrastructure. And this is why

ZTE and Huawei were disqualified from the building of Australia’s 5G cellular network – as indeed they have been similarly barred in the UK and the USA. Likewise, Russian computer security firm Kaspersky Lab has been disbarred from any government business in the USA (albeit perhaps a little late!). These are matters of national security – and that is not necessarily the same as the national interest. I am reminded of the historical case of the Great Seal Bug, which allowed the USSR’s security services to eavesdrop on successive US ambassadors for some seven years until its discovery in 1952. This cleverly designed passive listening device was hidden inside an impressive gift to the ambassador near the end of WWII. As a gift from an important ally, no doubt it was considered to be in the national interest to accept it and display it prominently in the ambassador’s office. The implications for national security, though, were entirely another thing!

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• INDUSTRY PERSPECTIVES

CYBER INSECURITY

Continued from cover

NO SUBSTITUTE FOR EXPERIENCE IN ABRASIVES BLASTING

Continued from cover

Protoblast has been around for more than 40 years, and its current workforce have more than a century’s worth of experience in the business between them. What’s more, they and their predecessors, starting with Ben Noble’s grandfather John Gillies, have designed and developed some of the key processes that make up the state of the art in abrasive blasting.

sensitive applications, and these involved US governmental organisations as well as tech giants Apple and Amazon. In total, the investigators concluded that 30 US companies has been compromised.

agencies and private companies via so-called "supply chain attacks". That it should happen during an escalating trade war between the USA and China is perhaps too much of a coincidence.

Bloomberg claims the top-secret investigation is still ongoing to find the source of the rogue hardware. Since the story has broken, Apple and Amazon have denied everything.

However, if hardware hacking is prevalent it would bear out the words of noted US cybersecurity authority William Yaeck in a recent address to the NSW Business Chamber: “Today, you cannot catch all the bad stuff… so have very good response plans in place.”

According to the Reuters news agency, the publication of the Bloomberg report coincides with the increasing concerns of about foreign intelligence agencies infiltrating US government

Industry Update will publish a special feature on computer security in November 2018.

From blasting equipment and blast chambers to dust collection and abrasive recovery, the company has devised, designed and built countless examples since it began in the business in 1975. And that experience counts. There is no “one size fits all” philosophy here. Each application has its own demands, and while Protoblast does have a list of standard products, it is the customisation of these and their combination along with a thorough understanding of the customer requirements that leads to a satisfactory solution. According to Ben Noble, his company’s expertise is as much in demand as its

products, with customers keen to draw on the industry experience of Protoblast, that has over 40 years seen the company fulfil projects as diverse as processing steel ingot moulds through to polyurethane water ski cores. Protoblast Company has vast knowledge across all industries, from the mining, oil and gas industry to the transport industry, including shipping, rail and road freight applications to the building, general engineering and structural fabrication sector. Protoblast also has much experience with abrasive blasting machinery in aluminium smelters in the Middle East. And that expertise is in demand overseas as well. The wholly Australian owned company has supplied equipment to New Zealand, Papua New Guinea, the USA and the Middle East.

Protoblast Company 1800 772 320 www.protoblast.com.au

CONTENTS FROM THE EDITOR.......................... 2

NETWORKING

SAFETY.............................................. 34

INDUSTRY POLITICS....................... 6

Elevating Ethernet intelligence.......... 24

Forklift fundamentals part 6...............37

INDUSTRY NEWS.............................. 8

INDUSTRY UPDATE VIDEO......... 26

MACHINERY.................................... 40

FANS AND COOLING

SOLAR................................................27

HYDRAULICS................................... 47

A fan is just a fan…..............................16

AUSTRALIAN MADE

ENVIRONMENT.............................. 48

EDUCATION AND TRAINING.......18

Counterfeiters to face the music....... 28

Spring cleaning tips.............................51

MOTORS AND DRIVES.................. 20

PACKAGING ................................... 30

PRODUCTS...................................... 52 FUN & GAMES.................................. 58

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• INDUSTRY POLITICS

TECHNOLOGY IS AT THE HEART OF ALL MANUFACTURING

By Karen Andrews

It is a privilege to be the new Minister for Industry, Science and Technology. I have come to the portfolio at a really exciting time.

Another AMGF grant recipient taking steps in the right direction is Victorian manufacturer Footwork Podiatric Laboratory.

Australia’s economy is in transition and so is our manufacturing sector. I am excited about some of the amazing stories coming out of manufacturing and am committed to working with our manufacturers as they continue to transition, create new jobs and new opportunities.

By embracing new approaches, Footwork has reduced wastage and cut costs, as well as improving the quality of its product and its competitiveness in the market.

More than 47,000 new manufacturing jobs were created in the 12 months to May of this year. Around half these new jobs were in advanced manufacturing, and it brings the total employment in the sector to more than 940,000 people. Manufacturing continues to play a significant role in the Australian economy, including contributing over $100 billion in exports and industry value add annually. There are hundreds of local manufacturers out there making an impact. A terrific example of a business using new manufacturing techniques and technologies is Micro-X, a South Australian company that received a $2.4 million Advanced Manufacturing Growth Fund (AMGF) grant from the Government to turn a lab-based process into a true manufacturing process, reducing supply risk and introducing groundbreaking advanced manufacturing capability in Australia. Micro-X’s approach uses cold cathode carbon nano tubes (CNTs) that are significantly smaller than conventional tubes, allowing Micro-X to make novel miniature products. The company intends to introduce this capability at a purpose-built facility adjacent to its manufacturing plant in Tonsley in Adelaide.

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Taking advantage of 3D digital manufacturing, Footwork is on target to become the first commercial Australian laboratory of its size to lead the way in technological innovation. This will underpin Footwork’s goal to expand further and increase its market share both domestically and internationally. As these businesses show, the future of manufacturing lies in embracing new technologies and developing high value-

Industry 4.0 technologies have the potential to enhance Australia’s manufacturing competitiveness, offsetting labour costs and helping overcome challenges associated with our geographical isolation. And I am not just referring to large companies - Industry 4.0 is already creating opportunities for businesses of all sizes and at all levels to become more agile and productive. For instance, by actively collecting and interpreting data on machine operations with the use of sensors, a business can streamline its operations. Similarly, by collecting and interpreting customers’ demands a business can redesign its business model to deliver more value to the customer. This can lead to businesses focusing on

Industry 4.0 technologies have the potential to enhance Australia’s manufacturing competitiveness added products and before and after market services. This will drive business efficiency, boost productivity and ensure Australian manufacturers continue to have a competitive edge in the global marketplace. Industry 4.0 - the fourth industrial revolution - refers to the current trend of improved automation and data exchange in manufacturing technologies. It is the most significant disruption to advanced manufacturing in half a century. For Australia, it isn’t a question of if businesses need to be thinking about how to adopt and integrate technology, it is a question of how do businesses do this.

higher value activities in the manufacturing value chain. In turn, this can increase the business’ profits and competitiveness.

operations to digital manufacturing. The tool covers all Industry 4.0 topics and is not tied to individual technology platforms. The AMGC is also supporting the Virtual Shipyard Project, which provides a structured learning programme for 15 South Australian SMEs to develop the digital capabilities needed to support the next generation of naval shipbuilding. It links the SMEs with global tier one companies and supply chains are also provided. The project is the first National Level Industry 4.0 capability development programme in Australia. Also through the AMGC, Dematec Automation is retrofitting the equipment of 17 manufacturers. Dematec Automation will supply and integrate Industry 4.0 enabling hardware and software into existing equipment that cannot currently provide digital monitoring.

I’m proud to say the Australian Government is supporting this transformation and is creating an environment that will allow businesses to grow and compete by embracing new technologies.

Technology is at the heart of all manufacturing. And manufacturing, as you can see, is in a buoyant state. With new jobs being created every day, the sector’s contribution to the economy is crucial.

For example, working with Bosch, the Government’s Advanced Manufacturing Growth Centre (AMGC) has produced an audit tool that identifies technological capability gaps preventing SMEs from embracing Industry 4.0.

As the new Minister in this exciting portfolio, I can assure you the Government remains committed to working with manufacturers, through the AMGC and other programmes, to help them transform their operations, create opportunities and jobs.

The tool makes recommendations on how manufacturers can transition their

Karen Andrews is Minister for Industry, Science and Technology.

OCTOBER 2018

INDUSTRY POLITICS •

REBUILDING INNOVATION REQUIRES A LEAD FROM GOVERNMENT

By Senator Kim Carr

Since Industry Update last published Australia has acquired a new Prime Minister and yet another Industry and Science Minister. I congratulate Karen Andrews, the sixth person to take responsibility for the portfolio since 2013. These ministers have not all had the same title. Ms Andrews’ title reverts to the traditional “Industry and Science”, and it is good to see that science has a voice at the Cabinet table. But a notable and regrettable omission from her title is the word “innovation”. We have come full circle. After being virtually banned from Government discourse under Tony Abbott, then returning enthusiastically but briefly under Malcolm Turnbull, the word “innovation” has been dropped once more. Why make a missing word into an issue? Because of the challenges confronting Minister Andrews, and the Morrison Government in the time that is left to it. According to the most recent ABS and OECD data (2015-16), Australia’s Gross Expenditure on Research and Development (GERD) has dropped to 1.88 per cent of GDP. That is down from 2.10 per cent in 2013 and 2.12 per cent in 2011. The OECD average in 2016 was 2.34 per cent of GDP.

OCTOBER 2018

When the GERD figure is broken into its component parts, the trend is relentlessly downward.

Since 2013, a net $2 billion has been cut from science, research and innovation (SRI) programmes.

Business Expenditure on Research and Development (BERD) dropped from 1.18 per cent of GDP in 2013 to 1.00 per cent in 2015.

The Turnbull Government did not have the political will to refund and rebuild the national innovation system that was shredded by the Abbott Government’s 2014 budget.

Government Expenditure on Research and Development (GOVERD) slid from 0.21 per cent of GDP in 2014 to 0.19 per cent in 2016, and Higher Education on Research and Development (HERD) was just 0.58 per cent of GDP in 2015, down from 0.63 per cent in 2013.

And, with all the political turmoil of the past month, the Morrison Government has given no indication that industry and science policy are high on its priorities either. The complex changes to the R&D

Choosing to leave “innovation” out of the minister’s title is like choosing to leave out a vision for the future. These figures reveal a nation that is not investing in its future. Without investment in R&D, we cannot broaden our knowledge base as an advanced industrial society. Our participation in the global economy will decline, and we will be less and less able to create new, high-skill, highwage jobs. The Government has been reluctant to take an active role in reversing the decline in R&D, not only through its own direct investment but through support for innovation programmes, higher education and the publicly funded research agencies.

Tax Incentive set in the 2018 budget have caused concern among industry stakeholders about a further withdrawal of support for R&D, which is why Labor will refer the legislation to a Senate inquiry when it is introduced. When Government is not willing to invest in R&D, there is less incentive for private business to do so. There is a less certain environment for investment generally, and some firms will be tempted to take their R&D overseas. The national innovation system must be rebuilt, but that will not happen if the government of the day is not resolved to do it and willing to

make the necessary investment. Anyone involved in manufacturing knows how rapidly technology is changing the workplace, and how our ability to participate in what has been called Industry 4.0 – the fourth industrial revolution – will determine Australia’s share of global economic activity. Government must work with business, unions, universities and research institutes to ensure that Australia is primed for Industry 4.0. It is a role that only government can undertake, and building an effective national innovation system will be required for it to happen. So the lack of that single word “innovation” in Minister Andrews’ title is cause for concern, if it indicates the Morrison Government’s broader agenda. Choosing to leave “innovation” out of the minister’s title is like choosing to leave out a vision for the future. Senator Kim Carr is the Shadow Minister for Innovation, Industry, Science and Research.

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• NEWS

DISTRIBUTION EXPANSION WITH NEW MELBOURNE HEADQUARTERS

DANISH TRADE COMMISSIONER TAKES THE REINS AT NILFISK Vice President for Nilfisk in the Asia Pacific region, Michael T Hansen has the competences and mind-set to continuously establish Nilfisk as trusted partner for customers across Australia. “The cleaning industry is undoubtedly changing, with new technologies paving the way for more intelligent ways of cleaning. Michael T Hansen has witnessed such an industry transformation first-hand. At the same time he has worked closely as an advisor to a wide range of companies which allows him to quickly understand the needs of our customers and ensure that we are a trusted partner for them,” says Ulger. The former Trade Commissioner of Denmark to Australia and New Zealand, Michael T Hansen has been named General Manager of Nilfisk in Australia. Originally from Denmark, Hansen has more than 25 years of experience in business development and sales. Over the last 9 years as Trade Commissioner, Hansen has been advising Danish companies on the Australian and New Zealand market and has established numerous commercial partnerships. This has given him a strong network within industries such as contract cleaning, warehousing and logistics and retail. Prior to that Hansen worked in sales, business development and marketing in the aviation industry. According to Serdar Ulger, Senior

Hansen says it was the opportunity to build long-lasting customer partnerships that attracted him to Nilfisk. “Nilfisk has a strong Danish heritage which impacts how quality and design are perceived across the company. At the same time, the company has a clear vision for the future and is determined to be a front-runner when it comes to innovative cleaning solutions. I believe that is a strong recipe for building long-lasting customer relations and I look forward to being part of the Nilfisk team,” says Hansen. Hansen replaces the previous General Manager Quintus Strydom.

Nilfisk 1300 556 710 www.nilfisk.com

APS Industrial has relocated its Melbourne base into an all-new 4500m2 head office and national distribution centre in Rowville. The new facility includes an interactive product showcase room and state of the art conference facility. According to APS Industrial MD David Hegarty, “Since our launch earlier this year we have made increasing our service level and delivery capability a core focus. We want our customers to enjoy doing business with APS Industrial and experience all the benefits that come from partnering with a local supplier.” “First and foremost this move gives us the scale to significantly increase our local stockholding and in turn deliver the products our customers need faster – both now and into the future,” Hegarty added. “It also represents our

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• NEWS

CROSSLEY TAKES CHARGE AT SICK David Crossley is the new Managing Director at SICK Australia and New Zealand, replacing David Duncan who is set to become Senior Vice President, APAC. Before joining SICK, Crossley spent five years with Thermo Fisher Scientific, latterly as Director of Environmental and Industrial Process Technologies for Australia and New Zealand. Before that he held management positions at ABB, Headland Machinery, Amcor and ABB, including a spell in the UK. Commenting on his appointment, Crossley said: “I am honoured to be given the privilege of leading SICK as the Managing Director for Australia and New Zealand. “It‘s a very exciting time for SICK globally as Industry 4.0 takes hold. The requirement for quality smart sensors

The latest SME Growth Index from Scottish Pacific reveals that more businesses are in growth mode than at any time since March 2016. However, manufacturing SMEs are more negative about revenue growth. Just 46% of the manufacturing SMEs (with turnovers from $1 million to $20 million) are expecting growth over the coming six months, at an average of only 2.2%. to capture data will accelerate and the outstanding team at SICK across Australia and New Zealand are here to support our existing and new customers, to be competitive on the global stage,” he concluded.

SICK Australia 1800 334 802 www.sick.com

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AUSTRALIAN MANUFACTURING SMES STRUGGLE WITH CASH FLOW

Worse than that, according to Scottish Pacific senior executive Wayne Smith, almost one in three manufacturing SMEs are expecting revenues to decline, by 8.8% on average. "Nine out of 10 manufacturing SMEs thought better cash flow could have given them a revenue boost of 5- 50%, with one-third of those saying they could have achieved at least a 5-10% revenue boost,” said Smith. "Our study also found that manufacturing business owners are putting in longer hours than all other sectors apart from mining - almost 45% work 60-80 hour weeks, with one in five clocking 80-plus hours." Cash flow is an increasing problem for the whole SME sector, and business owners

are really putting in the hard yards (on average, spending 66 hours a week working on or in their business). “Many business owners are cashstrapped, time-poor and confused about the options available to them to fund their growth,” Smith said. “With a declining property market and banks exercising caution, the concern is that a lack of credit could hamper growth prospects. Business owners will need to consider funding alternatives to traditional property secured lending. “Those SMEs who find alternative ways to fund growth and master cash flow management will have a clear advantage over their competitors,” he said. Continuing the trend of SMEs looking beyond banks to fund growth, 96% could name a key reason to borrow from an alternative lender, with fast credit approval and reduced compliance the main drawcards. Almost one in 10 business owners (8%) say revelations from the Banking Royal Commission will prompt them to seek out non-bank alternatives.

MANUFACTURING GROWTH ACCELERATES INTO A THIRD YEAR Australia’s manufacturing sector has capped off a 24th consecutive month of growth with the Ai Group’s Australian PMI increasing to 59.0 in September. With all areas of activity continuing to grow and the new orders subindex reaching a six-month high of 62.6, the overall growth shows no signs of slowing. Also on the up, the employment subindex reached 58.1, which is well above its 12-month average of 55.2. This adds confirmation to recent ABS data that found the manufacturing sector made the strongest job gains across the economy over the year to August 2018, raising national manufacturing employment to its highest level since 2010. By sector, the nonmetallic mineral products (mainly building-related) hit another record high of 79.3 points in September thanks to the continuing

backlog of both residential and nonresidential construction work yet to be completed. The food and beverage industry continued its positive form, with growth easing but remaining above 59. Announcing the results, Ai Group Chief Executive Innes Willox said: "The run of strong performance by Australia's manufacturing sector hit a new milestone in September capping two years of growth. “The benefits of this expansion have been widely distributed with a healthy rate of employment growth over the past year and very strong signs of wages growth over the past three months following a more gradual pace of increase in the preceding few years. The signs are good for the immediate outlook also with exports, production, employment and new orders all in the black and improving on the previous month.”

OCTOBER 2018

NEWS •

EARLY BOOKINGS LEAD TO AUSTECH SHOW EXPANSION AMTIL reports strong early exhibitor bookings for the Austech 2019 manufacturing technology exhibition, setting the stage for an impressive (and larger) show next year. Billed as Australia’s premier advanced manufacturing and machine tool exhibition, Austech will take place at Melbourne Convention & Exhibition Centre from 14th to 17th May 2019. AMTIL has always held a ballot to ensure that floor space is distributed fairly among the companies who register early as exhibitors, and recently conducted the ballot to allocate initial floor space for Austech 2019. The ballot revealed high levels of early interest in next year’s show, with exhibitors registering early and committing to large stands on the exhibition floor. In total, more than 3600m2 of floor space has already been sold, representing more than 70% of the available exhibition area. And, as that accounts for only 65 exhibitors, there appears to be a trend towards taking larger stands at Austech 2019. Space sales for Austech 2019 are currently comfortably exceeding the levels seen at the same point during preparations for the last exhibition, held in Melbourne in 2017 and one of the most successful shows in the history of Austech. As a result of such strong early interest, AMTIL has taken the decision to expand its booking with the Melbourne Convention & Exhibition Centre to accommodate the additional

exhibitor numbers expected. As well as showing strong overall numbers, the ballot showed a high degree of diversity among the exhibitors. As well as Austech’s foundation exhibitors of machine tools and ancillary equipment, strong enquiries have been received for the show’s dedicated technology areas: the Additive Manufacturing Pavilion; the Air Technology Pavilion and the Digitalisation Pavilion. There has also been strong interest in the Manufacturers Pavilion, an area devoted to highlighting some of the great manufacturing companies working in Australia.

“The Austech floor space ballot has always been a great litmus test for overall levels of confidence in the manufacturing industry in Australia,” says Kim Banks, AMTIL’s Events Manager. “We’re gearing up for a great, big show. We anticipate many more bookings of regular and new exhibitors over the coming months. All the indications suggest we’re in for a bumper exhibition in May 2019.” Austech 2019 will showcase the very latest in advanced manufacturing technology, including specialised equipment areas showcasing additive manufacturing, air technology and digitilisation. As well as manufacturing technology, Austech will also be

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showcasing some of the very best Australian manufacturing companies in their own dedicated area, the Manufacturers’ Pavilion. Companies who are interested in exhibiting at Austech 2019 should contact AMTIL’s Events Manager Kim Banks. Space is selling fast, so companies are advised not to delay to ensure they get a good spot on the exhibition floor.

AMTIL 03 9800 3666 www.amtil.com.au

EMAIL US TODAY sales@mrtaustralia.com.au www.mrtaustralia.com.au OCTOBER 2018

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• NEWS

NEW LEADERSHIP TEAM SETS SIGHTS ON EXPANSION Control Logic has set its sights on expansion, with a new leadership team incorporating key roles in products and marketing, sales and development, and operations and services. The move aims to increase the company’s skill set and focus to drive innovation and expand the company’s expertise and service. Thanks to on-going investment, Control Logic now has a national team to support local industry Australiawide so customers can experience the benefits that come from partnering with a local supplier. This includes strategic local stock holdings, customer training facilities and an expanding staff of technical and application experts. Control Logic is owned and operated by brothers Michael, Steven and Greg Bacon, the sons of one of the company’s founding members Geoff Bacon. Having grown up and witnessed many changes over three decades, Control Logic’s Executive Director &

CEO Michael Bacon is excited for the future. “The industry is constantly evolving and shifting to suit the pace in which the world is moving, and as a result Control Logic has had to as well, “ he says. “I am immensely proud of our achievements over the past 37 years, and I put that down to our strong team, core values and genuine willingness to assist our customers. I’m very excited to see where this next phase will take us.” “Control Logic is growing and growing fast by adding value to our existing products and services whilst developing entirely new and improved technologies and solutions that continue to differentiate us.”

Operations & Service), Greg Bacon (Executive Director), Michael Bacon (Executive Director & CEO) and Steven Bacon (Executive Director).

provide the focus required to ensure our core values, that have served us so well, continue to guide us into the future,” adds Michael Bacon.

The new leadership team comprises Lee Papadimitrious (General Manager – Products & Marketing), Kurt Martin (General Manager – Sales), Ben Allwood (General Manager –

“We are extremely confident that through the efforts and decisions of our new leadership team, Control Logic’s legacy will continue to flourish and evolve. Appointing these roles will

Control Logic 1800 557 705 www.controllogic.com.au

Greg, Michael and Steven Bacon (all seated) are joined by Lee Papadimitrious, Kurt Martin and Ben Allwood

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OCTOBER 2018

NEWS •

EXPO TO EMPOWER INDUSTRY TO TAKE CONTROL OF ENERGY Energy Efficiency Expo is a new annual trade exhibition and conference dedicated to energy productivity and affordability. Organised by Reed Exhibitions Australia in partnership with the Energy Efficiency Council, the new event will be held for the first time in October 2019 at the Melbourne Convention & Exhibition Centre alongside All-Energy Australia and Waste Expo Australia. Energy Efficiency Expo will offer a platform for Australian industry to discover practical solutions for energy efficiency investments. The two-day event will combine an exhibition showcasing the latest low-carbon and cost-reducing developments with a conference programme featuring industry leaders providing expert advice on energy efficiency and productivity. According to Luke Menzel, Chief Executive Officer of the Energy Efficiency Council, the benefits of energy efficiency extend beyond basic cost savings. “Energy has become a first-order strategic issue for most Australian businesses,” he says. “As a result, they are actively assessing any option that can reduce their exposure to an increasingly volatile energy market. And they are finding that energy efficiency is one of the quickest and cheapest ways to bring down energy bills while raising business productivity.”

IU VIDEO CHANNEL EXPANDS WITH FIRST LIBRARY OF TUTORIAL VIDEOS

“We are excited to be partnering with Reed Exhibitions Australia to deliver the Energy Efficiency Expo,” adds Menzel. “I'm confident it will provide a valuable forum for Australian businesses to get across how they can act to take control of their energy costs."

Industry Update is delighted to announce that we are expanding our video offerings with a new series of tutorial style videos that perfectly complement our existing library of news style videos.

Robby Clark, Exhibition Director at Reed Exhibitions Australia, reckons that the Energy Efficiency Expo will be a perfect complement to All-Energy Australia and Waste Expo Australia.

In the first series, we are partnering with sensor specialist Vega to publish eight playlists of videos, each focusing on different aspects of sensor applications.

“Governments, businesses and industries are seeking innovative solutions and approaches to keep pace with the evolving energy sector, particularly around rising costs,” says Clark.

Each of the eight playlists is introduced by our own Tim Webster, who provides the fast facts on the content of the videos in the playlist. Then it is over to Vega’s applications engineers to

“Following strong interest from our attendees to better address energy efficiency, we are pleased to partner with the Energy Efficiency Council and shape this event into an engaging forum for collaboration and innovation.

present the detailed tutorials. All told, the library will include 60 videos to be released over the next 12 months via the Industry Update website and our twice weekly eNewsletters. These tutorial videos also mark a first for multimedia trade publishing. We will be publishing previews of each video in Industry Update magazine, complete with a QR code linked to the video. Simply scan the QR code with your mobile device of choice and you will be taken straight to the video on our YouTube channel. Turn to page 26

“Energy Efficiency Expo is an exciting new addition to our calendar of events, creating a one-stop shop for renewable energy, energy efficiency and waste and recycling events under one roof and providing a unique offering for the sector.” The first Energy Efficiency Expo will be held on 23rd and 24th October 2019 at the Melbourne Convention & Exhibition Centre.

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• NEWS

OFFSHORE BOUTIQUE FACILITATION MODEL OFFERS SKILLS SHORTAGE SOLUTION Integrated Office Solutions has an intriguing proposition for any company (manufacturing or otherwise) that is experiencing difficulties recruiting and retaining staff in roles that are not location dependant. Why not outsource the roles or set up a team in a country where skills are plentiful and affordable? The company will help recruit exactly the staff required and host them in its state of the art communications hubs in Manila, capital of The Philippines. Integrated OS is the brainchild of The Lamson Paragon Group CEO Rodney Frost, who was looking to recruit coding talent for his own Australian SME manufacturing operation. With a shortage of suitable candidates available in Australia, he set about investigating a number of typical countries and concluded that The Philippines offered the best balance of a suitably educated talent pool, English

language proficiency and a suitable time zone. No sooner had Frost established his own operation, complete with a local management team, than he started to receive requests for business space and services from other Australian companies throughout his network. As a result, Integrated Office Solutions now hosts more than 60 staff, performing roles from IT development, computer-aided design and web development to graphic design and customer service for a growing number of Australian SMEs. Frost insists that the workforce is entirely owned by the client companies. Integrated OS is there to coordinate and customise the dedicated professional teams in the Philippines that operate as a direct extension of the client companies’ businesses, working towards each company’s goals.

There are a number of advantages for the partner companies. And while the ability to recruit skilled staff and the reduced overheads are both strong draws, there are also competitive advantages to be gained from the time offset from the Australian east coast, which reduces the turnaround time for many projects. This allows SMEs to become 24 hour operations at little cost. Rodney Frost describes Integrated OS as a “boutique business”, and insists that it will not be allowed to grow beyond its critical mass – which he

believes to be around 500 employees. In the meantime, Integrated OS has begun to give a little back to the local community in Manila, partnering with the Upskills Foundation to increase educational opportunities for local children via a school funded with current partners. Integrated Office Solutions 02 9743 8577 integratedos.com

FINANCE PARTNERSHIP EASES MATERIALS HANDLING ACQUISITIONS Materials handling equipment company East West Engineering has enlisted the help of iFin Capital to offer equipment finance solutions to customers. The partnership will help East West Engineering customers to secure new equipment and grow their business operations by offering flexible finance options tailored to the needs of their business. East West Engineering offers a range of quality engineered material handling equipment such as forklifts, telehandler and loader attachments, crane and overhead lifting equipment, stillage cages, and waste and storage bins. iFin Capital specialises in developing long term finance strategies to help businesses to grow by allowing them to renew and upgrade their equipment and giving them the freedom to make positive business decisions.

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As an example, iFin Capital has helped one long term mutual client double its fleet size in the last 12 months (including many rotators from East West Engineering) helping it to secure new long term contracts, save money on its finance, negotiate to have security released from its existing bank loan and

secure finance limits for future growth. iFin Capital can finance any East West Engineering product outside companies’ existing funding lines, and offers access to all lenders in the Australian Market. The company claims that its extensive experience end deep

relationships with each lender can give customers a competitive advantage through their finance arrangements. East West Engineering 1800 061 998 www.eastwesteng.com.au

OCTOBER 2018

GET FIT FOR SUMMER Fit out your facility now with Big Ass Fans to make sure all your bits are summer ready. Increase comfort. Increase productivity. Increase savings. Increase chance of clothes staying on...winning! You'll save up to 30% on power bills and feel confident your facility is safe and comfortable for your workers. With fans ranging from 762mm up to 7.3m, we have a fan for every space, indoors or out. Call 1300 244 277 today and mention promo INDUSTRYFANS for a Free Beer Mug + Facility Recommendation or visit bigassfans.com.au for more information.

• COOLING AND FANS

A FAN IS JUST A FAN… BUT BIGGER IS BETTER Large, overhead diameter fans are an energy-efficient way to keep manufacturing facilities cool during summer, improving worker productivity and saving significant energy costs. As temperatures begin to heat up across Australia and the country prepares for one of the hottest summers on record, workers are already planning ‘sickies’ for any upcoming 40+ degree heat days. And those that do turn up will have productivity slashed by hot and stuffy conditions that drain motivation and reduce workplace efficiency. HVAC and other cooling systems don’t have the opportunity to pull a sickie, and are often over-worked when conditions start to heat up. Manufacturing and production facilities, warehouses and other working quarters can consume enormous amounts of energy just keeping workers comfortable on hot days – and this can be a major business expense. One solution from cheeky innovators Big Ass Fans that’s paying dividends across Australian industry is, exactly as the company’s name suggests, to install some big ass fans to circulate air more effectively and maintain consistent climatic conditions. Here are three ways a Big Ass Fan, in diameters up to 7.3m, can benefit workplaces this summer.

Cooler workers (in temperature – their fashion sense is still up to them!) Studies indicate comfortable workers are safer and more productive. And in the hot Aussie summer, a cooler worker is a comfortable worker. The addition of airflow can make people feel 5.6°C cooler during the summer months.

Energy savings Big Ass Fans are far more energyefficient than using several standard overhead or pedestal fans, and consume less energy than using HVAC throughout warehouses or production facilities. In fact, a single Essence fan – one of Big Ass Fans’ hard-working and economical overhead fans – provides cooling over the same area as 64 standard ceiling fans. Alternatively, Big Ass Fans can be used in conjunction with HVAC systems, to reduce the strain on these hard-working cooling devices and better circulate the cool air they are pumping out.

Better hygiene (and not just the reduced sweat from the workers!) The giant fans move air throughout the entire space, including in and around objects, such as machinery and stacked product. This airflow pattern ensures air reaches all corners of the building for optimum cooling. It also eliminates condensation and stagnant areas, which can compromise product quality if left uncleaned. “It’s really a triple benefit – workers are more productive, energy bills are down, and the risk of compromised product quality is reduced. Businesses can even apply for energy saving rebates, since Big Ass Fans are so much more efficient than standard alternatives,” says Big Ass Fans. Big Ass Fans provides energy-efficient

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cooling solutions for a diverse range of industrial and commercial needs, including indoor and outdoor use, with fans situated on ceilings, walls, or freestanding.

Let’s start from the top The largest, most powerful and most durable of the range, the Powerfoil X3.0 overhead fan, is backed by a comprehensive 15-year warranty and comes with optional SmartSense technology. SmartSense takes the hard work out of fan operation by automatically adjusting the speed based on temperatures and pre-programmed preferences. Using one large overhead fan instead of several pedestal fans on the floor not only provides more effective cooling, but it simultaneously frees up more floor space, allowing better utilisation of the space. A hermetically sealed NitroSeal gearbox keeps contaminants out, which means the gearbox requires zero maintenance. Ever. And for smaller (but still pretty big-ass) fan needs, the Big Ass Fans Essence spans up to 4.3m in diameter and can operate on ceilings as low as 3.8 metres. Its completely silent operation is ideally suited to spaces that are trying to minimise noise for workers, or for their neighbours.

Take the floor For facilities that can’t use a ceiling fan, or where a directional or floor-based fan is needed, Big Ass Fans provides portable, durable and effective mobile fans. These

options are ideally suited to manufacturing and industrial facilities that have outdoor spaces, or that need highly directional cooling in specific areas. The Black Jack and Yellow Jacket mobile fans both come with wheels for ease of movement, and have been designed to fit into tight spaces, including corners. The Black Jack has a diameter of 2m, so that it can easily fit through standard interior doors. It has rubber wheels to handle any terrain, and its slender design makes it ideally suited to narrow aisles. It is lightweight, manoeuvrable and easy for a single person to push around.

The perks of being a wall… mounted fan The Yellow Jacket, with 762mm diameter, can also be column or wallmounted to keep the floor clear and direct air from different angles. Its tough design means it can be completely cleaned with a hose if it gets dirty over time.

Fans of efficiency “We hope businesses across Australia are Big Ass Fans of comfy, productive and energyefficient workplaces, and we encourage them to look into the cost and energy savings before the summer heat hits,” says Big Ass Fans.

Big Ass Fans 1300 244 277 www.bigassfans.com.au

OCTOBER 2018

COOLING AND FANS •

COOL LOOK FOR HIGH-EFFICIENCY FANS Big Ass Fans reckons that its Haiku range offers the ultimate airflow solution paired with iconic design. The fans are designed and manufactured to provide silent, cooling comfort to both indoor and outdoor spaces. With a world reputation for excellence, Haiku uses ultra-efficient DC motors and patented aerofoils to create a cooling effect of up to 6°C. Ranging in size from 1.3 to 2.1m and available in premium finishes like luxurious aluminium and sustainable Moso bamboo, Haiku adds elegance and style to the ceiling. The fan’s SenseME Technology allows users to automate the fan to their personal preferences, keeping them comfortable and providing energy savings year round. Big Ass Fans 1300 244 277 www.bigassfans.com.au

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• EDUCATION AND TRAINING

WELDING TRAINING TO ANSWER QUEENSLAND SKILLS SHORTAGES

HIGHER APPRENTICESHIPS TAKE INDUSTRY 4.0 ONBOARD South Australia is set to host a ground-breaking Industry 4.0 Higher Apprenticeship scheme, led by Ai Group and funded by a grant from the Skilling Australians Fund and the Skilling South Australia Initiative.

"This new project will create 100 engineering technician apprenticeships over the next four years in both defence industries and the broader manufacturing sector."

"Ai Group has a strong commitment to developing the skills required for companies embarking upon their digitalisation journey. As Chair of the official Industry 4.0 Advanced Manufacturing Forum, successor to the Prime Minister's Industry 4.0 Taskforce, we are working with industry and government to ensure companies can engage in the ongoing industry transformation. Central to this is the development of Industry 4.0 capability and strategy inside business," said Ai Group Chief Executive, Innes Willox.

The programme will combine aspects of vocational and higher education to develop a range of skills, with a focus on emerging technologies. Existing mechanical engineering trade units will be complemented with the study of robotic systems, cloud-based data and computer aided design tools.

Steve Myatt, Head – South Australia, Ai Group, added:

Weld Australia is teaming up with the Queensland State Government and TAFE Queensland SkillsTech to improve welder training in Queensland to meet the demands of the state’s defence and manufacturing industries. The Government has pledged $800,000 to the project to fund the purchase of ten augmented-reality welding simulators, with five to be based at SkillsTech in Acacia Ridge, with the remaining five destined for regional areas. According to Queensland Minister for State Development, Manufacturing, Infrastructure and Planning Cameron Dick, “We want Queensland welders to have the technology and coursework to meet the international welding standard increasingly being required for major defence and commercial projects, so we are planning for the future.” “Training with the augmented reality system is considerably faster than traditional welding training, enabling us to get experienced welders to the ISO 9606 level in

INDUSTRYUPDATE.COM.AU

reduced time and cost over traditional training methods,” he added. Weld Australia CEO Geoff Crittenden added: “Queensland as a whole faces a significant shortage of qualified and certified welders. Without action, the state will be unable to meet future demand for defence, rolling stock, infrastructure and resources projects.” “In particular, Queensland’s welders must be properly trained and ready to deliver the $5 billion LAND 400 project. This landmark project is an economic game-changer that is expected to create over 450 advanced manufacturing and engineering jobs across the state,” said Crittenden. “With global defence giant Rheinmetall set to establish its Australian headquarters in south-east Queensland, local welders must be trained and qualified according to global best-practice to ensure they can reap the benefits of this huge defence industry programme,” he added.

The new apprentices will develop advanced technical skills through theoretical and on-the-job training while employed as an apprentice, before graduating with a Diploma in Applied Technologies.

FACTORY OF THE FUTURE TO HOST INDUSTRY 4.0 HUB Swinburne University of Technology is to host an Advanced Manufacturing Industry 4.0 Hub at its Factory of the Future. Set up with a $2 million grant from the Future Industries Fund, the hub aims to pioneer a new model of universityindustry collaboration covering both technology and business strategies. “Digital transformation of manufacturing is a game changer - which is why we’re creating a new Advanced Manufacturing Hub – to ensure Victorian businesses are well equipped to take advantage of this technology,” said Victorian Minister for Industry and Employment, Ben Carroll, in announcing the new hub. “The hub will help local manufacturers unlock the opportunities that exist with digital technologies to transform their operations, and deliver cutting edge products and services.”

Swinburne Deputy ViceChancellor (R&D) Professor Aleksandar Subic added: “Industry 4.0 is all about the next stage of development in the manufacturing sector driven by digitalisation. Automation and the Industrial Internet of Things in particular are transforming the manufacturing industry, presenting us with new business opportunities through better integration with the global supply chain,” Professor Subic said. The hub will leverage Swinburne’s $100 million investment in advanced manufacturing infrastructure and expertise. The Factory of the Future is Australia’s first fully immersed Industry 4.0 facility, featuring cutting edge and globally connected technologies including MindSphere – a cloud-based Industrial Internet of Things operating system developed by Siemens.

OCTOBER 2018

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• MOTORS & DRIVES

NOTHING LIKE A SPLASH OF SMOOTH RED conveyor lines meant that all the operators would be working in a shared space, so they could help each other for changeovers and other tasks. SEW-Eurodrive’s engineering and customer service together with energy efficient Movigear mechatronic drive system and high precision servomotors and Movidrive controllers were fundamental in obtaining the desired result. “This was probably one of our most successful projects undertaken”... “The premium for the high-efficiency, low-energy drives was not that much and, looking back on it now, it absolutely was the right decision.”

Taking the time to plan and prepare has paid dividends for this winery, after a redesign and refit of its bottling plant. Completed in only eight weeks, the upgrade required new drives for the bottle-conveyor system, plus the addition of air conditioning and hospitalgrade air filtration. The result? Three years on, productivity is up by 50% while energy consumption is down, despite the power requirements of the additional equipment. At a time when energy costs continue to spiral upwards, saving energy is not just good for the environment. It is just as important for the commercial bottom line. According to Jesse Auricht, Engineering Manager, Yalumba, decisions taken when planning the upgrade have turned out well in both regards. He says the choice of energyefficient SEW-Eurodrive Movigear mechatronic drive units to keep the conveyor lines and bottles moving contributed significantly to this positive outcome. The winery is serious about reducing energy costs, and monitors energy consumption continuously. Auricht says that typically half the cost of energy is based on network charges, so it is important to avoid any spikes in consumption as the wine bottles are filled, capped, labelled and packed in the bottling plant. “In the energy market, 50% of your cost can be dictated by a half-hour event,” he says. “If you hit that peak

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once, depending on the time of day, you’ll see an ongoing energy cost increase”. John Gattellari, National Industry Specialist – Food & Beverage, with SEW-Eurodrive, says the Movigear units are carefully designed to minimise the use of electrical power and help manufacturers make savings. Movigear complies with efficiency class IE4 (Super Premium Efficiency) and reduces energy costs by up to 50%, due to the high efficiency of all its components.

Planning pays off Once it was clear that the plant needed refurbishing, Yalumba decided not to rush in. Instead, the company embarked on a precision planning exercise that led to a completely redesigned system. Starting with its own design concepts, it issued a tender for detailed design and implementation of the project, and awarded it to Foodmach, a specialist Australian provider of machinery-design, manufacturing and control services. Working closely with Yalumba, Foodmach designed and installed the new conveyor and line control system. The revamped system consisted of the original bottling line with new controls, a new conveyor and new palletisers, and a second line with a new depalletiser, filler and packer. A radical new layout of the two

In addition to saving costs by reducing energy consumption, the upgrade led to a safer work environment, as forklifts no longer enter the bottling operator area. Instead, because of the improved layout, the bottles are palletised outside the main bottling area, away from pedestrian traffic. The upgrade also provided an opportunity to solve an engineering challenge in the labelling area. Labels on wine bottles need to look good. If the corner of a label is lifting slightly from a bottle on display, the consumer may select a different bottle. One of the problems for wine bottlers is condensation build-up in the labelling area due to the prevailing dew point temperature. If the wine temperature is lower than the dew point, there is a likelihood that the labels won’t adhere properly. To overcome this, Auricht and his team introduced an enclosed air-conditioned room around the bottling area, set to the correct dew point. At the same time, they introduced a positively pressured, hospital-grade filtration system to maintain clean conditions. “It was a large investment for something that might have seemed trivial at the start but, in hindsight, everyone is rapt with the decisions that were made. We look back now and don’t know how we managed without that room,” says Auricht.

Noise amplification – and reduction While solving the dew point

problem for better labelling conditions, the fully enclosed air-conditioned room did introduce additional noise. “By effectively putting it in a big esky, all the noise in the bottling area was amplified,” says Auricht. The issue of noise is significant, especially given the running speeds of the conveyors. Line 2, which is used for wine only, runs at 12,000 bottles per hour. “You get glass bottles banging into each other at that rate and it’s noisy – and potentially dangerous as well,” he says. Trevor Burgemeister, Process Control Technician at Yalumba, says that to alleviate the noise and danger of uncontrolled collisions, the system has been designed to detect when bottles are about to collide. When this happens, it sets a maximum collision speed. Auricht says that to achieve this, the drives need to be accurate, reliable, efficient and controllable. As for the noise component, he says that the Movigear is so quiet it’s negligible in

OCTOBER 2018

MOTORS & DRIVES •

and at different speeds, cause bunchedup groups of bottles to be fed into a single line. Complex programming, communicated to each Movigear drive in the system, makes the operation look easy. For Auricht, this is what good engineering is all about. He describes the process with a single word: “Poetry.”

Yalumba winery is serious about reducing energy costs, and monitors energy consumption continuously

of bottles per hour, it’s more of a cacophony.

comparison with the rest of the system. These characteristics, along with past performance and a strong relationship, were major factors in the choice of SEW-Eurodrive. “They have been a solid partner of ours for a long time. It’s a recognised brand and we’ve had a lot of success,” he says.

No pressure Key to reducing the noise is creating a ‘pressure-less line’. In this case, pressure refers to the accumulation of bottles at any point on the conveyor system, and not to the pressure of the wine within the bottle. It occurs when the conveyor is transporting more bottles than the individual machine process rate. If a processing machine for filling, capping or labelling is operating at a slower speed than bottles are being delivered, the bottles bump into each other, and that familiar sound of glass against glass can be heard. On a grand scale, though, it’s not a pleasant clinking sound that you might hear in a restaurant. At a rate of thousands

OCTOBER 2018

Auricht says that if the conveyor keeps running when this happens, the pressure continues to build up. This means energy wastage, inefficiency and noise, along with wear and tear on all the conveyors. On Line 1, which is used for many different bottle types ranging from sparkling wine with a cork to table wines with screw tops, the flow is between 5000 and 9000 bottles per hour. While the aim is zero pressure on the conveyors, the processing machines require a degree of pressure to function correctly. To achieve this, the conveyors on this line run at set speeds, while the line’s process machines vary their speed as necessary to maintain head pressure of between five and eight bottles. In the Foodmach line control system speeds are controlled by software programmed according to a ‘recipe’ that varies for each production variety. The recipe specifies which processing machines are required for the product and also their operating parameters.

during production, or if pressure buildup does begin to occur at one of the process machines, the conveyors are progressively halted to correct the situation. At the same time, the machine will be instructed to operate faster, so that the flow evens out again. According to Gavin Alder, Foodmach’s Controls Manager, “An added benefit of such fine line control is the ability to run reverse taper bottles (bottles wider at the shoulder than the base) which traditionally are difficult to run at speed, as bottle collisions result in fallen bottles.”

Poetry in motion Correct flow is set up at the start of the operation on the Foodmach depalletisers, where thousands of bottles per hour are fed into the two bottling conveyor lines. At this point, several ‘mini’ conveyor lines, running side by side

According to Gattellari, the compact design of the Movigear is optimised for horizontal conveyor systems like these. “The motor, gear units and electronics are combined in a single mechatronic drive system,” he says. “It caters for a range of communication systems, single line network installation (SNI), SEW system bus controller (DSC), binary (DBC) or AS-interface (DAC).”

Taking it to the world A flow-on benefit of the wellplanned upgrade has been preparedness for recent tightening of international quality standards in the wine industry. Because of the upgrade, the plant has continued to achieve positive audit outcomes, resulting in consistent export sales for this important Australian industry. “This was probably one of our most successful projects undertaken – both in timeframes and outcomes,” says Auricht. “In the scheme of things, the premium for the high-efficiency, low-energy drives was not that much and, looking back on it now, it absolutely was the right decision.” SEW-Eurodrive 1300 739 287 www.sew-eurodrive.com.au

Recipe data – speed, diameter of bottle, gap between bottles and the like – are communicated from the programmable logic controller (PLC) to the SEW-Eurodrive gears and units. These are calibrated so that the speed of the conveyor is set correctly. Burgemeister says that connecting the motion-detecting sensors to the motors and gear units, in order to manage the flow of bottles, was a simple operation. “It was just a matter of plugging the photoelectric in,” he says. If further calibration is required

Movigear complies with efficiency class IE4 (Super Premium Efficiency) and reduces energy costs by up to 50%.

INDUSTRYUPDATE.COM.AU

• MOTORS & DRIVES

BEWARE COUNTERFEIT BEARINGS Schaeffler reckons that counterfeit bearings are still placing vital machinery, plant and operations at risk in Australia and New Zealand. While genuine Schaeffler bearings comply with all relevant safety and quality standards and are comprehensively backed in the field by Schaeffler’s own staff and network of distributors, the counterfeit products come with no such assurances. “The best way for buyers to protect themselves and their customers from counterfeit bearings is purchasing only from a reliable source – such as direct from the manufacturer or through a certified distributor,” says Martin Grosvenor, Industrial Projects and Services Manager, Schaeffler Australia. The incidence of counterfeit industrial products is on the rise, and a recent study from the International Chamber of Commerce estimated that the annual economic and social costs resulting from their failure amounts to US $1.7 billion worldwide. “Globally, product counterfeiting is on the increase. Not just in consumer goods such as music, film, home electronics and designer clothing, but also in industrial, safety-critical products such as bearings and seals,” says Grosvenor. “The Internet has opened up more opportunities (and risks) for purchasers to buy bearings manufactured in India, the Far East and Africa but sold through non-certified traders across the world, including a growing number of European outlets,” he adds. So how do purchasers of bearings know that the products they are buying

EFFECTIVE

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are genuine and will perform as the product datasheet states? Most don’t have to worry because they purchase these products either direct from the bearings manufacturer or via a certified distributor. This method guarantees that any technical problems with the product can be resolved quickly and efficiently. Schaeffler has been active worldwide in identifying counterfeit bearings and removing them from the market. In 2013, the company destroyed 26 tonnes of counterfeit bearings with a value of more than Eur 1 million. A large proportion of the counterfeit products marked with the INA and FAG brand were seized in raids on bearing distributors across Europe, including Italy, Germany and the UK. The spindle bearings, spherical roller bearings, ball bearings and needle roller bearings scrapped during this operation were part of a much larger seizure of confiscated counterfeit products.

RELIABLE

Schaeffler Australia performed a similar operation in Sydney in 2012, where it destroyed more than 9.5 tonnes of counterfeit INA and FAG branded product it had confiscated throughout the year. Schaeffler is stepping up its work with customs authorities to fight product piracy. And recently, in March 2017, an importer in Turkey was imprisoned and counterfeit rolling bearings with a nominal value of Eur 250,000 were destroyed after customs officials at the port of Mersin began to suspect that the FAGbranded bearings might not be genuine. The customs staff sent photographs to Schaeffler’s Brand Protection Team, which then took over and handled all subsequent measures. In a measure designed to help users check the authenticity of their bearings, Schaeffler has now introduced the OriginCheck app, which an easy method

of clarification when suspicion about a bearing arises. The app is used to scan the twodimensional data matrix codes on the packaging of the bearings, and the user will receive immediate verification of whether the code appears in the Schaeffler database. However, if an authentic Schaeffler code has already been scanned multiple times, the user will be warned that the product might be suspect and asked to send photographic documentation to Schaeffler, giving a step-by-step explanation of which photographs are relevant. The OriginCheck app is available free of charge for iOS and Android operating systems in German and English. Schaeffler Australia 02 8977 1000 www.schaeffler.com.au

ECONOMICAL

OCTOBER 2018

MOTORS & DRIVES •

BOOST ELECTRIC MOTOR RELIABILITY WITH AUTOMATIC LUBRICATION Electric motors are the workhorses of manufacturing industry, with most processes from goods inward to dispatch relying on some form of motor. The reliability of these motors is critical: one breakdown can create a production bottleneck, and even stop an entire factory. With bearing failure identified as the most common cause of motor failure and costly downtime, it is easy to appreciate the importance of correct lubrication practices as a key strategy towards maintaining productivity. The lubrication of electric motor bearings is not a one-off action. All lubricants have a limited service life, and so relubrication is essential. And that relubrication needs to occur at regular intervals, using the correct quantity of the correct lubricant, making it a process subject to human error if it is performed manually.

In addition, WH&S practices may well dictate that manual lubrication is performed with the motor powered down or even cold, and this introduces additional challenges, such as ensuring that the old spent grease is not blocking the path of the fresh lubricant. In extreme cases this can even lead to lubricant being diverted into the motor windings, potentially causing catastrophic failure. Automatic lubrication using the GreaseMax system overcomes these limitations. A precise flow of the correct lubricant is continuously delivered directly to the bearings over the lifetime of the GreaseMax canister chosen, which can be up to 12 months. Underand over-lubrication are avoided. There is no need to stop the motor

to perform the lubrication, and so the warm lubricant easily flushes away the old spent lubricant, removing the risk of contaminating the motor windings. The result: properly lubricated bearings reduce the risk of motor failure,

leading to improved reliability and maximum up-time. GreaseMax 03 9723 8600 www.greasemax.com.au

Split Bearings/ Split Costs Schaeffler’s new Split Spherical Roller Bearings are purpose-engineered to minimise downtime of machinery vital to industries seeking to minimise production shutdowns and process interruptions. Split SRBs are designed to radically simplify the process of bearing inspection and replacement, reducing maintenance downtime by 50 per cent or more – while also reducing costs by eliminating complicated bearing replacement procedures in machinery and plant. So if maintenance is getting expensive, split the cost with Schaeffler Australia’s Split Spherical Roller Bearings. Discover more: www.schaeffler.com.au info.au@schaeffler.com

OCTOBER 2018

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• NETWORKING

ELEVATING ETHERNET INTELLIGENCE: IMPLEMENTING ETHERNET TECHNOLOGY IN INDUSTRIAL APPLICATIONS

By Cameron Dwyer

Manufacturers are faced with constant demands to increase productivity and reduce operating costs. A powerful industrial tool being implemented today to streamline production is reliable, enterprisewide connectivity, providing the highest level of visibility, control and flexibility. To accommodate evolving networking requirements, such as decentralisation of control, integrated diagnostics and simplified maintenance, network protocols integrate with industrial equipment and control systems to communicate crucial status updates and production data. As practices migrate away from pointto-point topology, advanced architectures ensure connectivity, collaboration and integration from the device level to enterprise business systems. With multiple protocols available, each offering diverse features, benefits and performance capabilities, this white paper will assist users in selecting the ideal communication solution to suit individual application needs. Used to connect various machines, devices and office equipment, networks enable manufacturers to visually manage all production parameters for continuous and complete control over data - streamlining efficiency and minimising production downtime.

By understanding the need for enterprise connectivity, the various challenges and considerations associated with implementing network protocols, users can maximise data acquisition and management capabilities.

Instead of using separate networks, Industrial Ethernet can unite a company’s administrative, control-level and device-level networks in a single network infrastructure.

OSI reference model What is Industrial Ethernet? Industrial Ethernet (IE) applies the Ethernet and Internet Protocol (IP) suite of standards developed for datacommunications to manufacturing control networks. It is based on the IEEE 802.3 standard, which is similar to Ethernet found in an office environment but adapted to an industrial environment for automation. This adaptation is not only an adaptation of the IEEE standard to industrial/automation environments, but also the adaptation of the hardware contained within the devices to withstand harsh environments that may have extreme temperature ranges, humidity and/or vibration that traditional office environment/ IT equipment are not designed to withstand. Many manufacturing companies maintain separate networks to support their factory floor operations and business operations. For example, the corporate IT network supports traditional administrative functions, the control level network connects control and monitoring devices and the device-level network links the controllers with the plant floor’s I/O devices.

The Open Systems Interconnection (OSI) reference model describes how information from a software application in one computer moves through a network medium to a software application in another computer. The model was developed by the International Organisation for Standardisation (ISO) in 1984, and is considered the primary architectural model for inter-computer communications. The OSI reference model divides the tasks involved in moving information between networked computers into seven smaller, more manageable task groups. These tasks are then assigned to seven layers in the OSI model. Each layer is self-contained so that the tasks assigned to it can be implemented independently.

The seven OSI layers are: • Application layer consists of application programs that use the network • Presentation layer standardises data presentations to the applications • Session layer manages sessions between applications • Transport layer provides end-to-end error detection and correction • Network layer manages connections across the network for the upper layers • Datalink layer provides reliable data delivery across the physical link • Physical layer defines the physical characteristics of the network media

The seven layers are stratified into two layers: upper and lower. The lower layers (physical, datalink, network and transport) focus on data transport functions while the upper layers (session, presentation and application) focus on the applications. While Ethernet technology refers to only the physical and data link layers, Industrial Ethernet encompasses the physical, datalink, network and transport layers by using Internet Protocol (IP) addressing in the network layer and Transmission Control Protocol (TCP) in the transport layer. This is also known as the IP suite.

Internet Protocol (IP) suite The Internet Protocol (IP) suite is a set of protocols and standards used for the Internet and enterprise networks. It is commonly referred to as TCP/IP because of its most important protocols: Transmission Control Protocol (TCP) and Internet Protocol (IP). IP is the primary network, defining the address by which the network can transmit the packet from its source to destination. IP provides connectionless delivery of datagrams or packets through a network and provides fragmentation and reassembly of datagrams to support datalinks with different maximum transmission unit (MTU) sizes. TCP provides reliable delivery of packets between two devices, relying upon IP. TCP establishes connections between applications, allowing them to send packets to each other. It also maintains the state after the packet is sent, ensuring all packets have arrived. Or if a packet is dropped, lost or corrupted during transmission, TCP can also request retransmission.

TCP/IP has four layers, each with its own protocols: • Link layer (Ethernet) contains communication technologies for a local network • Internet layer (IP) connects local networks,

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OCTOBER 2018

NETWORKING •

information. EtherNet/IP provides users with tools to deploy standard Ethernet technology for industrial applications. With EtherNet/IP, the exchange of data is based on the producer/consumer model. This means that a transmitting device produces data on the network and multiple receiving devices consume this data simultaneously. Traffic generated during this data exchange can include input/output data and status updates produced by a remote device for consumption by one or more programmable controllers.

establishing internetworking • Transport layer (TCP) handles host-tohost communication • Application layer (HTTP) contains all protocols for specific datacommunications services on a process-to-process level (ie how a web browser communicates with a web server).

Selecting networking protocols When choosing a networking solution, users must understand the individual communication requirements as well as any environmental challenges present in each application. Evaluating the performance capabilities, features and characteristics of EtherNet/IP, Modbus TCP and Profinet will help manufacturers in selecting the ideal networking solution for their critical communication needs.

EtherNet/IP Ethernet is a relatively new addition to the industrial arena. Developed with the primary purpose of conveying large amounts of information, it was originally relegated to office level networks, where multiple clients use the network to share information. Recently, Ethernet has expanded beyond traditional usage, and with the advent of EtherNet/IP, Ethernet has been implementing on the plant floor. Ethernet is a superior solution for data collection, transmission and monitoring. EtherNet/IP is a communication protocol supported by the ODVA and is designed for use in industrial automation and process control applications. It takes the Common Industrial Protocol (CIP) and implements it onto the foundation of Ethernet. CIP envelops a wide-ranging suite of messages and services for a variety of applications, including safety, control, configuration and

OCTOBER 2018

Data collected and controlled via EtherNet/IP can use an unacknowledged method of sending information between devices on a network, which means that data delivery is not guaranteed. Therefore, to ensure delivery, a higher layer must be implemented prior to data transfer. For enhanced industrial communication, Transmission Control Protocol/Internet Protocol (TCP/IP) provides a set of services so devices may communicate over an Ethernet network. With the increased prevalence of Internet and intranets for internal information distribution, TCP/IP has grown, and has been transported to all major computer operating systems. A typical example of when a manufacturer would implement an Ethernet TCP/ IP network is to extend communication plant-wide to connect to a corporation’s worldwide network via the Internet. Ethernet TCP/IP can take advantage of Ethernet’s high capacity for data management to perform a wide variety of tasks, without requiring a high level of determinism or repeatability for message response time. Common TCP/IP applications include program maintenance, data transfer, web page retrieval, supervisory control, connectivity for operator interfaces and events and alarm recording.

Modbus TCP Modbus TCP is a variant of the Modbus family of simple communication protocols intended for use with automation equipment. It covers the use of Modbus messaging in an environment using the TCP/IP protocols. Although it can be used in a variety of applications, the most common use of these protocols is for Ethernet attachment of PLCs, I/O modules and gateways to other fieldbuses or I/O networks.

to the IP; the data are then placed in a packet and transmitted. TCP must establish a connection before transferring data as it is a connection-based protocol. The master (or client in Modbus TCP) establishes a connection with the slave (or server). The slave waits for an incoming connection from the master. Once a connection is established, the slave then responds to the queries from the master until the connection is closed. Modbus TCP offers many advantages, including its openness, simplicity, low-cost development and minimum hardware required to support it. Operators can simply use standard PC Ethernet cards to communicate to implemented devices. Further, interoperability among different vendors’ devices and compatibility with a large installed base of Modbus-compatible devices makes it an optimal protocol solution.

Profinet Profinet is the open Industrial Ethernet standard of Profibus and Profinet International (PI) for automation. It uses TCP/IP and IT standards and complements them with specific protocols and mechanisms to provide real-time performance capabilities. Profinet enables the integration of existing fieldbus systems like Profibus, DeviceNet and Interbus, without changes to existing devices. This makes it ideal for multiple industrial applications, including factory and process automation. It is also recognised as a standard in the automotive industry for machine building, food, packaging and logistics applications. Featuring integrated, Ethernet-based communication, Profinet satisfies a wide range of requirements, from data-intensive parameter assignment to synchronous I/O signal transmission. Further, Profinet communication takes place over the same cable in all applications – from a simple control task to highly demanding motioncontrol applications. Profinet easily conforms to existing plant settings, eliminating the need for costly custom solutions. As it is based entirely

on standard Ethernet, operators can easily combine wired and wireless transmissions. This allows WLAN and Bluetooth communication to be integrated into the solution, including for real-time data. Profinet offers several advantages in comparison to other protocols, including more flexibility to control automation devices, high-speed operation through real-time communication, a simple network structure for easy implementation and cost-efficient technology. Profinet uses three different communication channels to exchange data with programmable controllers and other devices. The standard TCP/IP channel is used for parameterisation, configuration and acyclic read/write operations. The real time (RT) channel is used for standard cyclic data transfer and alarms. RT communications bypass the standard TCP/ IP interface to expedite the data exchange with programmable controllers. The third channel, isochronous real time (IRT) is the high-speed channel used for motion-control applications.

Three protocols, one device For a reliable solution across hardware platforms, these three protocols - EtherNet/ IP, Modbus TCP and Profinet - can be deployed in one device to create easier integration with host control systems. This can be applied in any application that uses a host system with Modbus TCP (client), EtherNet/ IP (scanner) or Profinet (master). On network power-up, the Ethernet device recognises the network protocol available to the network, allowing only one Ethernet master to control the outputs while the input and diagnostic data are available to the other two protocols. This technology eliminates the need to configure a device based on the Ethernet host system that will be deployed, ensuring easy device application, minimal maintenance and simplified product specification. Cameron Dwyer is Managing Director of Turck Australia.

As stated in the previous section, TCP and IP protocols are used together and are the transport protocol for the Internet. When Modbus information is sent using these protocols, the data are passed to TCP where additional information is attached and given

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VEGA TUTORIAL VIDEOS - PART ONE OF A SIX PART SERIES - PART TWO NEXT MONTH

COMMS MODULES SIMPLIFY SENSOR SETUP AND ADJUSTMENT Radar sensors from VEGA provide unparalleled accuracy in level measurement, but many of their applications mean that they are mounted in hard to reach places. That’s where the VEGA Plicscom module comes in. The Plicscom communications module can be used to add Bluetooth capabilities to any Vega sensor produced since 2002. In this series of videos, VEGA engineers Ralf Holl and Juan Garcia demonstrate how this communications capability can be used to set up, adjust

and perform diagnostics on radar sensors in the field. The videos show how the Plicscom module can be accessed using a magnetic pen, a laptop, tablet or smartphone, providing full access to sensor data and parameters, even in hard-to-reach applications. Ralf and Juan go on to show how the Bluetooth module’s 25 metre range can be extended using Vegadis remote display modules in applications where sensors are mounted on tall vessels and in particularly remote locations.

Scan the QR codes with your mobile device to see each video or visit www.youtube.com/c/ IndustryUpdate. VEGA Australia 1800 817 135 www.vega.com

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OCTOBER 2018

SOLAR •

PALLET REPAIR FACILITY HOSTS FIRST PRINTED SOLAR INSTALLATION

A new form of low-cost renewable energy is nearing the market with the unveiling of Australia’s first commercialscale organic printed solar installation at the CHEP Beresfield pallet repair facility in Newcastle. The organic printed solar cells are have been created by a University of Newcastle team led by Professor Paul Dastoor, and were manufactured in-house on a lab-scale printer at the university’s Newcastle Institute for Energy and Resources facility. According to Prof Dastoor, “This is the first commercial uptake of printed solar in Australia, most likely the world. It’s an historic step in the evolution of this technology and another example of private enterprise and community leading the charge in the adoption of renewables.” The printed solar cells come in the form of a roll of ultralightweight laminate material that is installed using standard industrial double-sided adhesive tape, and costs less than $10 per square metre. The installation at the CHEP facility covers 200m2 of the roof and was made up of 640m of the solar cell material, which was installed by a team of five in just one day. The installation was unveiled at a ceremony on Thursday, with the official opening conducted by Federal MP for Newcastle Sharon Claydon, who highlighted the University’s work on the project as “exactly the work the Australian Government should be supporting.” CHEP is a Brambles company, a group that has its origins in Newcastle, and Claydon went on to praise the role

OCTOBER 2018

of Brambles in the project as a “great global citizen.” Brambles is no stranger to renewable energy, with the company’s Senior Manager for Sustainability, Lachlan Feggans, pointing out that globally, the company currently uses 20% renewable energy – a figure that will certainly rise as part of its embracing of the circular economy model. According to Feggans, “Our cost benefit analysis of PV solar shows that it isn’t viable just yet. But this printed solar could be a game-changer.” Feggans went on to highlight this year’s increases in energy costs, which for Bramble meant a 52% increase across Australia. “We have to consider the energy cost per pallet,” he concluded. Meanwhile, the printed solar installation is up and running at CHEP, and will provide University of Newcastle team with valuable data on the commercialisation of the technology. And at mid-day on the official opening day, the installation was producing 699W per square metre. While the solar cells themselves are nowhere near as efficient as conventional PV cells, they are much cheaper and quicker to manufacture, much lighter in weight, and much easier to install. They also suffer from a considerably shorter operating life – currently calculated at around two years. The CHEP installation is scheduled to run for just six months, after which the cells will be removed and recycled. Says Prof Dastoor: “My goal is to completely recycle the old material and use that resource to manufacture new solar cells.”

INDUSTRYUPDATE.COM.AU

• AUSTRALIAN MADE

COUNTERFEITERS TO FACE THE MUSIC AFTER BRISBANE PIANO BUST documentation showing that they had come from Australia. According to Australian Made Campaign Chief Executive Ian Harrison, the importer had provided evidence that it had registered a “copycat” Australian Made logo as a Class 15 trademark in China in a bid to further con consumers.

The Australian Made Campaign has revealed the lengths to which some makers of counterfeit goods will go to falsely claim Australian manufacture for their goods, with false claims, a bogus logo and a tortuous import/export route all parts of a recent episode. Last month, the campaign’s offices were informed that Border Force Queensland had intercepted and impounded ten pianos that had arrived at the Brisbane Port from China days earlier. These pianos carried a number of logos and stamps claiming to be “made in Australia” or “Designed and Assembled in Australia” with one closely replicating the iconic green-and-gold Australian Made logo.

“We discovered the logo they trademarked was not even the logo used on the imported pianos – it was a direct copy of our trusted Australian Made logo,” he said. “Fraudulent manufactures like this one have clear agendas; to swindle consumers,” continued Harrison. “This was a clear-cut situation whereby the manufacturer’s intention was to build

dubious-quality pianos in China to pass off as premium Australian Made products to sell back to Chinese consumers.” “They put the bogus Australian Made logos on them to further deceive

potential buyers then shipped the instruments to Australia and back again in attempt to have appropriate paperwork in attempt to prove they came from here.” Having originally applied to have the goods released, the importer has since contacted Border Force to rescind its claim on the goods, and so the pianos will be destroyed. AMCL is now investigating what legal action can be taken to challenge the company’s trademark in China.

Border Force officials said the imported pianos were due to be transhipped back to China so the retailers involved could provide

Australian Made Campaign 1800 350 520 www.australianmade.com.au

A VERY AUSTRALIAN ALLIANCE In a move uniting two iconic Australian names, the nation’s leading debit payments network, eftpos, has joined the Australian Made Campaign. “It’s wonderful to think that when consumers are at the checkout buying Aussie products, they can be doing so via the eftpos system – another fantastic Aussie innovation,” said Australian Made CEO, Ben Lazzaro. “eftpos is an Australian success story and a household name. The organisation should be commended for its commitment to local software development and providing Australians with best-in-class, secure 28

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payment systems.” According to eftpos Managing Director, Stephen Benton: “Our Australian-ness is very important to us, to our members, merchants and consumers. We have operated in Australia for 34 years and being Australian directs the way we operate our daily business - it’s who we are and what we do.” “Our rock-solid network, with built-in system redundancy, provides surety and security,” added Benton. “All transactions are processed in Australia

Australian Made CEO Ben Lazzaro welcomes eftpos CEO and Managing Director Stephen Benton to the Australian Made Campaign

and there hasn’t been a single eftpos network outage since the current platform launched in 2014.”

Australian Made Campaign 1800 350 520 www.australianmade.com.au

OCTOBER 2018

• PACKAGING

BUBBLE BAGS PROVIDE MADE TO MEASURE SHIPPING PROTECTION

Each bag has a 1mm-thick foam lining

Bubble wrap is everywhere. It has become the go-to solution for protective packaging for everything from glassware to industrial spare parts. But while it protects its contents well, it is also wasteful of both resources and time. Bubble wrap takes time to apply properly, has to be cut to size and needs to be secured with tape or strapping. And when it’s removed it usually becomes trash.

reusable and recyclable, and OJ Holdings reckons there’s no limit to the applications that can take advantage of this time and resource saving innovation.

OJ Holdings 1300 764 788 www.ojh.com.au

Custom-fitted bags provide uniform padded protection

But now there’s a serious alternative in the form of the Foam-Lined Bubble Bag from OJ Holdings. The bags are made using three layers of bubble wrap with a 1mmthick foam lining. They are custom manufactured for each application with durable industrially stitched seams, and can be produced with virtually unlimited dimensions. The custom fitted bags provide uniform padded protection, and are water-resistant, thereby avoiding internal condensation that might tarnish metallic contents. With a custom-sized bubble bag for each product, the job of preparing goods for despatch is made considerably easier, saving significant time typically used to cut and apply multiple layers of bubble wrap and secure it with tapes or bands. And the flat surfaces of the bubble bags are ideal for direct labelling, saving even more time in dispatch. Foam-Lined Bubble Bags are 30

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Bags can be produced with virtually unlimited dimensions

OCTOBER 2018

INDUSTRY UPDATE MEDIA SNAPSHOT PRINT MEDIA

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• PACKAGING

PROTECTIVE WRAP CUTS PACKAGING COSTS AND SAVES TIME The Geami WrapPak system, available from Signet, protects similarly to traditional bubble wrap, but contains no plastic. The Geami machine expands the patented die cut Kraft paper and layers it with tissue interleaf to provide shock-absorbing cushioning to goods in transit. Providing stylish, clean product presentation, the system saves valuable time thanks to the enhanced wrapping rates. The compact wrapping requires less storage room, and it provides further cost efficiencies due to reduced material handling. And no tape is required; the angled cells lock together easily. For Signet customer 99 Bikes, just one Geami machine has cut costs by 60% and reduced packing time by 50%. The product also enhances the ever-important shopping experience

for customers. Ecommerce manager Tom Dodd says Geami gives products the right protection, without sacrificing presentation.

“Having never seen a product like the Geami WrapPak before, we were intrigued as to how it stacked up to conventional solutions. For fragile items especially, choosing the right packaging is critical,” he says. “As an online retailer, we know what the customer sees when they open their box is just as important as the product itself. The simple yet effective product presentation, protective capabilities and ecofriendly qualities this solution offered were all the convincing we needed.”

Signet is the largest and longest serving Australian distributor of Geami WrapPak systems, catering for small packaging operations through to larger high-volume users.

Signet 13 74 46 www.signet.net.au

PROTECTIVE PACKAGING KEEPS CORROSION AT BAY Available now Australia from Pack King, PropaSteel is the latest in a long line of innovative packaging materials from PropaGroup in Italy.

Screw Compressors For full range scan QR code or go to

pneutechgroup.com.au/iu Call 1800 763 883 for all of your compressed air needs.

PropaSteel combines a super tough, flexible plastic film with an anticorrosive agent that allows it to protect steel and other metal objects and products at the raw material stage, after production, during shipping, and during storage. PropaSteel is suitable for protecting coils of steel, machinery shafts, engine blocks, parts, pipes and tubes. The film is super strong, and

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was developed in the Propa labs specifically to resist sharp edges, corners and product protrusions. It can be welded. It can be supplied in rolls, as sheets, bags, pallet covers, or in any task- or product-specific shape required. One area where PropaSteel can be particularly useful is in shipping steel goods overseas, as temperature changes during transit can often produce adverse conditions.

Pack King 03 9720 0425 www.packking.com.au

OCTOBER 2018

PACKAGING •

CAN LABELLING IMPROVE PACKAGING RECYCLING OUTCOMES?

Complete Packaging Lines Technical Support

Spare Parts

By Laurence Marchini

Partnership Programs Maintenance

Training

Powder Handling But can a label really make a difference? Recycling labels have been printed and embossed on packaging in Australia for decades. Yet many of the packages require specialised recycling that is not available in all municipalities.

If the past 12 months have taught us anything, it is that Australians are not as good at recycling as we thought we were. As Federal Environment Minister Melissa Price puts it: “One of the biggest issues for disposal of our waste, is the contamination of what goes into our yellow bins – running the risk that it ends up as landfill rather than used in a product such as recycled plastic pallets or bottles.”

This isn’t about to change. One of the new label varieties is for “conditionally recyclable” packaging types, and this is unlikely to remove the confusion. And a visit to the Planet Ark website reveals just how many goods fall into this category, and the different approaches of various waste authorities.

The Minister was speaking at the launch of the new Australasian Recycling Label, an initiative developed by Planet Ark and APCO, the Australian Packaging Covenant Organisation. The objective is to clarify the recyclability of various forms of packaging, thereby keeping recycling streams “clean” and improving the economics of recycling.

“This label does neither and industry believes that this label will not help hit the targets set by the Australian Packaging Covenant Organisation.”

This is not a surprise. Before the introduction of the new standard labels, it is estimated that there are no fewer than 200 different recycling labels currently used in Australia. To date, more than 50 Australian businesses have committed to the Australasian Recycling Label programme, with the likes of Woolworths, Officeworks, Nestle, Blackmores, Australia Post, T2 and Plantic already using the standardised labels.

OCTOBER 2018

Bagging & Palletising

Some criticism of the scheme has come from the Waste Management Association of Australia (WMAA). “In real terms, the label needs to solve two problems; it needs to tell consumers how they can dispose of the waste, and if the packaging is made from recycled product,” said WMAA CEO Gayle Sloan.

“Australians want to do the right thing but we’re confused,” said Minister Price at the launch of the new labelling.

Proven turnkey systems for powder processing industries. Delivery to dispatch.

The new label was launched along with new National Packaging Targets drawn up by APCO to set a sustainable path for Australia’s recyclable waste. There are four targets: 100% of all Australia’s packaging will be reusable, recyclable or compostable by 2025 or earlier; 70% of Australia’s plastic packaging will be recycled or composted by 2025; 30% average recycled content will be included across all packaging by 2025; and problematic and unnecessary single-use plastic packaging will be phased out through design, innovation or introduction of alternatives.

Lifting Systems

Ergonomic solutions for manual handling tasks.

(03) 9457 8244 Call to speak to your local representative www.kockumsbulk.com.au

INDUSTRYUPDATE.COM.AU

• SAFETY

PALLET RACKING PROTECTION IS MADE TO MEASURE

RUBBER STAIR TREADS SAFEGUARD STEPS AND STAIRWAYS

For bottom beam applications, Rack Armour’s custom designed units are individually modified to suit exact specifications and customer requirements, and the company is committed to working with its clients to ensure the best possible rack protection is made available.

Rack Armour Australia’s upright protectors have been designed to securely fit major pallet racking brands. From selective racking to drive-in options, Rack Armour has a product suitable.

Like the standard Rack Armour Protector, the custom units are effective down to -40°C, will not rust or corrode and offer an affordable investment for any warehouse looking to minimise pallet racking repair costs. Rack Armour Australia 02 9722 0502 www.rackarmour.com.au

Premises owners can improve both the safety and the look of new and existing steps and stairways by applying Floorsafe’s Full Step Safety Rubber Stair Treads. These stair treads not only provide outstanding slip resistance under wet or dry conditions, they are hard wearing and reduce noise. Made from heavy-duty 8mm rubber, Floorsafe Full Step Treads can be custom made to fit any step size. They

are available in a range of colours, and each tread is finished with a choice of aluminium or coloured fibreglass nosings. The treads come with a two-part adhesive that will provide a to concrete, timber, tile and metal surfaces.

Floorsafe Australia 1300 717 769 www.floorsafe.com.au https://youtu.be/hObX6ZZMJkI

Optimise performance with Intelligent Motor Control NHP delivers Intelligent Motor Control to provide key diagnostic information that enables you to optimise performance with real-time access to operation and performance trends. Access to production and machine data helps you to make informed decisions that improve production, mitigate downtime, increase productivity and boost profitability, offering substantial benefits over conventional approaches. Work smarter and increase asset utilisation by implementing an Intelligent Motor Control solution from NHP to improve productivity and avoid motor failures with an integrated, data-driven approach.

NHP ELECTRICAL ENGINEERING PRODUCTS 1300 NHP NHP | nhp.com.au |

34 98987_Industry INDUSTRYUPDATE.COM.AU Update_June_AD.indd 1

NHP 98987_06/18

To enhance your operations, visit nhp.com.au/more/intellmc

OCTOBER 12/06/2018 9:272018 AM

RACK ARMOUR

SAFETY •

DRUG AND ALCOHOL TESTING CAN BE CUSTOMISED TO NEEDS

PALLET RACKING PROTECTION SIMPLE, SUPERIOR, SOLUTION

Rack Armour will be on display at the Safety in Acton show Sydney from 9th – 10th October. We welcome you to our stand D18 to discuss how Rack Armour can provide ongoing rack protection, saving you thousands in potential rack damage. Having been installed into some of Australia’s leading organisations over the years, Rack Armour continues to impress. According to leading workplace drug and alcohol tester Andatech, substance use and abuse still play a significant role in work-related injuries and fatalities. According to the company’s Business Development Manager Jaka Exstrada, "Australian businesses are losing an estimated $6 billion annually due to substance use-related productivity issues and 7.5% of hospital morbidity is related to alcohol consumption in the workplace. "This abuse also contributes to adverse productivity outcomes such as absenteeism, lateness, a decrease in attention span, poor coordination, difficulty in comprehension and slower reaction time." However, most employers cannot justify having an in-house drug and alcohol testing regime, and so many are now turning to third-party testing, which is becoming more readily available.

"Organisations may not realise that on-site drug testing services, either urine or oral, can be set up for as little as one person per year,” says Exstrada. “In addition, they can also opt for education and awareness presentations and inductions, and policy and procedure development. "Third party testing is ideal for smaller businesses who want to comply with workplace health and safety but would prefer a professional with experience in testing to undertake the tests. "The testing service can also deal with awkward situations and it doesn’t hinder relationships between employees," he adds. Exstrada points to one Melbourne manufacturer that commenced testing earlier this year that has seen the incidence of positive readings halved from an average of 6% to 3%. The

THE TOTAL MATERIALS

HANDLING SOLUTION

If safety and cost saving is important to your business, Rack Armour is the product for your racking protection.

Hope to see you there

Telephone: (02) 9722 0502 • www.rackarmour.com.au improvement is expected to continue as staff realise they can't get away with it. The purpose of this company's testing regime is to prevent staff from arriving at work still under the influence of drugs or alcohol as they are putting themselves and others at risk from injury or worse. For companies who want to manage their own testing regime, Andatech offers urine and oral DrugSense kits that test for nine different drug types. The company also has the widest range of Australian Standard-certified breathalysers in Australia, including

Ask us about our hire & finance options

AlcoSense workplace breathalysers. However, many small enterprises are now turning to third party on-site drug and alcohol services from Andatech that uses a NATA accredited lab, certified collectors/testers and offers 24/7 on-site testing in all major cities in Australia, which is crucial when emergency and post-incident testing is required quickly.

Andatech 1300 800 200 www.andatech.com.au

YEARS

N I V E R S A RY

www.lencrowforklifts.com.au | 1300 536 276 (Australia wide) OCTOBER 2018

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• SAFETY

KERB BARRIER OFFERS RELIABLE GROUND LEVEL PROTECTION with A-Safe pedestrian barriers to prevent forks from penetrating into defined pedestrian areas, potentially putting personnel at risk. The eFlex ForkGuard is made from the same Memplex material as the company’s safety barriers, so it is flexible and capable absorbing repeated impacts with no need for replacement. This is combined with a pierce-resistant core structure for top-level fork protection. The high-visibility self-coloured material is effectively maintenance free. And because the ForkGuard units are hygienically sealed, they are food safe, and suitable for use in areas such as cool rooms down to -10°C. In facilities where forklifts and pallet trucks are used in confined areas, the eFlex ForkGuard kerb barrier offers reliable ground-level protection for walls, buildings, equipment and personnel.

Used on its own, a floor-mounted ForkGuard barrier will prevent forklift and pallet truck tines from impacting valuable infrastructure. The barrier can also be used as a pallet stop or

buffer, preventing stored goods from encroaching into pedestrian areas or walkways. Alternatively, it can be integrated

A-Safe Australasia 02 9625 8927 www.asafe.com

NO DRILLING – NO MESSY ADHESIVE – SECURED FIXING

PVC Tactiles

Stainless Steel

Carborundum inﬁll

Brass tactiles

Floorsafe Australia’s new and cost effective self-adhesive Quick-Fix individual tactiles have already proved a huge success with contractors, maintenance staff, centre managers, building owners and architects. Now you don’t have to fear about drilling holes and cracking tiles or using messy adhesives that may fail. The Quick-Fix peel and stick self-adhesive compound assures 99% adhesion every time and therefore requires no dry time. New installation works and replacement of missing tactiles can be carried out quickly and effectively.

For further information or samples contact Floorsafe Australia Pty Ltd

1300 717 769 or order from the online shop www.ﬂoorsafe.com.au or email sales@ﬂoorsafe.com.au

INDUSTRYUPDATE.COM.AU

OCTOBER 2018

SAFETY •

FORKLIFT FUNDAMENTALS 6 SAFETY AND MONITORING It was many years ago that seat belts were first added to forklifts, but it has been a challenge for many years to encourage operators to use them. This is particularly perplexing when it has been proved that in the case of a rollover an operator wearing a seatbelt is less likely to be injured and more likely to survive.

Like so many other pieces of equipment, today’s forklifts are safer to use thanks to improvements in both their design and functionality. The addition of safety systems such as sequential seat belts and operator present systems has taken safety a step further. But, as Ross Grassick points out, it is important to understand the workings of these safety systems to appreciate their full benefits. Operator present systems are common now on many units, and will not allow the unit to operate without operator sitting on the seat. When the operator is not in the seat the hydraulics and/or drive are isolated. Sequential seat belts are now fitted to most models. The idea behind this concept is to stop the unit starting or operating without the seat belt being fastened.

The solution has been to make the fastening of the seatbelt an essential part of the start-up process. With sequential seat belts the unit will not operate until the belt has been fastened properly. The down side of this is there are several different startup procedures for different brands of forklifts (none of these is wrong - just different). Today’s electric forklifts several other safety systems. For example, there are those that reduce cornering speed when carrying a raised load. Others will automatically put the unit into limp mode when the battery is discharged below a given level. It is important to remember that a forklift is not just a danger to the operator but also to other staff in in the vicinity. So now laser technology is used to make pedestrians aware there is a unit nearby by illuminating exclusion zones around a unit. Blue laser technology places a blue spot on the ground three metres behind a unit to make people aware that a unit is present, and this technology has been shown to reduce injures. There are also light exclusion zones projected on each side of the unit to make staff aware

THE TOTAL MATERIALS

HANDLING SOLUTION

of the proximity of the forklift, which is particularly useful in avoiding foot crushing. Making pedestrians more aware reduces incidents, and having these visible exclusion zones improves this one more level. A number of different systems are available for electronic pedestrian/ forklift identification and isolation. These are complete subject on their own as so many factors are need to make them work effectively in a commercial environment. Electronic forklift monitoring has become very popular in the past few years for companies with fleets of units. These systems use keyless access to regulate who operates each unit, whether by swipe card, fob or pin entry. The best monitoring systems maintain information on each operator’s licence data and will not allow use if it has expired. These systems also ensure that staff go through a thorough pre-start check routine before the unit will start.

Ask us about our five year warranty programs

Electronic forklift monitoring systems have multiple inputs that allow different parts of the unit to be monitored. These can include speed controls in certain parts of a facility. Also, should the unit experience a collision, the system will measure the impact and even shut the unit down with only a supervisor able to reset to allow the contact to be assessed. The systems use a variety of wireless technologies, such as GPRS or local RF monitors. This gives management real-time access to operational parameters such as run times, idle times, collision incidents and in some systems even unit travel plotting. They are designed to create a safer workplace by measuring KPIs to track that safety. Lencrow Forklifts has been involved on forklift hire and sales for more than 42 years and has worked with many of these systems. Lencrow Forklifts 1300 536 246 www.lencrowforklifts.com.au

YEARS

N I V E R S A RY

www.lencrowforklifts.com.au | 1300 536 276 (Australia wide) OCTOBER 2018

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FOLLOW PAS 13 FOR SAFETY BARRIERS USED IN

WORKPLACE TRAFFIC MANAGEMENT

â&#x20AC;˘ SAFETY

BLUETOOTH ADDON BRINGS MOBILE COMMS TO PROTECTIVE EARMUFFS

Make sure your workplace traffic management practices and barriers are compliant with PAS13. PAS 13:2017 contains industry-leading guidance in both the use and design of safety barriers in workplace environments. It is essential reading for anyone working in health and safety in workplace environments. This code of practice will revolutionise workplace safety for the benefit of every industry, every workplace, every person. PAS 13 covers:

Minimum requirements for barrier tests Pass/fail criteria for barrier survival and fixings integrity Tests for assessing kinetic energy of impacts

3M has developed a Bluetooth wireless accessory for its Peltor X series protective earmuffs available from RS Components. The Bluetooth addon is designed to allow workers to make and receive calls using their mobile phones without having to leave the site or remove their hearing protection. It will also allow them to communicate with colleagues also on site with a single push of a button. The wireless accessory simply snaps into place in between the headset and the earmuff cushion of an X series earmuff while

maintaining an IP54 rating for use in harsh environments. It includes a noise-cancelling microphone, and is designed to provide 8h of operation on a single charge (with 250h on standby). The Peltor Bluetooth wireless communication accessory and the X series earmuffs from 3M are now shipping from RS in the Asia Pacific region.

RS Components 1300 656636 au.rs-online.com

Appropriate force resistance measures This is the final word on safety barrier practice and

workplace traffic management procedures, worldwide. Make sure you comply.

tional product al, commercial and

nd equipment from impact damage, esence to prevent access or guide

e, A-SAFE bollards permanently 38 INDUSTRYUPDATE.COM.AU afe driving and can also act as

A-Safe Australasia Pty Ltd 02 9625 8927 www.asafe.com

OCTOBER 2018

SAFETY •

BOOTS BRING COMFORT TO RUGGED AND TOUGH WORK SITES

FIRE SAFETY SERVICES HELP MAINTAIN COMPLIANCE

Queensland legislation places obligations for fire and emergency safety on the business owner or manager occupying a building. The All-Terrain 55 (AT 55) series from Oliver Footwear combines comfort, performance and durability, and is specially designed for those working in labour-intensive industries such as construction and manufacturing. The AT 55 range is built to take on the most rugged and tough work sites, with total foot support and superior stability for all day protection. Each model is made using Oliver’s own innovative technology to help the industrial workforce perform at its best. These features include Comfortcushion to absorb impact, Heelguard for added stability and impact protection and a premium Coolstep lining to absorb moisture and odour for optimum freshness and hygiene.

Oliver backs itself with a 30day comfort guarantee that allows customers who have been fitted in-store the option to return or exchange the AT 55 series if they are not satisfied. The Oliver AT 55 series complies with Australian and New Zealand safety standards and is each made with top-quality water-resistant leather to enhance comfort while on the job.

Some of the compliance requirements within the Building Fire Safety Regulations include: maintaining service records; ensuring occupants are given appropriate instructions; conducting evacuation practice; and annually reviewing the emergency plan and evacuation signs. Qualified fire safety advisors may only be mandatory for certain buildings,

but their services in helping operators maintain compliance can be invaluable, regardless of the building size. Fire EMT provides flexible and professional services focusing on planning, compliance and training. The company’s services include an online compliance management system so information on obligations is always at users’ fingertips. Fire EMT 07 5428 1843 www.fireemt.com.au

The range includes lace-up, zip-sided and elasticsided boots with options of black and wheat colours. Oliver Footwear 1300 126 687 www.oliver.com.au

THE TOTAL MATERIALS

HANDLING SOLUTION

Ask us about our fixed price service contracts

YEARS

N I V E R S A RY

www.lencrowforklifts.com.au | 1300 536 276 (Australia wide) OCTOBER 2018

INDUSTRYUPDATE.COM.AU

• MACHINERY

EXEMPLARY PERFORMANCE BEGINS WITH UNRELENTING PRECISION Every workshop manager is aware of the relationship between precision in the manufacture of machines and their reliability, efficiency and life.

by a series of rapidly recurring current discharges between two electrodes. The process depends on the tool and workpiece not making physical contact.

One company in Queensland is acutely aware of this relationship because it is a key factor in staying ahead of its rivals – especially brands imported from Europe and the USA. Jenmick Gear Cutting & Engineering is first and foremost a well-equipped machining workshop with the capacity to carry out very precise and complex tasks on its CNC equipment.

Managing Director of Jenmick, Clifton Dimitrov, explains: “Wire-cut EDM can cut intricate contours or cavities in prehardened steels without the need for heat treatment to soften and re-harden them.

From its early days, Jenmick has built an Australia-wide reputation for the quality of its gears, and this dedication to excellence is reflected in its choice of new machinery for its Bassett Street workshops. The latest machines to be installed are a Joemars AWT3S wire cut and a 3-metre Harrison Alpha 1550XS lathe. Both machines were supplied, installed, and commissioned by the exclusive agent in Australia, 600 Machine Tools. The AWT3S is the latest in a family of wire cut machines from one of the world’s leaders in this technology. It handles workpieces up to 210 x 560 x 205mm, weighing up to 300 kg. Calibrated in millimetres, it boasts X travel of 350, Y travel of 250, Z travel of 210, U travel of 80, and V travel of 80. In electric discharge machining (EDM) technology, a thin single-strand metal wire, usually brass, is fed through the workpiece, submerged in a tank of dielectric fluid, typically deionised water. Material is removed from the workpiece

“This method can be used with other metals or metal alloys, including titanium, Hastelloy, Kovar, and Inconel.”

High precision Dimitrov notes that the AWT3S has Windows-based operation, with a very stable power system that increases machining efficiency: “We are now capable of machining even more complex shapes that would otherwise be difficult to produce with conventional cutting tools, and we can cut extremely-hard material to very close tolerances,” he says. “Our customers all over the country will appreciate our ability to machine very small workpieces where conventional cutting tools may damage the part from excess cutting-tool pressure. “With EDM, there isn’t any direct contact between tool and workpiece and, therefore, delicate sections and weak materials can be machined without perceivable distortion.” He adds: “Furthermore, a good surface finish can be obtained by redundant finishing paths, very fine holes can be achieved, and tapered holes produced. Pipe or container

Joemars Engineer Stanley Chang with Sandra and Clifton Dimitrov

internal contours and internal corners are achievable down to R .001."

A good turn The second machine now on line at Bassett Street is a CNC combination lathe from one of the most famous names in turning – the century-old Harrison of Yorkshire. Clifton Dimitrov notes that the XS CNC combination lathe range is popular for its fast, high-quality repeatability, accuracy, and surface finish to exacting toolroom accuracy standards (DIN 8605). “As we moved into general engineering, our client-base expanded and, accordingly, our workshops implemented a wider range of services,” he says. “For example, in addition to CNC lathes, we now have large radial arm drills, a drill press, and a 100-tonne press. In prototype or production runs, the new Alpha combination lathe, with its Fanuc OiTF control, means that we can now apply our renowned precision to workpieces of up to three metres in length.”

A quantum leap

600 Machine Tools Applications Engineer Dave McDonald (in the middle) demonstrates the Harrison Alpha 1550XS lathe to Clifton Dimitrov and Miguel Vasquez of Jenmick

INDUSTRYUPDATE.COM.AU

Manager of the Brisbane branch of 600 Machine Tools, Wally Nujin, says: “The ease of operation of the user-friendly Alpha range has been appreciated not only in the workshops of industry, but also in the workshops of education and training centres around the world.

“Fast, easy set-up times and simple operation in all modes are the keys to the Alpha’s global success. The series benefits from the ultra-high speed OiTF CNC control along with Harrison's own developed Alphalink software.” Nujin adds: “Now available is the remarkable Alpha XC model. It can execute off-centre drilling and boring, hexagonal milling, and much more. It is a combination CNC lathe that gives workshops the ability to perform secondary operations that usually require machining centres or expensive slant-bed CNC turning centres.”

The personal touch Established in 1999 by Clifton and Sandra Dimitrov, Jenmick is a familyowned and operated business. It has built a reputation throughout Australia for being a world-class gear cutting company. It is based in Gladstone, the fifth largest multi-commodity port in Australia, and the world's fourth largest coalexporting terminal, handling 50 million tonnes annually. Major exports include cement products, sodium cyanide, ammonium nitrate, alumina, and aluminium from the nearby Boyne Island smelter. Jenmick provides exemplary services to the industries that export these products – and many others around the country. 600 Machine Tools 02 9674 4738 www.600machinery.com.au

OCTOBER 2018

Charge right through your most challenging projects! The Rhino Cart Mobile Fixturing Station is a turnkey system for fixturing and clamping in welding and fabrication. Clamp and fixture at any point on the reversible, flat, nitrided (heat treated) 1200 x 750mm tabletop for accuracy in all setups. Rhino Cart Package Includes: 66 piece fixture kit.

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• MACHINERY

FIVE-AXIS MACHINING CENTRES PROVIDE PRECISION MOULD AND TOOL MAKING

Some of the five-axis machining centres in Hetec’s air-conditioned factory building

German machining services provider Hetec operates under the philosophy that "performance is not a matter of chance" – an ethos born out of company founder Friedhelm Herhaus' experience. Having felt hampered in his desire to put his specialist knowledge and skill to practical use and to the customer’s benefit, Herhaus joined his brother Günter to set up Hetec OHG, originally in Bad Laasphe. As the business grew, a third brother, Werner Herhaus, joined the company and in 2000 the next milestone was reached with the founding of Hetec GmbH. The early years of the new century saw the company make significant investments in CAD/CAM systems (three-axis) and, in 2002, in the first five-axis machining centre. In 2003, a new production facility focusing on large part machining was built at the present company headquarters in Breidenbach. The three brothers have continued to invest in CAD/CAM systems, CNC machine tools, workflow optimisation and remote monitoring of processes. This has put them into a position to provide their growing customer base with state-of-the-art manufacturing technology for highly demanding, complex tool and mould construction

INDUSTRYUPDATE.COM.AU

components as well as large scale basic tools at all times. By 2009, this investment in technology led the company into the world of five-axis machining with Hermle. This began with a C40 machining centre that was followed by a C 30 U and – as soon as they became available – the first large machines of the C 60 U and C 50 U series. In the course of time, a C 400 U was purchased for machining smaller items, and more recently by another large machine, a C 52 U.

Despite the broad range of applications to which they are put, the Hermle machining centres at Hetec use the standard tool magazines. Hetec has developed its own tool/magazine management system that allows all the milling machines and machining centres (each of which has the same HSK-A63 tool-holding fixture) to be tooled according to the order and the work to be done. Altogether this involves around 2000 ‘sharp’ tools, each provided with a chip, including around 250 different milling tools and around 300 for drilling and thread

cutting. This means that the tools can be changed ‘blind’ (deployed as required and with drastically reduced changing and equipping times). When Hetec purchased the new C 52 U five-axis machining centre, the company also adopted the Hermle Information Monitoring Software (HIMS), which provides a display of the life status and transmission of the information by email as required. This fits perfectly to HETEC's manufacturing and (remote) monitoring strategy: single-shift normal

According to Friedhelm Herhaus: "We have always received very good and fair advice from Hermle and we were and still are delighted with the 5-axis concept, with the performance, the very high degree of precision, the accessibility, the excellent and fast service as well as the very good support in all phases of a project." To illustrate this, Herhaus highlights that the C 40 U machining centre purchased in 2009 has already clocked up more than 30,000 spindle running hours – and it is still using the original spindle! Not to mention the fact that the precision values recorded in a measurement log from 2016 simply repeated those that had been recorded seven years previously!

The large machining area of the Hermle C 52 U

OCTOBER 2018

MACHINERY •

for 8 x 140 hours of manufacturing performance should be available on schedule. With Hermle’s help, we managed to set up and commission the C 52 U in a short space of time, and to meet the availability requirements not just temporarily, but in the long term as well.” “It really isn’t every supplier that can supply such a consistent and comprehensive package exactly on time – even in Germany with its reputation for machine construction there is not a great deal of choice," he concludes. The Hermle C 52 U five-axis machining centre

operation and otherwise (monitored) automatic operation. With a working range of x = 1000, y = 1100, z = 750mm and the 700mm swivelling rotary table with a load-bearing capacity of 2000kg, the C 52 U machining centre is ideally suited to full/finishing machining of extremely intricate tool and mould components or baseplates. Friedhelm Herhaus is full of praise

for Hermle, remarking: "Despite their increasing complexity, the Hermle machining centres can be set up very simply, commissioned quickly and they are operator friendly. The good accessibility also enables us to carry out a full redeployment on the large machines from one workpiece to the next within 15 minutes. This means that even without further automation,

we achieve spindle running times of 400 hours per month and machine as a single-part manufacturer.” “Another example of Hermle’s performance capabilities can be seen in the C 52 U five-axis machining centre project,” says Herhaus, “which we needed very quickly to satisfy urgent customer requirements. We received our order on condition that capacity

Hermle’s five-axis machining centres are now operating in an air-conditioned hall at Hetec, where they can supply the required degree of precision giving the company a significant edge over the competition. Applied Machinery is the exclusive distributor for Hermle in Australia. Applied Machinery 03 9706 8066 www.appliedmachinery.com.au

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Sydney Office:

600 Machine Tools 27 Foundry Road, SEVEN HILLS NSW 2711 Phone: (02) 9674 4738 | Email: machines@600machinery.com.au

OCTOBER 2018

Brisbane Office:

600 Machine Tools 292 Evans Road, Salisbury QLD 4107 Phone: (07) 3277 4844 | Email: qldbch@600machinery.com.au

â&#x20AC;˘ MACHINERY

LASER PROJECTION SYSTEM GUIDES ASSEMBLY FROM 3D CAD DATA

FARO has released a new generation of its Tracer platform for laser-guided assembly and verification. The TracerSI Advanced Laser Projection System is a fully integrated, optimised solution that includes both innovative, improved hardware built on the successful TracerM product and the best-inclass BuildIT Projector software.

Virtual template TracerSI uses 3D CAD data to project 3D laser images onto a physical surface and provides a live, visually rich virtual template which assemblers can use to quickly position components with precision and complete confidence. This solution can deliver significant ROI as organisations no longer have to invest in physical templates like moulds or tools that have to be built, maintained, stored or even repaired. According to FARO, the use of TracerSI will reduce manufacturing errors and minimise costly scrap and reworks costs. The company has documented cases where rework and scrap savings alone have provided payback periods as short as 90 days. TracerSI will transform 2D imagery and its use in every industrial application as it represents the first of its kind laser-scanning camera, with projection and high-resolution image scanning capabilities throughout its entire projection volume. As the laser scanning camera does 44

INDUSTRYUPDATE.COM.AU

not rely on lenses or conventional image capture, the depth of field is equal to the full projection range, there are no lighting limitations as it is laser illuminated, and there are no limitations on frame size and resolution. This combination of laser scanning imagery and high accuracy projection establishes a new industry standard for repeatable laser-guided assembly.

Synchronised alignment Feature based alignment substantially reduces the time required for setup. And the system performs high-resolution image scans of the part or assembly to synchronise alignment by matching known features to the CAD model. Throughout the assembly process, at any point, users can quickly run an image-based quality check and confidently take any corrective or preventive actions to facilitate the end-to-end assembly process. This includes the ability to detect presence or absence of features during the assembly process or at final assembly.

FARO Technologies +65 6511 1350 www.faro.com

OCTOBER 2018

’S APPLIED World class performance, without the price tag. That’s Applied thinking.

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To find out more, call: 03 9706 8066, Email: sales@appliedmachinery.com.au, or visit: www.appliedmachinery.com.au 22/12/16 9:27 am

• MACHINERY

BARFEEDER ADDS A LARGE DOSE OF PRODUCTIVITY Campagno Engineering was set up in 1979 in Dandenong Victoria by Jorge Campagno as a specialist in CNC milling and turning, and the design and manufacture of special-purpose tools. From a one-person operation with floor space of 75m2, the company has grown to now employ 26 highly skilled tradespeople and support staff in a purpose-built 930m2 factory. Jorge, his wife Amanda and their family have invested in the latest machine technology to ensure that Campagno stays at the cutting edge of engineering in Australia and maintain the ethos of providing fast efficient service and prompt on time delivery. The company specialises in product categories that include packaging, medical, truck, defence and general engineering. Prototyping is another key area where the company’s extensive experience has frequently enabled Campagno to suggest better and more efficient ways for new parts to be manufactured.

company was the key reason for the purchase.

Jorge Campgano was keen to acquire a barfeeder to complement a new CNC machine to assist in producing parts in a more efficient way. The increased productivity that the barfeeder would bring to the

“We looked at a number of different brands but it was the sheer quality and rugged construction of the servo-driven Hydrafeed that won us over,” said Campgano.

The Hydrafeed barfeeder allows a CNC machine to run unattended and is a very user friendly unit with an additional productivity benefit over other barfeeders on the market. “Once you’ve set a bar size and saved the setup, you are not required to open the cover again. You simply call up the program from the touchscreen and the Hydrafeed will set itself on centreline automatically thanks to the servo drive bar lifter mechanism,” Campagno added. Standard features of the Hydrafeed include a fully automated setup through a user friendly HMI screen and the versatility to accommodate different bar diameters and lengths including random bar lengths. A wide variety of models are available to suit any application. “One of the other features is that the Hydrafeed is very easy to use, so it doesn't take long for staff members to become proficient at operating it,” explained Campagno. “Price of course was also important in our purchase decision, but it’s the support and service from the supplier which I believe is crucial, as it can become very expensive in time wasted. I’ve been dealing with Dimac for 30 years and it’s their knowledge, quality products and after sales support that was another key reason for opting for the Hydrafeed,” said Campagno. “Just like other products we’ve purchased from Dimac our purchase experience with the Hydrafeed was excellent, from the first inquiry to the delivery, installation and end training,” he added. “The Hydrafeed barfeeder has added a large dose of productivity and I would certainly recommend the Hydrafeed without hesitation to any company,” Mr Campagno summed up.

Dimac Tooling 03 9771 6121 www.dimac.com.au industry update ad.indd 1

INDUSTRYUPDATE.COM.AU

30/08/2011 5:25:30 PM

OCTOBER 2018

HYDRAULICS •

AUSSIE ICONS BROUGHT TO LIFE IN BRONZE WITH A HYDRAULIC HELPING HAND Virine. But in addition to the artistic sensitivity Piperides shows towards his subjects, there is also the matter of the considerable force requirements and weights encountered in the manoeuvring of often monumentally sized projects that come through the foundry on a regular basis. “Any casting never comes out perfect, so we use Enerpac equipment to shape and adjust the casting elements to match each other,” says Piperides.

Phillip Piperides

An Australian art foundry with works featured in major public and private spaces and projects around the country uses Enerpac hydraulics to delicately and deftly manoeuvre components of the heavy bronze masterpieces during the casting, assembly and placement processes. The Perides Art foundry in Brisbane is headed by international sculptor Phillip Piperides. The foundry provides classic, contemporary, sporting and memorial pieces among its range of hundreds of artworks highlighted at major architectural, commercial and construction sites around Australia, as well as in retail, hospitality facility, art gallery and private collections. The sculptures range from classic beauties and military themes, to famous figures such as the Bee Gees and Rugby League legend Darren Lockyer, and Brisbane Lord Mayor Clem Jones, each lovingly crafted to the artists’ specifications under Piperides’ watchful eye. And they are manipulated and moved into place using the same compact, tough, safe and reliable Enerpac 700bar hydraulic technologies proven in the hardest industrial applications, including mining, construction, steel fabrication and manufacturing applications. The Cyprus-born Australian-raised and globally experienced Piperides is a recipient of the Churchill Fellowship (Sculpture) in recognition of his clay and bronze monumental castings and his artistic experience gleaned throughout America, Europe and Australasia, including private classes here from Russian-born master sculptor George

OCTOBER 2018

“The sculpture components typically weigh from 10 to 500kg, and are irregular shapes, so there can be a bit of adjustment involved. Sometimes too we need to press out sections with some deformation, such as where welding lugs have pulled at the base – so we adapt the Enerpac tools for the pressing task.” It is heavy and painstaking work, which was previously accomplished using older, less reliable and less precise manual and hydraulic technologies now replaced by compact and powerful 700bar Enerpac gear. The RSM 50 5t-capacity low-height cylinder, RC 55 5t single-acting cylinder and easily portable P392 hand pump were specified and supplied by Enerpac Territory Manager – SE Queensland and Northern NSW, Sandy Whyman. SM Flat Jac and complementary RCS series cylinders, in capacities from 5 to 150t with strokes from 6 to 62mm, are designed to offer maximum power-toheight ratios for working in inaccessible or awkward spaces. RC series general purpose cylinders, in capacities from 5 to 95t, with strokes from 16 to 362mm, are a workhorse of Australian mining, construction and infrastructure sites, where they are valued for their reliability and Enerpac service and safety backup. P392 hand pumps are part of the P series of versatile easily portable hand pumps with large oil capacity to power a wide range of cylinders or tools. The 4.1kg P392 used by Piperides features twospeed operation to reduce handle strokes by as much as 78 per cent compared with single-speed pumps. They easily actuate the cylinders, attachments and WR5 Enerpac spreader used to manoeuvre, bend and straighten solid objects.

“These tools are globally proven in tough applications – ranging from mining and construction, through to steel fabrication and manufacturing – so they are ideal for applications such as this requiring the reliable, safe and precise application of force,” says Whyman. “The sculptures handled by Mr Piperides and his staff are precious and wonderful objects that deserve the greatest of care, respect – and considerable power to manoeuvre them this way and that.”

happy with the quality and versatility of the tools we have, and we will use them as a base for future expansion.” Enerpac 02 8717 7200 www.enerpac.com.au

“So hydraulic power proven in tough industries was also just right for this artistic application,” said Whyman, who also advises architecture, construction, engineering, mining and other Enerpac customers on the best, most efficient and safest tools for the job. Piperides says Sandy Whyman provides exemplary advice and service: “She is wonderful actually. We have no doubt that we will find uses for other Enerpac tools she has shown us, as we move along.” “We can see many uses for Enerpac pull cylinders, for example, which could be very useful in foundry applications. But for now, we are very

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• WASTE MANAGEMENT/ENVIRONMENT

A SAFER AERATION ALTERNATIVE operators can only access them via floating walkways or some kind of vessel, requiring working over water. Alternatively, the aeration devices may need to be lifted out using cranes or other lifting apparatus.

Most of the safety issues/risks associated with surface aerators can be eliminated by using “bank mounted” Venturi-Aerators without performance

reduction, according to Australian distributor Hydro Innovations. With surface mounted aerators,

Maintenance of these units is relatively simple as well. With no moving parts in the aerator, only the pump will require any level of maintenance, and Gorman-Rupp

Venturi-Aerators are “powered” by Gorman-Rupp self-priming centrifugal pumps, so they can be mounted on the banks of the lagoons. This means that operators can perform all required servicing and maintenance without having to “work over water”, “work at heights” or “work with heavy swinging weights”.

pumps have a long track record of

When attempting to minimise risks associated with the aeration of ponds and lagoons, designers can eliminate most of them by simply choosing Venturi-Aerators over other technologies. This does not mean that efficiency has to suffer. Venturi-Aerators have been tested to produce as much as 1.86kg of oxygen transferred per kilowatt per hour.

more convenient, any minor issues

reliability and dependability. One operator can safely adjust clearances in minutes and check and adjust seal and bearing oil levels quickly and easily. And because monitoring is so much easier and can be addressed before they become problems – all in a relatively risk-free manner. Hydro Innovations 02 9898 1800 www.hydroinnovations.com.au

FAST CHARGERS TO ATTRACT EV DRIVERS TO WINE COUNTRY “Tritium’s success is a timely reminder that we have the smarts and skilled labour force here in Australia to be an advanced manufacturing powerhouse,” said Senator Tim Storer, Chair of the Select Committee on Electric Vehicles. “Imagine what they could achieve if we had a national strategy to support the development of the EV industry here in Australia. I hope my inquiry will prompt the Federal Government to be more proactive, so that companies like Tritium can more fully realise the benefits on the electric vehicle transition.”

Australia’s electric vehicle infrastructure continues to expand with the opening of the nation’s 50th publicly accessible 50kW DC fast charging location at the Hunter Valley Gardens in NSW. The NRMA has installed two of Tritium’s Australianmade Veefil-RT 50kW DC fast 48

INDUSTRYUPDATE.COM.AU

chargers as part of the rollout of its $10 million electric vehicle fast charging network.

that when the charging infrastructure

According to Chris Hewitt, Brisbane-based Tritium’s Head of Sales for Australia, “It’s been proven time and time again across the globe

the road and in showrooms. We now

is in place for electric vehicles, you’ll see an uptick in the number of EVs on have a significant number of publicly available chargers across the country with more to come.”

The NRMA’s electric vehicle network is scheduled to be completed in 2019 and aims to install approximately 40 DC fast charging sites across New South Wales and the ACT. Tritium’s Veefil-RT chargers accommodate most makes and models of EVs available in Australia, allowing users to charge their vehicles to 80 per cent within 30 minutes on average.

OCTOBER 2018

WASTE MANAGEMENT/ENVIRONMENT •

ASPHALT PLANT TO CONVERT TO SUSTAINABLE MIX Lake Macquarie in NSW is to be host to a new sustainable asphalt plant to be run by Downer Group. The $8 million plant was given the green light last month by Lake Macquarie City Council. It will replace the company’s existing plant at Teralba, and will be capable of incorporating recycled materials into the asphalt it produces. Annual production is expected to be up to 160,000 tonnes, incorporating waste materials such as soft plastics from plastic bags and packaging, glass and toner from used print cartridges. The move follows the successful trial of the sustainable asphalt on a road at Craigieburn in Melbourne’s north. For that project, soft plastics, glass, toner from more than 4500 used printer cartridges and 50 tonnes of recycled asphalt were all repurposed to create 250 tonnes of asphalt for the road. Because asphalt is a “hot-mix”

material, it has to be produced locally to the point of use, and so the output from the new plant will be used in the Lake Macquarie area. “It’s exciting to know we will be one of the first places in NSW to produce this new, sustainable asphalt, using materials that would once have been considered waste,” says Dr Alice Howe, Sustainability Manager for Lake Macquarie City Council. According to Downer General Manager Pavements, Stuart Billing, the new plant will use “significant quantities” of recycled materials. “The new facility will be able to manufacture innovative and sustainable asphalt products released through our extensive research and development programme,” he says. “This includes a better-performing asphalt product that repurposes soft plastics and toner from used print cartridges.

“This product has improved fatigue life and a superior resistance to deformation, making the road last longer and allowing it to better handle heavy vehicles.”

“Earlier this year, Council started using recycled glass ‘sand’ in civil works projects, potentially closing the loop on thousands of tonnes glass waste placed in household recycling bins each year,” says Dr Howe.

Commissioning of the new Teralba plant early next year will bolster Lake Macquarie’s reputation as a hotspot for pioneering new and innovative ways to avoid, reduce, reuse and recycle waste.

“And our adoption in July of a revamped three-bin service, where all food waste is placed in the green bin and converted into compost, has already diverted more than 1000 tonnes of organics from landfill.”

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OCTOBER 2018

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• WASTE MANAGEMENT/ENVIRONMENT

COMPACT SEPARATORS REDUCE THE COSTS OF SLUDGE DISPOSAL Tons of sodden, sticky, unhealthy and potentially environmentally hazardous wastewater byproduct from small-to-medium enterprises are expensively transported every day in Australasia to costly processing and disposal facilities. These wet cakes of byproduct from farms, food processors, kitchens, manufacturers and primary producers can cost upwards of A$150 a tonne to move by specialised transport from the places where effluent is produced, to centres where compacting, drying and disposal can take place in controlled environments. “Often this sodden waste has to be carried away by road, because many small- to medium-scale producers can’t afford to install expensive processing, compacting and drying plants at their own facilities,” says Australasian

wastewater authority Michael Bambridge. “So, these producers use up money, time and fuel they often can’t afford hauling sodden cake to facilities where it can be treated and disposed of in a way that doesn’t threaten groundwaters,” says Bambridge, Managing Director of CST Wastewater Solutions. One of CST Wastewater Solutions’ latest innovations to address the needs of small-to-medium business’ disposal issues is a compact and portable automatic liquid-to-solid waste separator that removes more than 50 per cent of the water from wastewater sludge to provide a 50 per cent reduction in transportation costs. The KDS separator uses less than 1kW of electricity to operate, far less than a centrifuge, and uses no water during operation, unlike a belt press

or a screw press. For a relatively low investment cost, it offers a high performance alternative to sludge drying beds and geobags, for example, says Bambridge. Used for thickening of dissolved air flotation sludge – a very common application throughout wastewater operations – it achieves solids capture of 97 per cent thickened sludge at a dryness of 17 per cent. Waste activated sludge dryness levels are typically 15-25 per cent. The clog-free automatic technology is suitable for compact dewatering applications from food processing to sewage treatment. The compact KDS multi-disc roller separator features a unique self-cleaning dewatering and conveying system with oval plate separation and transfer structure that prevents clogging and

permits automatic continuous operation that handles oily and fibrous material with ease. The advantage of such a system for small-to-medium operators is low maintenance so they don’t require a high level skilled operator in places where they might be difficult or expensive to obtain. The simple-to-maintain separator offers a high throughput within a small body, with the smallest model being just under 350mm wide and weighing 50kg.

CST Wastewater Solutions 02 9417 3611 www.cstwastewater.com

PLASTIC FILM WASTE BECOMES HIGHQUALITY FEEDSTOCK With plastics recycling very much in the spotlight in Australia, the pressure is on for companies of all sizes across the country to find new ways to deal with their waste material, and particularly their plastic film waste. The Polystar range of film recycling equipment is available exclusively in Australia from Applied Machinery. The range includes machines suitable for recycling all grades of post-

production film and plastic scrap, from injection moulding process residues to plastic films, and covering a wide range of plastic materials. Polystar recycling machines are fully integrated systems that are designed to be simple to operate and simple to maintain. Their output comes in the form of high-quality plastic pellets that can be fed straight back into the manufacturing process, saving on raw

material costs as well as saving on the costs of waste disposal. The Polystar solution processes the plastic in a way that ensures the material suffers minimal degradation. Therefore the recycled pellets have the same material properties as would be expected from a non-recycled pellet. This gives plastics processors the confidence that their final products will be of the highest standard.

Applied Machinery 03 9706 8066 www.appliedmachinery.com.au

The SAFER, more COST EFFECTIVE Aeration System! ty the Safe Eliminate ’t throw n o Risks - D them! at money

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Venturi-Aerator with Gorman-Rupp Pump

OCTOBER 2018

WASTE MANAGEMENT/ENVIRONMENT •

Polystar unwraps HIS YAWEI LASER IS SPRING CLEANING TIPS the value in film YAWEI LASER IS ESIGNED TO CUT recycling. GNED TO CUT BOVE THE REST. Now that’s OVE THE REST. OW THAT’S APPLIED Applied Thinking.

When spring rolls into town, it brings with it a sense of needing to clear the cobwebs. It’s a great time to mobilise your cleaning crews to perform annual maintenance tasks before the weather becomes too hot and steamy. In the lead-up to the Australian Christmas, the challenges of summer can include storms, bushfires and floods. Here are seven ways you can prepare your facilities for the home stretch to the end of the year.

PLE TO USE R

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Clear the drains Rubbish and autumn vegetation collect in drains and can cause problems during fires and rain. They need to be properly cleared throughout the year. Make it a definite springtime task.

Fix hazardous surfaces

Do your walkways have cracks? Are there any concrete slabs heaving from previous heatwaves? Are there any cement areas affected by tree roots? ts extreme accuracy, speed and consistency of cut, combined with very low operating Now’s a good time to remedy these Secure the perimeter! , accuracy, the new Yawei laser is the perfect way to take your business to the next level. speedHLF andfiber consistency of cut, issues for thecombined safety of all. with very low operating Well that sounds a bitis dramatic but Yawei HLF fiber laser the perfect way to take your business to the next level. maintenance theis grounds for basically, dollar,you theshould newscour HLF in a leagueConduct of its equipment own, opening up possibilities for companies for combustible materials. Clear away oss new the laser cutting sector;offrom start-ups to full production, 3-shift Youopening alwaysthrough wantup yourpossibilities equipment in for companies the HLF is in avegetation league fallen tree limbs, dead and its own, Designed for reprocessing of polyethylene & onments. perfect working order. Use spring as a 3-shift ser cutting sector; start-ups to full production, any rubbish. Anythingfrom that can fuel a fire through polypropylene flexible packaging material yearly reminder to repair or replace any or clog drains should be dealt with as a damaged machinery or tools. a quality cutting head, IPG laser source, Siemens Pelletising system with integrated cutter eliminates matter German of priority. built Precitec auto-focus SL controller and a fabricated, stress-relieved fully annealed frame it really is a cut above need for pre-cutting erman Repair built the Precitec cutting head, IPG laser source, Siemens building’sauto-focus exterior

st.and a fabricated, stress-relieved fully annealed frame it really is a cut above er 100% of pellets reusable straight back into your Bring back the sparkle

Inspect the outside of your building for damage and take this time to rectify any damage to the roof, downpipes and other external fixtures like air ore information: conditioning units and signage.

3 9706 8066 ion: sales@appliedmachinery.com.au www.appliedmachinery.com.au edmachinery.com.au Put your sweepers to use machinery.com.au

1.indd

Outside, your walkways, driveways, carparks and other assets (such as car sales lots) will benefit from a good 1 sweep. Not only will your premises look more presentable, but they will be cleared of debris, dirt and other pollutants.

OCTOBER 2018

The comfortable temperatures of spring are perfect for cleaning windows. Dust, dirt and salt residue all accumulate on glass surfaces, not to mention fingerprints and other pollutants.

production line Minimal material degradation without affecting material properties

Make the most of spring to take a good look at your facilities andConnect get them with us socially ship-shape for the rest of the year. Connect with us socially

22/12/16 9:27 am

Tennant Australia 1800 226 843 www.tennantco.com.au

22/12/16 9:27 am

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• PRODUCTS

SOLDER PASTE STENCILS ENABLE PRECISION ELECTRONICS ASSEMBLY

As electronic devices become smaller and smaller, the performance of the solder paste stencil becomes key to maintaining consistent high quality and reducing rework on surface-mount electronics assembly lines. Mastercut has 25 years experience in stencil manufacture and supply, and now offers fine grain shims made from Datum Tension alloy. This revolutionary fine-grain material enables the production of stencils with greatly improved paste release compared with conventional 304 stainless-steel shims. The shims are processed using German LPKF laser cutting technology for a consistently high quality cut,

producing a stencil of unsurpassed quality and accuracy. Customers can choose between framed, quick-plate or shim-only options, compatible with reusable framing systems including DEK and Zelflex. Australian made Mastercut laser-cut stencils maximise return by reducing printing errors, rework and rejects. And data modifications are allowed as required. Mastercut Technologies 07 5576 1900 www.mastercut.com.au

ENERGY METER PROVIDES MORE DETAILED INFORMATION The Carlo Gavazzi WM50 branch circuit energy meter, available now from NHP, is ideal for monitoring individual loads and critical equipment. Using TCD12 split-core current transducers, which are also designed for retrofit applications, the WM50 can monitor up to 96 current channels for single-, two- and three-phase measurements, providing granular insight into energy usage on each circuit at a greatly reduced measurement cost per channel. Perfect for applications in power critical environments, this scalable device can be integrated easily with accessory modules that expand its control and communication capacity. Installation is quick and easy using 52

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FLAT CABLES ARE HALOGEN-FREE

Cicoil now offers halogen-free versions of its high performance flexible flat cables for applications that require non-toxic, corrosive free and environmentally friendly cables. The cables are available in Australia from Treotham Automation. Free of harmful halogenated compounds, such as astatine, bromine, iodine, fluorine and chlorine, Cicoil’s cables also meet the Air Cleanliness Requirements of ISO 146441 and exceed the outgassing requirements of ASTM E595. When cables containing halogens are burned, toxic fumes and acidic gases are produced that can cause severe respiratory damage, disorientation and even death. Cicoil’s proprietary Flexx-Sil

jacketing material contains no halogens, no additives and are naturally flame retardant. Flexx-Sil does not ignite easily, and if ignited, will not produce black smoke or toxic gas during combustion. In addition, Cicoil’s crystal-clear, noncorrosive jacket does not contain colour additives, plasticisers or CFCs, which are typically found in most cable jacketing materials. Cicoil’s halogen-free jacketing material has a temperature rating of -65 to +260°C, and passes UL/CSA VW-1, FT 1 and FT 2, UL94V0 flammability testing and FAA burn testing. In addition, all cables are Class 1 clean room rated. Treotham Automation 1300 65 75 64 www.treotham.com.au

DC POWER CABLE IS A FIRST Responding to trends in both the power generation sector and in the industrial landscape, Lapp has developed its first power cable designed specifically to carry direct current.

quick connect cables between the TCD12 split-core CTs and the WM50 meter. And intuitive configuration using Carlo Gavazzi’s free to download configurator tool significantly reduces installation time and cost.

NHP Electrical Engineering 1300 NHP NHP www.nhp.com.au

Although in principle todays AC power cables can be used for carrying direct current, research has shown that direct current fields place different strains on the plastic of the insulation compared with alternating current fields. The new cable, Ölflex DC 100, is designed to withstand decades of use with direct current, just like its AC equivalent the Ölflex Classic 100. Where the two cables differ is in their insulation. Otherwise their specifications are similar,

with sheaths and identical dielectric strength. The only visible difference is in the colour coding of the wires within. The Ölflex DC 100 has red, white and green/ yellow cores in accordance with the latest version of DIN EN 60445:2018-02. Lapp Australia 1800 931 559 www.lappaustralia.com.au

OCTOBER 2018

PRODUCTS •

AIR GUN AND SCRAPER COMBINE TO CLEAN UP STUBBORN DEBRIS

LINEAR GUIDES ARE MAINTENANCE AND LUBRICATION FREE

Exair has come up with a novel device for removing stubborn debris found in industrial facilities. The patent pending design of the Soft Grip Super Air Scraper combines a safety air gun with a scraping blade. The scraper is ideal for removal of caulk, sealant, adhesives, tape, paint, stickers, labels, grease, lubricant and difficult to sweep metal chips, flakes or discs. The electroless-nickel-plated springsteel scraper is used in combination with Exair’s 51mm flat super air nozzle and installed on the soft grip safety air gun to provide power, durability, corrosion resistance and comfort. The CE compliant Soft Grip Super Air Scraper is available with extensions from 51 to 1829mm to aid in cleaning table tops, inside machines, reaching the floor or other remote surfaces. Exair’s air nozzles meet OSHA standards for dead-

used for almost any application and in a wide variety of environments, including extreme ones. Unlike recirculating ball bearings, there is no limit to the travel of drylin linear guides, nor is there a minimum stroke length.

end pressure and noise exposure. Chip shields are also available. All of Exair Safety Air Gun product lines use air nozzles engineered to maximise safety and minimise air consumption. Compressed Air Australia 1300 787 688 www.caasafety.com.au

Treotham offers a range of linear guides that glide rather than roll. Unlike the recirculating ball bearing systems, drylin linear guides run on sliding elements made of high-performance polymers with particularly low wear rates and coefficients of friction. The polymers enable lubrication-free and maintenance-free dry operation, and that saving in maintenance time translates to reductions in costs incurred by process stoppages. The robust drylin linear guides can be

The guides are not sensitive to influences such as dirt, water, chemicals, heat and impacts. In addition, they are lightweight and have a very low noise because of the materials used and the special design. Treotham offers customised support for special applications, including hygienic environments and robotics, and the company also offers a free drylin linear guides sample box. Treotham Automation 1300 65 75 64 www.treotham.com.au

CIRCULAR CONNECTORS PROVIDE QUICK CONNECTIONS FOR SERVOS Lapp has turned its attention to the increasing demand for quick-connect circular connectors with the release of the Epic Power LS1 with its quickconnect system. Featuring a robust and practical locking mechanism, the new connector

is compatible with the market standard increasingly used on servo cables, in robotics and machinery, as well as in wind turbines.

is also an EMC version that prevents electromagnetic interference – which is particularly useful in motor drive applications.

With a simple twist, both halves of the connector are securely locked and protected against vibration. There

The Epic Power LS1 with quickconnect system is available in all common contact arrangements and will

be available for delivery worldwide from December. Lapp Australia 1800 931 559 www.lappaustralia.com.au

GET A COMPETITIVE EDGE

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OCTOBER 2018

INDUSTRYUPDATE.COM.AU

• PRODUCTS

STRIP DOORS ARE EFFECTIVE BARRIERS TO DUST AND DRAFTS

THREE-PHASE POWER METER IS MULTIFUNCTION MONITOR

Thru strip doors provide an economical solution to a wide range of barrier issues in shops, workrooms, food processing facilities, and even display fridges.

Available from Control Logic, the PMC-340-B NMI is CET’s latest offering for the low-voltage power and energy market. The high-accuracy NMIapproved three-phase energy meter offers multiple inbuilt measurements and a large easy-to-read 7-segment LCD.

These strip doors are custom made in a wide range of single or mixed colours, including clear PVC. The overlapping strips create an effective barrier against dust and drafts, while also providing an efficient temperature control screen. There’s a choice of thicknesses to suit all applications from domestic to heavy industrial duties, and special ribbed strips for an extra-secure fit. The simplicity of the design means that these doors require minimal

maintenance to provide years of reliable service. And there’s a novel choice of head sections that includes hook-on/hook-off and sliding curtain configurations.

MTI Qualos 1300 135 539 www.mtiqualos.com.au

The PMC-340-B complies with IEC 62053-21 Class 1 and IEC 6205322 Class 0.5S kilowatt-hour accuracy standards for 100A direct input and 5A current transducer input, respectively. A standard RS485 port provides Modbus protocol support, allowing the meter to be integrated into an intelligent, multifunction monitoring solution for any energy management system.

The PMC-340-B is suited to industrial and commercial metering, substation, building and factory automation, and submetering in applications where NMI approval is required. Control Logic 1800 557 705 www.controllogic.com.au

HIGH-TECH CONTROL PANEL BOOSTS COMPRESSOR EFFICIENCY Southern Cross Compressors has developed a novel high-tech touchscreen control panel for its industrial screw compressor models over 18kW. The new controller provides users with increased levels of information and ensures the compressors operate at the highest efficiency in the most economical operating mode. “This new controller technology provides the highest level of protection to all key machine functions and components, ensuring longevity and reliability,” says Southern Cross National Service Manager Shane O’Brien. “Most importantly however, this controller encompasses the ability to optimise

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machine efficiency and can be readily adapted to suit customer’s individual requirements.” All key machine information can be accessed through an onboard interface that makes it easy for users to remotely monitor the key operating parameters of the machine, including pressure, temperature, power and service running hours. The new controller has a novel “block mode” function that allows a single compressor to control up to 16 additional compressors enabling them to work together in order to conserve energy. The number one compressor operates as the master with the other compressors

used as required to maintain system pressure and to ensure that the minimum number of machines are running at any given time. The integrated PLC intelligently manages both safety and control elements of the air compressor package to provide reliable and efficient air. With up to 52 different inputs and outputs the touch controller monitors critical data such as pressure, temperature and power to ensure that both user and manufacturer settings are maintained. And the Modbus II interface provides access to critical control functions for SCADA and remote management systems.

With inbuilt functions such as remote stop/start, remote load/unload, time clock stop and start and time clock pressure changes, this technically advanced but simple controller delivers the flexibility and reliability demanded by industry. Southern Cross Compressors (Australia) 1300 098 901 southerncrossaircompressors.com.au

OCTOBER 2018

HELP REDUCE MAINTENANCE COSTS ON OVERHEAD CRANES

PRODUCTS •

MODULAR FRAME MAKES CUSTOM CONNECTORS EASY TO ASSEMBLE

LOAD LIMITERS

ROPE AND CHAIN CRANES AND HOISTS: • Helps reduce the risk of accidents • Protects against overloading of Crane and supporting structures • Quick and easy installation and available for all capacity cranes • Available preset or easily calibrated on site • Helps reduce maintenance costs • Minimizes down time • Automatic reset by reducing the load

Available now in Australia from Lapp, the Epic MH modular connector system combines energy, signals and data in one connector. Importantly, the new connectors are significantly easier to assemble, thanks to the fixed Epic modular frame. According to Lapp Australia General Manger Simon Pullinger, the stable frame of the EPIC connector system combines time-saving simplicity with in-service reliability. Overall, the modular system can handle current up to 200A, voltages up to 1kV and datarates up to 10Gbit/s. All told, there are up to 138 million connector combinations possible, covering applications from electronics and communications to mechanical engineering, motor drives and industrial automation. Each connector module is firmly fitted into the MH system frame with an

CONDUCTOR BAR • Available in steel and copper • Quickly and easily installed • Supports required only every 1.5m • Also available in a compact cluster range

audible click to ensure proper assembly. Foreign modules can be included using the Lapp MH red clip adapter.

SIDE PULL PREVENTERS/ROPE GUIDE PROTECTOR Prevents side pulling and protects rope guides and drums on most multi-fall Cranes and Hoists. • Prevent dragging of loads

Complementing the Epic MH system, the MH Online tool enables the design of individual housings for other Epic MH Modular system components and other Epic inserts.

• Helps reduce down time.

Liftco Industrial Supplies Pty Ltd

Freecall: 1800 LIFTCO (543826)

Lapp Australia 1800 931 559 www.lappaustralia.com.au

Email: liftco@optusnet.com.au Web: www.liftco.com.au

DISPLACEMENT SENSOR USES STRETCHABLE STRAIN GAUGE Available now from Bestech Australia, the ElastiSense EDS is a novel capacitive contact displacement sensor that is capable of both linear and off-axis measurement. The device uses a stretchable hyperelastic elastomer strain gauge that comprises a dielectric sheet with deformable electrodes. The stretching of the sensor element changes its capacitance and thereby enables measurement of displacement.

OCTOBER 2018

Unlike piston-based displacement sensors, this low-cost sensor has no sliding parts, and so requires no maintenance. It is highly resistant to shock and vibration and tolerant of misalignment, making it ideal for harsh industrial applications. The sensors are available with measurement ranges from 20 to 200mm with 0.1% full-scale accuracy. And measurement rates up to 10ksample/s are supported. Both analogue and digital

(RS485) outputs are available, making the EDS easy to integrate. Early applications for this novel displacement sensing technology have included metal forming machinery in which the sensors have been used to detect faulty operation of stamping tools due to the presence of metal slugs. Other suitable applications will be found in process automation, structural condition monitoring and predictive maintenance.

Bestech Australia 03 9450 5100 www.bestech.com.au

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• PRODUCTS

PLC TAKES DETERMINISTIC CONTROL TO THE EDGE Billed as pioneering a new deterministic control ethos at the edge, the GE Automation & Controls CPL410 PLC is available now from Control Logic. The new PLC works with any cloud platform provider and combines an embedded Linux Ubuntu operating system with GE’s advanced rack-less RX3i programmable logic controller platform. Described as an Outcome Optimising Controller, the CPL410 is very versatile and can interact with weather forecasts, stock indices, electricity prices, IoT cloud databases, Linux software apps, onboard web server and historical process data to deliver near-real-time advice, delivering new levels of control variables for prediction, advanced analytics and control optimisation. The PLC is based on a 1.2GHz quadcore processor with real-time hypervisor technology to execute deterministic control concurrently, yet independently to the embedded Linux Ubuntu OS applications. Built for heavy industry and reliable control with hot standby CPU redundancy, the RX3i PLC supports 32,000 I/O points, SQLite, Apache, Python, Profinet, Modbus, DNP3, OPC connectivity via five Gigabit Ethernet ports and incorporates advanced cybersecurity technology.

WIRELESS MODEM RUNS LOW-BANDWIDTH 4G FOR ECONOMICAL IOT Available now in Australia from NetComm, the NTC-100 is a wireless IoT module that enables access using Cat-M1 and NB-IoT over LTE networks (such as Telstra 4G). The new technologies have been added to the latest LTE revisions to enable typical low-power IoT devices that only require a very limited amount of bandwidth to economically use the cellular network.

By allowing users to develop and run Linux-based data-processing applications next to the control system the CPL410 allows process optimisation in a range of applications, from water and wastewater to automotive, chemical, oil and gas, discrete manufacturing, and modular machine designs.

Control Logic 1800 557 705 www.controllogic.com.au

According to Els Baert, NetComm Director of Marketing and Communications, “This is the first lowpower low-bandwidth device introduced to our industrial IoT portfolio and the only device of its kind to integrate a dual technology LTE module using Cat-M1 and NB-IoT technologies to economically track and monitor low-cost applications that were traditionally too costly to connect. “This will accelerate the uptake of Industrial IoT by providing diverse industry sectors with the chance to connect and cost-effectively manage large fleets of small, low-value assets

everywhere where there is an LTE network available.” The NTC-100 is the first commercially available modem to support Cat-M1 and NB-IoT connections. It incorporates remote management capabilities to query status information, run advanced diagnostics, troubleshoot and execute commands via SMS. The unit has an IP40-rated industrial housing, and is built to handle the vibration and extreme temperatures encountered in industrial and automotive environments. NetComm Wireless 02 9424 2070 www.netcommwireless.com

POLYMER PARTS AND PROFILES ARE QUALIFIED FOR RAILWAY APPLICATIONS Available now from Treotham Automation, iglidur RW370 is a novel polymer material that is qualified to the EN 45545 fire protection standard for use in railway applications. The highperformance igus plastic is available as lubricant- and maintenance-free plain bearings and also as a bar stock for the production of special components. The iglidur RW370 bar stock and sheet is available in a range of different sizes and thicknesses, enabling a wide range of designs. For example, it can be used on the bogie or in couplings of trains and trams, where it will allow the carriage to slide onto the bogie and pivot the coupling in the event of lateral misalignment of the rails or cornering. In addition to special parts made of bar stock, Treotham can also provide special profiles of different shapes made from iglidur RW370 that can save costs

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by reducing rework and material scrap. These, for example, might be used for guiding train or tram doors. In this application, iglidur RW370 is lighter than metal alternatives, and it is also quieter in operation. Treotham Automation 1300 65 75 64 www.treotham.com.au

OCTOBER 2018

PRODUCTS •

METER IS COMPLETE ENERGY MANAGEMENT SOLUTION

GET HEAVY LOADS MOVING EFFORTLESSLY WITH THE

TENTE E-DRIVE FLEX STARTING ASSISTANCE SYSTEM

Available now in Australia and New Zealand from NHP, the Conto D6 energy meter is a three-phase, fourwire direct connect meter for current measurements up to 100A. The Conto D6 delivers accurate and reliable measurement that is ideal for distributed submetering applications in cabinets and control panels. The meter has a programmable pulse output and can be remotely monitored via Modbus RTU. It can measure total and partial energy, both active and reactive power and also boasts two tariff management inputs for a complete energy management solution. The lightweight and compact meter is quick and easy to install using DIN rail mounts, easily accessible sealable terminals and an intuitive user interface.

The full list of measurement variables includes: total active and reactive energy, partial active and reactive energy, active power demand, an hour meter, phase current and voltage, frequency and power factor.

NHP Electrical Engineering 1300 NHP NHP www.nhp.com.au

Demonstration Unit Available Contact Tente Castors & Wheels for further information 1300 836 831 - E-Drive Flex system can be retrofitted to most trolleys - Increase manpower efficiency by saving effort - Used a a 5th wheel to improve direction stability - Retractable wheel system ensures easy manouverability - Reduces potential injuries for staff – neck, back, shoulder and wrist pain - Infinite speed control (forward and reverse) - Egonomic handle design with system and battery charge LED indicators

Contact Tente Castors & Wheels To Find Your Product Solution Phone: 1300 836 831

tente.com.au

sales@tente.com.au

RESIDUAL CURRENT DEVICES PROVIDE UNIVERSAL PROTECTION ABB’s compact F200 B residual current devices assist in detecting different waveforms of residual fault currents and operate when the electrical system has a high leakage current to earth. The F200 residual current circuit breaker (RCCB) features a bidirectional cylindrical clamp for safe electrical connections. Two distinct cable entries

remove the chance of miswiring. The front of the circuit breaker features a test button to check the proper operation of the device and a LED indicator to signal the type of leakage that the RCD is detecting. Type B RCDs are considered universal devices as they provide protection against all the tripping

waveforms listed in the EN 62423 standard. In addition they ensure high protection levels under all working conditions, and are certified for operation in extreme weather conditions up to +60°C. Control Logic 1800 557 705 www.controllogic.com.au

Rapid, Detailed Texture Analyzer for Food and Packaging materials • • • • •

Flexible, anti-rotation load cells with load accuracy of 0.5% Wide range of jigs, probes and fixtures to choose from for strength and integrity testing of food, cosmetics and packaging Extensive range of built-in test method Large working area (180mm) Maximum force: 1kN

Advance texture analysis software, NEXYGENPlus for calculation of textural parameter For more information, visit:

www.bestech.com.au/texture-analysers/

Email: enquiry@bestech.com.au

GLOBAL TECHNOLOGY LOCAL SUPPORT OCTOBER 2018

Phone: (03) 9540 5100

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TEABREAK TRIVIA 1

What is the most venomous creature in the world?

2 What year saw the the Commonwealth Franchise Act enabling women over 21 to vote in national elections and stand for parliament? 3 Before that date, which two states were the only ones to allow women to vote? 4 Which Hollywood great was born Marion Robert Morrison in Winterset, Iowa on 26th May 1907? 5 Which nation has won the Rugby World Cup the most times (3)?

The best industry and political quotes of the past and present: “Politics have no relation to morals. ” Niccolo Machiavelli "Quality means doing it right when no one is looking." Oscar Wilde “Always forgive your enemies; nothing annoys them so much. " Henry Ford

7 Where in Australia is the Big Bull? 8 Which musical innovation was first demonstrated at the 1927 Sydney Royal Easter Show?

“If things are not failing, you are not innovating enough. " Elon Musk

9 … and who was the inventor? 10 Which question has been removed from the standard list used to test cognitive function?

“The reason we have elected officials is so we don’t have to think all the time. " Homer Simpson “TTechnology is not a solution for ignorance. It makes the opportunities for the educated even greater. " Alan Finkel

FORTHCOMING EVENTS CORROSION & PREVENTION 2018

NATIONAL MANUFACTURING WEEK

11-14 November 2018, Adelaide Convention Centre

14-17 May 2019, Melbourne Convention & Exhibition Centre

conference.corrosion.com.au AUSTRALIAN WASTE TO ENERGY FORUM 19-21 February 2019, Mercure Ballarat, Victoria aien.com.au/wteforum AUSPACK 2019 26-29 March 2019, Melbourne Convention & Exhibition Centre www.auspack.com.au

THEY SAID IT.. LATERAL THINKING

“The best argument against democracy is a five-minute conversation with the average voter.” Winston Churchill

6 Which is further north, New York City or Rome?

1) Mary’s mother has four daughters. The first is called April, the second is called May, the third is called June. What is the name of the fourth daughter? 2) A man built a rectangular house, each side having a southern view. He spotted a bear. What colour was the bear? 3) Is it legal for a man to marry his widow's sister?

END THE YEAR ON A HIGH 2018 has been a remarkable year so far, with Australian manufacturing industry defying expectations and continuing month after month of sustained growth. And the year is set to end on a high with the November issue of Industry Update - traditionally one of the best read of the year.

Plus all our regular sections on

This year’s November edition will be a special one as we expand our coverage of all things economic with our new expanded Business and Finance section.

The deadline for editorial submissions is

Other special features include: • The second part of our focus on Cooling and Fans • IT – Hardware and Software • Fasteners and Adhesives • Workplace Hygiene • LED Lighting • Drug and Alcohol Awareness • and our ever-popular Christmas Gift Guide

Machinery, Workplace Safety, the Environment and Industry Politics. This is a great opportunity to get your message to our readership of more than 72,000 manufacturing professionals.

Monday 22nd October 2017. Don’t miss out. Editorial copy and images should be sent to editor@industryupdate.com.au. Advertising enquiries to Scott or Glyn on 02 9439 1288. All advertisers are guaranteed editorial coverage

www.nationalmanufacturingweek.com.au AUSTECH 14-17 May 2019, Melbourne Convention & Exhibition Centre amtil.com.au/austech WORKPLACE HEALTH & SAFETY SHOW 22-23 May 2019, Sydney International Convention Centre whsshow.com.au

1 Box jellyfish, 2 1902, 3 South Australia and Western Australia, 4 John Wayne, 5 6 Rome 7 Wauchope, NSW, 8 The automatic record changer, 9 Eric Waterworth of Hobart, 10 Who is Prime Minister of Australia? Teabreak Trivia (1) Mary. (2) White. Only at the North Pole can all four walls be facing South. (3) No. Because he is dead.. Lateral Thinking ANSWERS

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OCTOBER 2018

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